MOLDED PAPER CUSHIONING AND METHOD OF MANUFACTURE

Abstract

A molded paper structure that provides cushioning and the method of manufacturing. The molded paper cushioning is flexible, with a continuous surface, without the use of folds or external adhesives. In the method of manufacture, paper sheet material is soaked with water and subsequently passed through a compression mold that forms the paper into a cushioning shape.

Claims

1. A cushioning material made of molded paper.

2. A molded paper material formed in alternating concave and convex bumps.

3. The method of producing molded paper cushioning by soaking paper stock material with water and passing it through a compression mold.

4. The method for molding paper stock material into a formed shape by soaking paper stock material with water and passing it through a compression mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a perspective view of molded paper cushioning.

[0013] FIG. 2 is a top plan view of molded paper cushioning.

[0014] FIG. 3 is a front sectional view of molded paper cushioning.

[0015] FIG. 4 is a side sectional view of molded paper cushioning.

[0016] FIG. 5 is a front sectional view that schematically depicts the paper molding machine.

[0017] FIG. 6 is a top plan view that schematically depicts the paper molding machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Molded paper cushioning is shown in FIGS. 1 through 4. The molded paper is formed in a continuous shape of alternating concave and convex bumps. Wave formations along the width and length axes form together to create the alternating bump shapes. The cushioning surface is smooth and continuous without folds, cuts, or external adhesives.

[0019] The method in which molded paper cushioning is produced is shown in FIGS. 5 and 6. A roll of sheet-like stock material such as paper 1 sits on a spindle that can rotate freely. The paper material advances off of the roll 2 as it is pulled through the system by the compression mold rollers 7.

[0020] The stock material is guided by a roller 3 and submerged into a bath of water 4. It is held beneath the surface of the water by another roller 5, soaking the paper material and softening the fibers. Once the paper material is saturated, it continues out of the bath 6 and proceeds into the rotating compression mold 7.

[0021] The compression mold 7 is comprised of a pair of mated shaped rollers and forms the paper into the cushioning material 8 which is extruded from the mold.