Void fill packaging product and methods for making
Briefly described, embodiments of the presently disclosed subject matter relate to void fill packaging products and one or more methods for making the void fill packaging products. The void fill packaging product is configured to cushion items for transport whether that be shipping long distances, local delivery, or self-transport in a vehicle. Specifically, in one aspect, a void fill product for packaging, may include a single spiraled continuous paper sheet surrounding a hollow center and forming at least two layers that overlap in a first direction. The portions of the at least two layers may overlap and may be mechanically joined in a second direction that is approximately perpendicular to the first direction.
1 . A void fill product for packaging, comprising:
a single spiraled continuous paper sheet surrounding a hollow center and forming at least two layers that overlap in a first direction,
wherein portions of the at least two layers overlap and are mechanically joined in a second direction that is approximately perpendicular to the first direction, and
wherein at least a first layer of the at least two layers surrounds the hollow center at an angle in relation to a longitudinal axis of the void fill product.
2 . The void fill product of claim 1 , wherein the portions of the at least two layers are mechanically joined without adhesive or stitching.
3 . The void fill product of claim 2 , wherein the at least two layers are crumpled in the second direction.
4 . The void fill product of claim 1 , wherein the at least two layers overlap and are mechanically joined in a third direction opposite of the second direction.
5 . The void fill product of claim 4 , wherein the at least two layers are crumpled in the third direction.
6 . The void fill product of claim 1 , comprising a triangular cross-section, a square cross-section, or a circular cross-section.
7 . A void fill product for packaging, comprising:
a single spiraled continuous sheet surrounding a hollow center and forming at least two layers that overlap in a first direction,
wherein portions of the at least two layers overlap and are mechanically joined in a second direction, and
wherein at least a first layer of the at least two layers surrounds the hollow center at an angle in relation to a longitudinal axis of the void fill product.
8 . The void fill product of claim 7 , wherein the portions of the at least two layers are mechanically joined without adhesive or stitching and the single spiraled continuous sheet comprises paper.
9 . The void fill product of claim 7 , wherein the at least two layers are crumpled in the second direction.
10 . The void fill product of claim 7 , wherein the at least two layers overlap and are mechanically joined in a third direction opposite of the second direction.
11 . The void fill product of claim 10 , wherein the at least two layers are crumpled in the third direction.
12 . The void fill product of claim 7 , comprising a triangular cross-section, a square cross-section, or a circular cross-section.
13 . The void fill product of claim 1 , wherein each of the at least two layers surrounds the hollow center at the angle in relation to the longitudinal axis of the void fill product.
14 . A process for forming the void fill product of claim 1 , the process comprising:
wrapping the single spiraled continuous paper sheet around a mold at least twice to form the at least two layers overlapping in the first direction with the hollow center filled by the mold;
cutting an unwrapped portion of the single spiraled continuous paper sheet to separate the unwrapped portion from the at least two layers;
crumpling the at least two layers in the second direction to mechanically interlock the at least two layers without stitching or an adhesive; and
removing the at least two layers from the mold.
15 . The process of claim 14 , wherein the mold comprises a triangular, square, or circular cross-section.
16 . The process of claim 14 , further comprising unrolling the single spiraled continuous paper sheet from a roll of paper.
17 . The process of claim 14 , wherein crumpling the at least two layers in the second direction comprises using one or more first sets of rollers to force portions of the at least two layers in the second direction to overlap and interlock while wrapped around the mold.
18 . The process of claim 17 , further comprising crumpling the at least two layers in a third direction that is opposite of the second direction.
19 . The process of claim 18 , wherein crumpling the at least two layers in the third direction comprises using one or more second sets of rollers to force portions of the at least two layers in the third direction to overlap and interlock while wrapped around the mold.