PAPER CUSHIONED SHIPPING ENVELOPES AND METHODS OF MAKING THE SAME

Abstract

According to some illustrative embodiments, a protective product is provided that includes: an envelope having a two-layer wall structure, the two-layer wall structure including a) a first outer paper layer, and b) a second inner paper layer, wherein the second inner paper layer includes width-wise positional variations of the side surface of the second inner sheet that cushions items placed within an inner pouch of the envelope, and forms an interior wall of the inner pouch of the envelope and directly contacts the items placed within the inner pouch of the envelope. In some preferred implementations, the width-wise positional variations of the side surface of the second inner paper layer includes pleats, undulations and/or embossments, and, preferably, the pleats, undulations and/or embossments include ridges that extend perpendicular or substantially perpendicular to an outlet of the envelope.

Claims

1. A protective product, comprising: an envelope having a two-layer wall structure, the two-layer wall structure including: a) a first outer paper layer, and b) a second inner paper layer, wherein the second inner paper layer: i) includes width-wise positional variations of the side surface of the second inner paper layer that cushions items placed within an inner pouch of the envelope, and ii) forms an interior wall of the inner pouch of the envelope and directly contacts the items placed within the inner pouch of the envelope,

2. The protective product of claim 1, wherein said first outer paper layer and said second inner paper layer are folded together to form a pouch, with said second inner paper layer forming the interior wall of said pouch that directly contacts items placed within said pouch during use and with said first outer paper layer forming an outside wall of said pouch at an exterior of the envelope.

3. The protective product of claim 1 or any of the preceding claims, wherein said width-wise positional variations of the side surface of the second inner paper layer includes pleats, undulations and/or embossments.

4. The protective product of claim 3, wherein said pleats, undulations and/or embossments include ridges that extend perpendicular or substantially perpendicular to an outlet of the envelope.

5. The protective product of claim 4, wherein said ridges extend a distance of greater than 30% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 40% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 50% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 60% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 70% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 80% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 90% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein said ridges extend a distance of greater than 95% of the depth of the envelope from the opening to a bottom of the pouch of the envelope

6. The protective product of claim 1 or any of the preceding claims, wherein said width-wise positional variations of the side surface of the second inner paper layer includes peaks adjacent said first outer paper layer, and wherein adhesive is applied between said peaks and said first outer paper layer that adheres said second inner paper layer to said first outer paper layer.

7. The protective product of claim 1 or any of the preceding claims, wherein said width-wise positional variations of the side surface of the second inner paper layer includes peaks adjacent said first outer paper layer, wherein said peaks extend substantially perpendicular to an opening into a pouch of said envelope.

8. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is an unembossed paper sheet.

9. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is an embossed paper sheet.

10. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a substantially flat paper sheet.

11. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a Kraft paper sheet.

12. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a Kraft paper sheet having a weight of 30# or more under the TAPPI standard paper weight specification for 3000 square feet.

13. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a Kraft paper sheet having a weight of 40# or more under the TAPPI standard paper weight specification for 3000 square feet.

14. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a Kraft paper sheet having a weight of 50# or more under the TAPPI standard paper weight specification for 3000 square feet.

15. The protective product of claim 1 or any of the preceding claims, wherein said first outer paper sheet is a Kraft paper sheet having a weight of 60# or more under the TAPPI standard paper weight specification for 3000 square feet.

16. The protective product of claim 1 or any of the preceding claims, wherein said second inner paper sheet is a Kraft paper sheet having a weight of 30# or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some examples, 40# or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some examples, 50# or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some examples, 60# or more under the TAPPI standard paper weight specification for 3000 square feet.

17. The protective product of claim 1 or any of the preceding claims, wherein the first outer paper sheet is adhered to the second inner paper sheet.

18. The protective product of claim 1 or any of the preceding claims, wherein the first outer paper sheet is adhered to the second inner paper sheet with cold glue.

19. A method, comprising: providing the protective product of claim 1 or any of the preceding claims; and placing an item within a pouch of said protective product.

20. A method of making the protective product comprising an envelope having a two-layer wall structure, the two-layer wall structure including a) a first outer paper layer, and b) a second inner paper layer, wherein the second inner paper layer includes width-wise positional variations of the side surface of the second inner paper layer that cushions items placed within an inner pouch of the envelope, and forms an interior wall of the inner pouch of the envelope and directly contacts the items placed within the inner pouch of the envelope, comprising the steps of: a) conveying the first outer paper layer in a machine direction; b) conveying the second inner paper layer in the machine direction alongside said first outer paper layer; c) creating width-wise positional variations of the side surface of the second inner paper layer for cushioning items placed within an inner pouch of the envelope, said width-wise positional variations including ridges that extend transverse to the machine direction; d) adhering the first outer paper layer to the second inner paper layer; e) cutting a composite section of the first outer paper layer and the second inner paper layer for forming at least one individual envelope by severing the first outer paper layer and the second inner paper layer across a width thereof transverse to the machine direction; and f) folding the composite section of the first outer paper layer and the second inner paper layer around a fold line parallel to the machine direction to create the inner pouch and such that the second inner paper layer forms the interior wall of the inner pouch of the envelope and directly contacts the items placed within the inner pouch, and wherein said ridges extend within said pouch substantially transverse to the opening of the pouch.

21. The method of claim 20, wherein said adhering includes cold gluing the first outer paper layer to the second inner paper layer.

22. An envelope, comprising: a composite of a) a first outer sheet of paper; and b) a second inner sheet of paper configured to provide cushioning, wherein the second inner sheet of paper forms an interior wall of the inner pouch of the envelope without an inner layer, the second inner sheet of paper being configured to provide cushioning and directly contacting items placed within the inner pouch of the envelope.

23. The envelope of claim 22, wherein the first outer sheet of paper includes a sheet of paper having no embossments.

24. The envelope of claim 22 or 23, wherein the first outer sheet of paper comprises a sheet of Kraft paper, or, in some embodiments, wherein the first outer sheet of paper is a Kaft sheet having a weight of 30# paper or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some embodiments, wherein the first outer sheet of paper is a Kaft sheet having a weight of 40# paper or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some embodiments, wherein the first outer sheet of paper is a Kaft sheet having a weight of paper or more under the TAPPI standard paper weight specification for 3000 square feet, or, in some embodiments, wherein the first outer sheet of paper is a Kaft sheet having a weight of 60# paper or more under the TAPPI standard paper weight specification for 3000 square feet.

25. The envelope of any of claims 22-24, wherein the first outer sheet of paper is sufficiently strong to inhibit inadvertent tearing of the envelope during use, such as, e.g., during shipping and/or mailing.

26. The envelope of any of claims 22-24, wherein the first outer sheet of paper includes embossments.

27. The envelope of any of the preceding claims, wherein the second inner sheet of paper is configured to provide cushioning by providing width-wise positional variations of the side surface of the second inner sheet.

28. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include pleats.

29. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include undulations.

30. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include embossments.

31. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include embossments extending in a direction away from an interior of the pouch.

32. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include embossments extending only in a direction away from an interior of the pouch.

33. The envelope of any of the preceding claims, wherein the width-wise positional variations of the side surface of the second inner sheet include embossments extending both in a direction away from an interior of the pouch and extending in a direction toward the interior of the pouch.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0230] A number of preferred embodiments of the invention are shown by way of example, and not limitation, in the accompanying figures, in which:

[0231] a) FIGS. 1-22 are figures from parent application Ser. No. 16/870,195, wherein:

[0232] FIG. 1 is a side view of the composite material of expanded slit sheets enveloped in indented Kraft sheets;

[0233] FIG. 2 is a perspective view of the composite material of expanded slit sheets enveloped in indented Kraft sheets;

[0234] FIG. 3 is a schematic side view of the manufacturing process;

[0235] FIG. 4 is a top view of the composite material;

[0236] FIG. 5 is a top view of the composite material with fold lines and double-sided adhesive;

[0237] FIG. 6 is a top view of the composite material folded into the unclosed envelope shape;

[0238] FIG. 7 is a perspective view of the composite unclosed envelope with release liner, where a pouch area is created by side gluing side crushing areas folding at a crush/fold area;

[0239] FIG. 8 is a perspective view of the composite closed envelope;

[0240] FIG. 9 is a perspective view showing a notched region for tear opening of a sealed envelope;

[0241] FIG. 10 is a side view of a single sided outer embossed layer of Kraft, a double layer of expanded paper and an inner layer of raised and recessed embossed paper;

[0242] FIGS. 11, 11A, 11B, 11C, and 11D are schematic representation of various patterns and sizes of hexagonal shaped embossments;

[0243] FIG. 12 is a side view of a single sided embossed layer, a layer of flat Kraft paper and a double layer of expanded paper between the embossed and flat layers;

[0244] FIG. 13 is a side view of an embossed sheet;

[0245] FIG. 14 is a side view of a two sided embossed paper as a cushioning inner layer;

[0246] FIG. 15 is a side view of the double sided embossed layer of FIG. 14 in combination with an inner and outer layer of single sided embossed Kraft paper;

[0247] FIG. 16 is a perspective view of the combination of FIG. 15;

[0248] FIG. 17 is a perspective view of a fan fold cushioning layer in combination with embossed layers;

[0249] FIG. 18 is a perspective view of an undulating two-sided pattern in combination with an embossed layer;

[0250] FIG. 19 is a plan view of two consecutive envelope pads that have been crushed in fold areas and die-cut in envelope end crush areas while, simultaneously being maintained under tension in the manufacturing direction in the sidecrushing areas;

[0251] FIG. 20 is a side view of the upper rotary tool that provides the crush and cut for making the padded envelope;

[0252] FIG. 21 is a side view of the die cut crush rotary system; and

[0253] FIG. 22 is a perspective view of the rotary padded envelope pad making section; and wherein:

[0254] b) FIGS. 23-34L illustrate preferred embodiments of the invention set forth in the present application, which are shown by way of example, and not limitation, wherein:

[0255] FIGS. 23-32 depict some preferred embodiments of the present invention in which cushioned envelopes are formed with a composite of a first outer sheet and a second inner sheet;

[0256] FIGS. 23, 24 and 25 are schematic and explanatory figures that only depict portions of the components (such as, for example, sub-portions of the inner sheet of paper 505A corresponding to particular envelopes 400A to be fabricated but prior to cutting or separating the inner sheet of paper 505A to form individual envelopes 400A).

[0257] FIG. 26 is a perspective view of an illustrative cushioned envelope according to some embodiments of the present invention;

[0258] FIG. 27 is a perspective view of a system for manufacturing cushioned envelopes in accordance with some embodiments of the present invention;

[0259] FIG. 28 is a schematic side view of additional components in the system for manufacturing cushioned envelopes shown in FIG. 27 according to some embodiments of the present invention;

[0260] FIG. 29 is an explanatory plan view depicting steps in relation to conveyance of first outer sheet 506A and second inner sheets 505A in a machine direction MD, and separation of a composite region for formation of individual envelopes in accordance with some preferred embodiments;

[0261] FIG. 30 is a plan view depicting a composite section for forming a single envelope 400A in accordance with some illustrative embodiments of the present invention;

[0262] FIG. 31 is a plan view depicting a single envelope 400A formed by folding over the composite section shown in FIG. 30 around the vertical line shown in the center of the region B in FIG. 30 to form the envelope 400A;

[0263] FIG. 32 is a perspective view of an illustrative envelope 400A similar to that shown in FIG. 31 in an open state with a flap 401A open, and with the pouch opening in an open position;

[0264] FIGS. 33A-33G are explanatory side views that show some additional illustrative embodiments of the invention employing alternative shapes and configurations of the second inner paper layer;

[0265] FIGS. 34A-34L are explanatory views showing various other surface configurations of the second inner paper layer in other embodiments of the invention, wherein the second inner paper layer includes other configurations for width-wise positional variations of the side surface of the second inner sheet that cushion items placed within an inner pouch of the envelope; and

[0266] FIG. 35 is a perspective view of a portion of a wall of a pouch of an envelope that is similar to the envelope shown in FIG. 26, which portion of the wall of the pouch of the envelope includes a first outer sheet 506A adhered a portion of a pleated second inner sheet 505A containing and cushioning an item within the pouch of the envelope.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0267] While the present invention may be embodied in many different forms, the illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and that such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.

[0268] According to some of the preferred embodiments, a novel cushioned envelope can be created with a composite of two sheets of paper. Among other things, creating novel cushioned envelopes from a composite of two sheets of paper can substantially reduced costs for manufacture.

[0269] According to some preferred embodiments, a novel envelope is created that improves upon the envelopes shown in, e.g., FIGS. 16-17 of the above-referenced parent application Ser. No. 16/870,195 by creating a cushioned envelope from a composite of two sheets. For example, in some of the preferred embodiments, the inner layer 104 can be eliminated. Among other things, eliminating the inner layer 104 can substantially reduce manufacturing costs.

[0270] According to some preferred embodiments, a novel envelope is created that includes a composite of: a) a first outer sheet of paper; and b) a second inner sheet of paper configured to provide cushioning, wherein the second inner sheet of paper forms an interior wall of the inner pouch of the envelope without an inner layer 104 (as shown in FIG. 16-17). Accordingly, in such preferred embodiments, the second inner sheet of paper configured to provide cushioning directly contacts items placed within the inner pouch of the envelope.

[0271] According to some preferred embodiments, the first outer sheet of paper can include a sheet of paper having no embossments or the like, such as to be substantially flat. In some embodiments, the first outer sheet of paper can comprise a sheet of Kraft paper. In some embodiments, the first outer sheet of paper can be a Kraft sheet having a weight of 30# (i.e., 30 lbs) paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the first outer sheet of paper can be a Kraft sheet having a weight of 40# paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the first outer sheet of paper can be a Kraft sheet having a weight of 50# paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the first outer sheet of paper can be a Kraft sheet having a weight of 60# paper or more under the TAPPI standard paper weight specification for 3000 square feet.

[0272] In some preferred embodiments, the first outer sheet of paper is sufficiently strong to inhibit inadvertent tearing of the envelope during use, such as, e.g., during shipping and/or mailing.

[0273] Although the first outer sheet of paper is an unembossed sheet in some preferred embodiments, it some other preferred embodiments, the first outer sheet of paper can include embossments. For example, in some embodiments, the first outer sheet of paper can include any of the embossments as described in the foregoing sections incorporated herein from parent application Ser. No. 16/870,105.

[0274] According to some preferred embodiments, the second inner sheet of paper is configured to provide cushioning by providing width-wise positional variations of the side surface of the second inner sheet. In some preferred embodiments, the width-wise positional variations of the side surface of the second inner sheet include pleats. For example, in some embodiments, the second inner sheet of paper can include a pleated paper similar to 1400 shown in FIG. 17. In some other embodiments, the width-wise positional variations of the side surface of the second inner sheet include undulations. For example, in some embodiments, the second inner sheet of paper can include a paper similar to that shown in FIG. 16 with undulations similar to that of sheet 1300. In some other embodiments, the width-wise positional variations of the side surface of the second inner sheet include embossments. For example, in some embodiments, the second inner sheet of paper can include an embossed paper similar to that described in the foregoing sections incorporated herein from parent application Ser. No. 16/870,195. In some illustrative examples, the second inner sheet of paper can include an embossed paper similar to that shown in FIG. 13, which shows an illustrative embossed paper sheet 1001 having a pattern of embossments 1002 (such as, e.g., an array of circular, polygonal and/or other shaped embossments), extending therefrom in a single direction. In some other illustrative examples, the second inner sheet of paper can include an embossed paper similar to that shown in FIG. 14, which shows an illustrative two-sided pattern layer 1100 (i.e., with embossments extending in both directions) which increases the final thickness of the embossed sheet.

[0275] In the preferred embodiments, the width-wise positional variations of the side surface of the second inner sheet are configured to facilitate use and operation of the envelope, such as, e.g., to facilitate placement of items within a pouch of the envelope. For example, in preferred embodiments, the second inner sheet is configured to include positional variations of the side surface with minimal or no interference during placement of items within a pouch of the envelope. For example, in some preferred embodiments, the second inner sheet includes pleats having peaks that extend towards a opening into the pouch, such that items placed into the opening of the pouch are inserted in a direction parallel to or substantially parallel to peaks of said pleats. As another example, in some preferred embodiments, the second inner sheet includes embossments similar to that shown in FIG. 13, in which the embossments are arranged to extend outward of the interior of the pouch, such as to avoid contact with items during placement within the pouch.

[0276] According to some preferred embodiments, the second inner sheet of paper can be formed from a sheet of Kraft paper. In some embodiments, the second inner sheet of paper can be a Kraft sheet having a weight of 30# (i.e., 30 lbs) paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the second inner sheet of paper can be a Kraft sheet having a weight of 40# paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the second inner sheet of paper can be a Kraft sheet having a weight of 50# paper or more under the TAPPI standard paper weight specification for 3000 square feet. In some embodiments, the second inner sheet of paper can be a Kraft sheet having a weight of 60# paper or more under the TAPPI standard paper weight specification for 3000 square feet.

[0277] Referring to FIGS. 23-32, these figures show some preferred embodiments of the present invention in which cushioned envelopes are formed with a composite of a first outer sheet and a second inner sheet. In the embodiment shown in FIGS. 23-32, the second inner sheet includes pleats. Additionally, in the embodiment shown in FIGS. 23-32, a novel and advantageous manufacturing process is depicted.

[0278] According to the preferred embodiments shown in FIGS. 23-32, a novel envelope is created having substantial advantages over prior envelopes. Additionally, according to the preferred embodiments shown in FIGS. 23-32, the novel envelope is advantageously manufactured employing a highly cost-effective, quick and efficient system and method. In particular, in some preferred embodiments, a manufacturing system 500A (see FIG. 28) is employed to manufacture cushioned envelopes 400A (see FIGS. 26, 31 and 32). As shown in FIG. 27, in the illustrated embodiment, envelopes 400A are manufactured by conveying at least one first outer sheet of paper 506A (one shown in the illustrated embodiment) that is wound into at least one first roll of paper 501A (one shown in the illustrated embodiment) in a machine direction MD alongside at least one second inner sheet of paper 505A (two shown in the illustrated embodiment) that is wound into at least one second roll of paper 502A, 503A (two shown in the illustrated embodiment).

[0279] As shown in FIG. 27, during manufacture of the cushioned envelopes, each of the at least one second inner sheet of paper 505A is conveyed through a roller pair 504A having outer peripheries with at least one lengthwise rib configured to impart pleats in the at least one inner sheet of paper 505A. As schematically shown in FIGS. 23, 24 and 25, the illustrated embodiments regions 100A of the sheet(s) of paper 505A are employed for making respective envelopes 400A, wherein the regions 100A are conveyed in the machine direction MD (see FIGS. 23, 24, 25, 27, 29 and 30), with the pleats extending substantially perpendicular or transverse to the machine direction MD.

[0280] FIGS. 23, 24 and 25 are schematic and explanatory figures rather than actual drawings of the system shown in FIG. 27 because the figures only depict portions of the components (such as, for example, sub-portions of the inner sheet of paper 505A corresponding to particular envelopes 400A to be fabricated but prior to cutting or separating the inner sheet of paper 505A to form individual envelopes 400A). It should be appreciated, however, that FIGS. 23, 24 and 25 are schematic and explanatory figures to facilitate appreciation of embodiments of the present invention.

[0281] With reference to FIG. 23, according to the preferred embodiments, envelopes 400A are formed by conveying second inner sheets 505A in a machine direction with pleats extending substantially perpendicular or transverse to the machine direction. In this manner, envelopes 400A can be manufactured, in which regions 100A of the paper 505A are cut (after being combined with the paper 506A) to form individual envelopes 400A. In particular, in the preferred embodiments, individual envelopes 400A are advantageously formed with regions 100A of the paper 505A arranged such that individual envelopes are formed by conveying the regions 100A in the machine direction, with such regions 100A including a first sub-region (e.g., first half) 102A and a second sub-region 103A (e.g., second half) that can be folded over for forming of an inner wall of a pouch of the envelope. As schematically shown in FIG. 23, in forming of an envelope 400A, a region 100A can be cut from the paper 505A (in composite with a corresponding region of the paper 506A), folded over the region 101A, with sides 51 within sub-regions 102A and 103A adhered together at a first side of a pouch and sides S2 within sub-regions 102A and 103A adhered together at a second side of the pouch, and with an opening into the pouch formed between adjacent end regions E1 and E2 of the folded-over region 100A.

[0282] As schematically illustrated in FIG. 24, in some preferred embodiments, plural regions 100A can be conveyed side-by-side in the machine direction such as to form a plurality of envelopes 400A concurrently. In the illustrated example, two envelopes 400A are, thus, concurrently formed side-by-side. In some preferred embodiments, the respective regions 100A, 100A (e.g., shown in FIG. 24) are formed by conveying separate sheets conveyed from separate rolls (e.g., rolls 502A and 503A shown in FIG. 27). In some alternative embodiments, separate regions 100A, 100A can be formed by cutting or separating a sheet conveyed from a single roll (e.g., providing a wider roll 502A (not shown) having a width comparable to that of rolls 502A and 503A combined, and cutting the conveyed sheet rather than employing two separate rolls 502A and 503A.

[0283] As shown in FIGS. 23, 24, 25 and 27, in some preferred embodiments, the adjacent regions 100A are separated from one another by a gap 201A (see FIG. 24). In some alternative embodiments, adjacent regions 100A can directly abut or contact one another. Additionally, in some alternative embodiments, adjacent regions 100A can be formed from a single sheet of paper (e.g., 505A not shown), which can be cut into separated sheets (e.g., similar to 505A shown in FIG. 27) either prior to or after being formed into a composite structure with the first outer sheet (e.g., 506A shown in FIG. 27).

[0284] With reference to FIG. 25, the figure schematically depicts plural regions 100A alongside a portion 506A of the first outer sheet 506A. As noted above, FIG. 25 is a schematic and explanatory figure and only depicts portions of the components (such as, for example, sub-portions 100A of the inner sheet of paper 505A corresponding to particular envelopes 400A to be fabricated but prior to cutting or separating the inner sheet of paper 505A to form individual envelopes 400A, as well as the portion 506A of the first outer sheet for explanatory purposes).

[0285] With reference to FIG. 27, in the illustrative example shown, in the manufacture of the envelopes 400A, the first outer layer of paper 506A is unwound from the roll(s) 501A and directed in a machine direction MD via conveying rollers R. Additionally, the second outer layer(s) of paper 505A is unwound from the roll(s) 502A, 503A and directed in the machine direction MD towards the roller pair 504A having outer peripheries with at least one lengthwise rib configured to impart pleats in the at least one inner sheet of paper 505A. Although such a roller pair 504A is provided in some embodiments, in other embodiments any other structure for imparting pleats to the paper 505A can be employed, such as, e.g., any of the structures for imparting pleats as described in the patents and/or publications incorporated by reference in the present application, such as, by way of example, patents and publications discussed above in relation to, e.g., FIGS. 16-18 of the parent application. Additionally, the pleats created in embodiments of the present invention can be formed like any of the pleats described in any of the patents and publications discussed and incorporated herein-by-reference above and/or like any of the pleated embodiments describe herein-above in relation to the parent application subject matter included herein.

[0286] With further reference to FIG. 28, after the second inner sheet(s) 505A are pleated and the first outer sheet 506A and the second inner sheet(s) 505A are brought close together (e.g., proximate roller R4), a composite structure of the first outer sheet 506A and the second inner sheet(s) 505A is formed by adhering the first outer sheet and the second inner sheet(s) together. Towards that end, in some preferred embodiments, an adhesive is applied in between the first outer sheet and the second inner sheet(s), such as, for example, employing a glue dispensing mechanism CG shown schematically in FIG. 28. In some embodiments, the glue dispensing mechanism is adapted to move (e.g., via computer automation) to apply glue at a plurality of locations. In some embodiments, the glue dispensing mechanism includes a plurality of outlets arranged to apply glue in specific regions (such as, for example, within regions A, B, C, D, E shown in FIGS. 28, 31 and 32).

[0287] In some preferred embodiments, as the first sheet 506A and the second sheet(s) 505A are conveyed adjacent one another as shown in FIG. 28, a plurality of pairs of pressing rollers 100R2 are aligned such as to press the first sheet 506A and the second sheet(s) 505A together, after the application of adhesive from the glue dispensing mechanism, which pressing rollers 100R2 are arranged to press at regions corresponding to regions A and C shown in FIG. 30. In some embodiments, the region B shown in FIG. can also be pressed and glued together to facilitate folding for formation of the envelope 400A. In the preferred embodiments, the pressing rollers 100R2 are arranged to apply pressure between the first sheet 506A and the second sheet(s) 505A such as to adhere the first and second sheets together across the entire width of the respective composite structure that forms a respective envelope 400A. Additionally, in some preferred embodiments, the regions A, B and/or C can be pressed such as to collapse the pleats within such regions in order to provide a strong adhesion between the first sheet 506A and the second sheet(s) 505A.

[0288] As further shown in FIG. 28, in some embodiments, as the first sheet 506A and the second sheet(s) 505A are further conveyed adjacent one another as shown in FIG. 28, individual envelopes are separated and cut from the elongated connected first sheet 506A and second sheet(s) 505A, such as, for example, employing a roller 100R1, which preferably is configured similarly to the rollers 100 shown in FIG. 20 of the parent application, and similarly includes a pressing portion 102R1 and a cutting portion 103R1. In some preferred embodiments, the pressing portion 102R1 is configured to press regions D and E shown in FIGS. 31 and 32, and the cutting portion 103R1 is configured to separate adjacent composite structures similar to that shown in the top of FIG. 29. For example, in some examples, the cutting portion 103R1 can be employed to cut the composite of the first sheet 506A and the second sheet(s) 505A at the position C1 shown in FIG. 29.

[0289] As shown in FIG. 29, although not shown in FIG. 27 or 28, in embodiments like that shown in FIG. 29, in order to separate adjacent composite members for forming plural envelopes, the first sheet 506A can also be cut along the machine direction along line shown at the position C2 in FIG. 29.

[0290] After separation of a composite section for forming a single envelope 400A similar to that shown in FIG. 30, the composite section shown in FIG. 30 can be folded over around the vertical line shown in the center of the region B in FIG. 30 to form the envelope 400A as shown in FIG. 31. As shown in FIG. 31, to form the envelope 400A, the lateral sides of the envelope 400A are preferably adhered together within the regions D and E. Additionally, the region 401A, formed by a section of the first sheet 506A that extends beyond the edge of the respective portion of the second sheet 505A operates as a flap of the envelope. In some embodiments, as shown in FIG. 31, an adhesive strip 402A can be provided to facilitate closing of the envelope. In some embodiments, the adhesive strip 402A includes a removable release liner for covering of the adhesive strip until it is desired to fold the flap over and seal the envelope.

[0291] Although in some preferred embodiments, the regions D and E have been pressed and adhered together employing the roller 100R1 shown in FIG. 28 (as discussed above), in some alternative embodiments, the roller 100R1 can simply cut the adjacent sections for forming individual envelopes 400A without pressing and adhering the first sheet and the second sheet. Then, after folding over of the envelope 400A as shown in FIG. 31, the lateral side regions D and E can be glued and pressed together, such as, e.g., employing pressing rollers and a glue dispensing mechanism similar to the pressing rollers and glue dispensing mechanism described above.

[0292] FIG. 32 shows a perspective view of an illustrative envelope 400A similar to that shown in FIG. 31 in an open state with the flap 401A open, and the pouch opening in an open position to receive an item therein in the direction of the arrow shown in FIG. 32. As described above, although not shown in FIG. 32, in the preferred embodiments, the pleats are arranged such that the ridges extend parallel to the lateral sides of the pouch, such that an item placed within the pouch opening is directed substantially parallel to the direction of the ridges.

[0293] In the embodiments shown in FIGS. 29-32, the composite of the portion 100A of the second sheet 505A and the corresponding portion 200A of the first sheet 506A employed for forming a single envelope 400A are sized such as to align with one another along upper left and bottom sides shown in FIG. 30, with the portion 200A of the first sheet extending further outward such as to form a flap 401A of the envelope. Moreover, as shown in FIG. 29, the strips 505A are shown as separated by a distance corresponding to the flap portion 401A. However, in other embodiments, the composite of the first sheet and the second sheet can include first sheets and second sheets having the same dimensions, whereby a flap portion that is created would have both sheets. In such an embodiment, the entire flap portion is preferably pressed and glued similarly to the region C shown in, e.g., FIG. 32.

[0294] With respect to the illustrative example of the envelope 400A shown in FIG. 26, the envelope shown in FIG. 26 includes some illustrative modifications from that shown in, e.g., FIG. 32. For example, in the embodiment shown in FIG. 26, the flap 401A is cut narrower. Additionally, in the embodiment shown in FIG. 26, the envelope is not pressed flat such as to flatten the pleats or undulations in the region B corresponding to the position at which the envelope is folded during manufacture. Additionally, in the embodiment shown in FIG. 26, the envelope is not pressed flat such as to flatten the pleats or undulations in the regions A and C corresponding to the position at which the envelope is folded during manufacture. Thus, as shown proximate the opening of the pouch in FIG. 26, in some embodiments, the pleatings or undulations can, thus, extend to the opening of the pouch (as shown). It should be appreciated that the second inner layer would, however, be adhered to the first outer layer, such that upon manual opening of the opening of the pouch, the second inner layer would adhere to the first outer layer on both sides of the opening of the pouch such as to enable a user to access the interior of the pouch.

[0295] In various embodiments, adhesives employed to form the envelopes 400A can include hot adhesives, cold adhesives and/or any other adhesives or sealants. In some preferred embodiments, the adhesives employed to form the envelopes (such as, e.g., employed within glue dispensing mechanism CG shown in FIG. 28) are or include cold glues. In some preferred embodiments, cold glues are water-based solutions. In some examples, the cold glues include adhesive are dissolved in water. In some embodiments, cold glues include one or more of the following types: 1) starch; 2) dextrine-depolymerized starches; and/or 3) polyvinyl alcohol solutions (PVOH).

[0296] In some preferred embodiments, pleats of the second inner sheet are adhered to a side surface of the first outer sheet using an adhesive. For example, in some preferred embodiments, an adhesive can be applied in a region of contact between the apices of the pleats of the second inner sheet and the side surface of the first outer sheet. In some embodiments, the adhesive can extend along a substantial portion of or the entire length of the region of contact between the apices of the pleats of the second inner sheet and the side surface of the first outer sheet. In some other embodiments, the adhesive can be located at discrete locations or at intervals along the length of the region of contact between the apices of the pleats of the second inner sheet and the side surface of the first outer sheet. For example, FIG. 35 is a perspective view of a portion of a wall of a pouch of an envelope that is like the envelope shown in FIG. 26, which portion of the wall of the pouch of the envelope includes a first outer sheet 506A adhered a portion of a pleated second inner sheet 505A containing and cushioning an item within the pouch of the envelope. As shown in the embodiment of FIG. 35, pleats P of a second inner sheet 505A are adhered to a side surface of a first outer sheet 506A using an adhesive (such as, e.g., using a glue dispensing mechanism CG like that shown in FIG. 28 with any of the adhesives described herein). For example, in some preferred embodiments, an adhesive can be applied in a region of contact between the apices (i.e., apexes) AP of the pleats P of the second inner sheet and the side surface of the first outer sheet. For example, in some embodiments, an adhesive can be applied along a substantial portion of or the entire length of the region of contact between the apices AP of the pleats of the second inner sheet and the side surface of the first outer sheet. For example, in some embodiments, a glue line GL (shown in dashed lines in FIG. 35 since the glue line would be located upon the apices AP situated below the sheet 506A in the view shown in FIG. 35) can extend along a substantial portion of or the entire length of the apices. In some other embodiments, the adhesive can be located at discrete locations or at intervals along the length of the region of contact between the apices of the pleats of the second inner sheet and the side surface of the first outer sheet. For example, in some embodiments glue spots GS (similarly, shown in dashed lines in FIG. 35 since the glue spots would be located upon the apices AP situated below the sheet 506A in the view shown in FIG. 35) can be applied at discrete locations or at intervals along the length of the region of contact between the apices of the plates of the second inner sheet and the side surface of the first outer sheet.

[0297] In some preferred embodiments, as shown in FIG. 35, each of the pleats P forms substantially isosceles triangles in which the length of each side of the pleat (e.g., sides P1 and P2) is the same and the apices AP of the pleats at the juncture between such equal length sides P1 and P2 of adjacent pleats P contact and are adhered to the side surface of the first outer sheet. In some preferred embodiments, each of the pleats P forms a substantially equilateral triangle in which the length of each side P1 and P2 of the pleat is substantially the same or the same and the pleat width PW parallel to the plane of the first outer sheet between adjacent apices AP is also substantially the same or the same as the lengths of each of the sides P1 and P2.

[0298] Among other things, the preferred embodiments of the present invention can achieve a very strong protective envelope structure with minimal materials. For example, the most preferred embodiments can employ merely two sheets of paper that are adhered together at limited regions. Additionally, the most preferred embodiments can also provide cushioning using triangular-shaped cushioning cells made with such pleats. Notably, triangles are the strongest polygon shapes, especially isosceles and equilateral triangles, enabling substantial cushioning with limited materials.

[0299] With further reference to FIG. 35, the most preferred embodiments not only achieve a highly effective cushioning with triangular-shaped cushion cells formed by the adherence of the pleats of the second inner sheet to the surface of the first outer sheet, but also achieve a substantial reduction of friction forces applied to an item when the item is inserted into and/or removed from the pouch of an envelope. For example, the illustrative structure shown in FIG. 35 advantageously achieves substantial cushioning capabilities that helps protect an item (see ITEM depicted in FIG. 35) from external vertical forces in the direction of the arrows VF shown in FIG. 35, while simultaneously achieving substantial reduction in friction forces imparted to items that are inserted into and/or removed from the pouch upon movement of the item relative to the wall of the pouch in the direction of the arrows HF shown in FIG. 35.

[0300] In some embodiments, each of the pleats substantially forms a triangle having an angle at the apices between adjacent pleats contacting the surface of the first outer sheet of paper, which angle is between 40 to 80 degrees, or, in some preferred embodiments, between 45 to 75 degrees, or, in some preferred embodiments, between 50 to 70 degrees, or, in some preferred embodiments, between 55 to 65 degrees, or, in some preferred embodiments, about 60 degrees. In other less preferred embodiments, the angle can be greater than 80 degrees, such as, e.g., 90 degrees or more, or 100 degrees or more, or 110 degrees or more, or 120 degrees or more. Similarly, in other less preferred embodiments, the angle can be smaller than 40 degrees, such as, e.g., 35 degrees or less, or 30 degrees or less, or 25 degrees or less.

[0301] It should be appreciated that in the preferred embodiments, the walls P1 and P2 of the pleats would not be exactly linear and formed as exact flat planes, but would have some variation in shape such as some curvature, dimples or other irregularities, and that the apices AP between the respective pleats P and the bottom tips BT at the bottom ends of the pleats P would not be exact angles, but would have some variation in shape such as rounding or other irregularities. Accordingly, in this application, the terminology triangle or triangular, or isosceles triangle, or equilateral triangle should not be construed as referring to mathematically or geometrically exact geometrical shapes.

[0302] With respect to FIGS. 33A-33G, these figures show some additional illustrative embodiments of the invention employing alternative shapes and configurations of the second inner paper layer, which provides cushioning within a pouch of the envelope. In particular, in the embodiments shown in FIGS. 33A-33G, the second inner paper sheet is formed to have a consistent cross-sectional shape across the entire sheet. Specifically, FIGS. 33A-33G show an edge-view of a sheet, similar to sheet 505A shown in, e.g., FIG. 29, from a direction perpendicular to the machine direction MD shown in FIG. 29. In each of the embodiments shown in FIGS. 33A-33G, the shapes includes pleatings or undulations that create ridges that extend substantially transverse to the machine direction. In some preferred embodiments, the ridges extend a distance of greater than 30% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, wherein the ridges extend a distance of greater than 40% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 50% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 60% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 70% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 80% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 90% of the depth of the envelope from the opening to a bottom of the pouch of the envelope, or, in some preferred embodiments, the ridges extend a distance of greater than 95% of the depth of the envelope from the opening to a bottom of the pouch of the envelope.

[0303] With respect to FIGS. 33A-33C, these figures show illustrative embodiments with smoothly curved variations in width-wise position of the sidewall of the second inner paper layer, with FIG. 33A showing a tighter or more compact sinusoidal structure and FIG. 33B showing a wider or less compact structure. It should be appreciated that the arc of curvature can vary in different embodiments, such as, e.g., between the arcs shown in these figures, or even greater than that shown in FIG. 33B or even less than that shown in FIG. 33A. Similarly, the various angles and dimensions of the embodiments shown in FIGS. 33D-33G can also be varied, as desired, in various embodiments of the present invention. Additionally, the distance between pleatings and/or undulations or the like can be modified, such as to, e.g., have similar sizes pleatings and/or undulations or the like separated at greater distances or closer together in some alternative embodiments. In some illustrative examples, the triangular shaped pleatings shown in FIG. 33E can be modified to adapt the angles at the peaks of the triangles to that desired. In some illustrative and non-limiting embodiments, such angles can be between about 20 to 135, while in some illustrative and non-limiting embodiments, such angles can be between about 45 and 90. In other embodiments, the angle can be similar to any of the embodiments described in any of the patents or publications incorporated herein by reference or in any of the embodiments of the parent application described and included herein above.

[0304] In some illustrative embodiments, the second inner paper layer can include width-wise positional variations of the side surface of the second inner sheet that cushion items placed within an inner pouch of the envelope, wherein the width-wise positional variations of the side surface result in an increased width h (see, e.g., width h shown for illustrative purposes in FIGS. 33A, 33C, 33E and 33G). In some illustrative embodiments, the increased width h of the second inner paper layer is at least 1/16 inch. In some illustrative embodiments, the increased width h of the second inner paper layer is at least inch. In some illustrative embodiments, the increased width h of the second inner paper layer is at least inch. In some illustrative embodiments, the increased width h of the second inner paper layer is at least inch. In some illustrative embodiments, the increased width h of the second inner paper layer is between about 1/16 inch and inch. In some illustrative embodiments, the increased width h of the second inner paper layer is between about inch and inch.

[0305] With reference to FIGS. 34A-34L, some further embodiments of the invention are depicted which employ other configurations for the second inner paper layer, wherein the second inner paper layer includes other configurations for width-wise positional variations of the side surface of the second inner sheet that cushion items placed within an inner pouch of the envelope. In some preferred implementations of the embodiments shown in FIGS. 34A-34L, the width-wise positional variations of the side surface result in an increased width h having a depth like that of the various embodiments described above.

[0306] With reference to the embodiment shown in FIG. 34A, the second inner sheet can include a plurality of undulations caused by forming the sheet to have curved (e.g., sinusoidal) configurations as viewed along both the x and y axes as shown, such as to create an array of curved protrusions extending upwardly in the axis z such as to have a width h.

[0307] With reference to the embodiment shown in FIG. 34B, the second inner sheet can include a plurality of pleats of different widths h, as shown, and/or with increased spacing between pleats as shown in some illustrative embodiments.

[0308] With reference to the embodiment shown in FIG. 34C, the second inner sheet can include an array or distribution of embossments, such as, e.g., the irregular (e.g., rounded) embossments as shown in the figure. In some embodiments, the edges of the embossments are arcuate and/or rounded to facilitate insertion of items into a pouch of the envelope.

[0309] With reference to the embodiment shown in FIG. 34D, the second inner sheet can include a plurality of elongated undulations or embossments in some illustrative embodiments. In the preferred embodiments, the elongated undulations or embossments extend such that ridges thereof extend substantially perpendicularly to the opening of the pouch, similar to the ridges of the pleats shown in FIG. 30.

[0310] With reference to the embodiment shown in FIG. 34E, the second inner sheet can include an irregular configuration as shown, such as to impart width-wise variation having a width h similar to that of other embodiments discussed herein. Upon adhering the second inner sheet to the first outer sheet (e.g., upon adhering by cold glue or the like the first outer sheet to adjacent portions of the second inner sheet), the variations of the second inner sheet can impart cushioning.

[0311] With reference to the embodiments shown in each of FIGS. 34F-34L, in various embodiments in which pleatings or undulations are formed, the pleatings or undulations do not necessarily have to have a consistent cross-sectional shape like that of the embodiments shown in, e.g., FIGS. 33A-33G, as well as in FIG. 8A. Specifically, FIGS. 34F-34L show illustrative embodiments that employ a variety of other pleating or undulation formations that can be provided in other embodiments of the invention for the second inner paper layer 505A. However, it should be appreciated that formation of pleatings or undulations similar to that shown in, e.g., FIGS. 33A-33G can be performed with less complex equipment (e.g., rollers, etc.).

[0312] According to the preferred embodiments, a highly advantageous and novel envelope is created having substantial benefits over prior envelopes, including substantial cost savings. Additionally, in the preferred embodiments, envelopes 400A are created that are recyclable, being made with paper, as described herein-above, with minimal glue in preferred embodiments of the invention.

Broad Scope of the Invention

[0313] The use of individual numerical values is stated as approximations as though the values were preceded by the word about, substantially, or approximately. Similarly, the numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both preceded by the word about, substantially, or approximately. In this manner, variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. As used herein, the terms about, substantially, and approximately when referring to a numerical value shall have their plain and ordinary meanings to a person of ordinary skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue. The amount of broadening from the strict numerical boundary depends upon many factors. For example, some of the factors which may be considered include the criticality of the element and/or the effect a given amount of variation will have on the performance of the claimed subject matter, as well as other considerations known to those of skill in the art. As used herein, the use of differing amounts of significant digits for different numerical values is not meant to limit how the use of the words about, substantially, or approximately will serve to broaden a particular numerical value or range. Thus, as a general matter, about, substantially, or approximately broaden the numerical value. Also, the disclosure of ranges is intended as a continuous range including every value between the minimum and maximum values plus the broadening of the range afforded by the use of the term about, substantially, or approximately. Thus, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

[0314] To the extent that determining a given amount of variation of some the factors such as the criticality of the slit patterns, paper width differential pre- and post-expansion, paper weights and type, as well as other considerations known to those of skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue will have on the performance of the claimed subject matter, is not considered to be within the ability of one of ordinary skill in the art, or is not explicitly stated in the claims, then the terms about, substantially, and approximately should be understood to mean the numerical value, plus or minus 15%.

[0315] It is to be understood that any ranges, ratios and ranges of ratios that can be formed by, or derived from, any of the data disclosed herein represent further embodiments of the present disclosure and are included as part of the disclosure as though they were explicitly set forth. This includes ranges that can be formed that do or do not include a finite upper and/or lower boundary. Accordingly, a person of ordinary skill in the art most closely related to a particular range, ratio or range of ratios will appreciate that such values are unambiguously derivable from the data presented herein.