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.

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.

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.

A hierarchical sandwich core in the form of a honeycomb, i.e. having repetitive and periodic lattice materials. The sandwich core can be made up of a macroscopic honeycomb structure with sandwich cell walls having a mesoscopic cellular core. The longitudinal axis of cells of the mesoscopic honeycomb cell can be perpendicular to the longitudinal axis of the cells of the macroscopic honeycomb structure. Alternatively, if a foam core is used having mesoscopic cells the shape of the mesoscopic cells can be made during the foaming process so that they are elongate in a direction perpendicular to the longitudinal axis of the cells of the macroscopic honeycomb structure.

Structures including a curved corrugated wall fabricated from a plurality of layers formed of one or more shaped strips and methods of forming the structures are described. A shaped strip used in the fabrication includes a variable profile across the width of the strip with a first edge of a strip defining a series of cell profiles of a first geometric shape and a second, opposite edge of the strip defining a series of cell profiles of a second, different geometric shape, with each cell transitioning from the first profile to the second profile across the width of the strip. The geometry of the cell profiles at either end of each cell can be designed with respect to one another to allow for radial orientation of the strip about an axis with little or no deformation or stress on the strip edges.

According to the present disclosure there is provided a method of forming a first structure (150), comprising the steps of: providing one or more slots (124) in a material, thereby to define a plurality of strips (122) of the material, the slots (124) defining a series of connecting elements (128) connecting adjacent strips (122) of the material, the connecting elements (128) being spaced apart along a first direction (130), forming the material to provide: an array of oppositely oriented channels (152), each channel (152) extending in a second direction perpendicular to the first direction, and the array itself extending in the first direction, each channel comprising a base, and sides extending from the base; and a first, non-continuous, outer plane; and a second, non-continuous, outer plane, such that the first structure is foldable along each of the series of connecting elements about the first direction to bring the first outer plane of a first strip toward, and optionally into contact with, the first outer plane of a second, adjacent strip.

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.

A folded core structure formed from an uncut flat body, has a plurality of consecutive 3D-structures and connecting areas each formed by plastic deformation, and includes first and second primary surfaces oriented plane-parallel to each other. The first and second primary surfaces include a first secondary surface extending over the entire width of the folded core structure and extending over a part of the length of the folded core structure. The first secondary surface is oriented parallel to the first primary surface, and the first secondary surface is located at a distance from the first primary surface between the first and second primary surfaces. A channel for fluid flow at least along the width of the folded core structure is provided. The first and/or second primary surface is/are configured to provide dimensional stability under a compression force applied perpendicular to the first primary surface of the folded core structure.

A food support tray comprised of an expanded paperboard mesh tray insert for a delivery carton such as a pizza carton or a fresh produce clamshell. The expanded paperboard mesh is adapted for supporting pizza or other food items on the bond peaks of the expanded mesh, thus isolating the food item from oil and juices that could make the fresh food item turn soggy.

The invention relates to a pallet (1), comprising a basic body (10) with a first panel (11), a second panel (12) and a layer (13) having a plurality of tube segments (14) which is arranged between the panels (11, 12), wherein the layer (13) has at least one cutout (131) which is continuous in the direction of a pallet height (HP), and wherein the first panel (11) has at least one first opening (111) which at least partially overlaps with the at least one cutout (131). The invention further relates to a foot (16) and a runner (17) for a pallet (1), to a sandwich block (2) for producing a layer (13) of a pallet (1), and to a method for producing a pallet (1).