Granted Patent B2

US 11,801,981 · App. 17/365,548 · Granted Oct 31, 2023

Inventor: Thomas D. Wetsch (Naples, FL)

Assignee: Pregis Innovative Packaging LLC

B65D65/42B65B51/10B65B61/06B65B61/24B65B67/1255B65D27/14B65D65/40B65D75/30B65D75/42B65D75/527B65D81/03B65D81/3266B65B2067/1283B65D2581/02

Abstract

Claims (75)

1. Packaging material, comprising:

at least one web layer having a surface that includes first and second regions, wherein, when corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions cooperatively surrounding a cavity defined between the at least one web layer;

a first sealing material disposed in the first region and configured to seal together the corresponding first regions of the at least one web layer upon application of first conditions to the first sealing material; and

a second sealing material disposed in the second region and configured to seal together the corresponding second regions of the at least one web layer upon application of second conditions to the second sealing material;

wherein the first or second conditions include a required temperature or pressure; where the second sealing material is configured such that the first conditions applied to the second sealing material do not cause the second sealing material to seal; and wherein the first conditions include a required first maximum temperature for the first sealing material; wherein the second conditions include a required second minimum temperature for the second sealing material; wherein the second minimum temperature is higher than the first maximum temperature, where the second sealing material; and

wherein the at least one web layer forms a plurality of walls of a packaging unit configured to cushion an object to be shipped; and

wherein at least one of the walls includes padding configured to provide cushioning to the object.

2. The packaging material of claim 1 , wherein the first and second sealing materials are different materials.

3. The packaging material of claim 1 , wherein:

at least one of the walls includes a wall cavity positioned therebetween; and

the padding is disposed in the wall cavity.

4. The packaging material of claim 1 , wherein the padding is positioned along the at least one web layer in sections in order to facilitate folding of the at least one web layer between adjacent sections.

5. The packaging material of claim 1 , wherein the padding includes an expansion material.

6. The packaging material of claim 1 , wherein the at least one web layer includes a substrate made of paper.

7. The packaging material of claim 1 , wherein the first sealing material is disposed over a majority of a surface of the at least one web layer.

8. Packaging material web, comprising:

first and second overlaid plies including a hinge area disposed for folding the overlaid plies over each other at a hinge line that extends through the hinge area to divide the overlaid plies into first and second wall portions on opposite sides of the hinge line, such that the wall portions are folded about the hinge line to a folded configuration, defining an interior cavity therebetween, the interior cavity being configured to receive and house an object;

an expandable material configured, when in an expanded configuration, to cushion the object, the expandable material being disposed between the first and second plies in a main padding area, wherein the hinge area between the plies has less of the expandable material than in the main padding area such that, in the folded configuration, the hinge area is thinner than the main padding area; and

a sealing material disposed to affix the wall portions in the folded configuration such that the first and second walls define a packaging unit.

9. Packaging material, comprising:

at least one web layer having a surface that includes first and second regions, wherein, when corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions cooperatively surrounding a cavity defined between the at least one web layer;

a first sealing material disposed in the first region and configured to seal together the corresponding first regions of the at least one web layer upon application of first conditions to the first sealing material; and

a second sealing material disposed in the second region and configured to seal together the corresponding second regions of the at least one web layer upon application of second conditions to the second sealing material;

wherein the first or second conditions include a required temperature or pressure; where the second sealing material is configured such that the first conditions applied to the second sealing material do not cause the second sealing material to seal; and wherein the first conditions include a required first maximum temperature for the first sealing material; wherein the second conditions include a required second minimum temperature for the second sealing material; wherein the second minimum temperature is higher than the first maximum temperature, where the second sealing material; and

wherein the at least one web layer forms walls of a packaging container when the first regions are sealed to each other, which walls cooperatively bound at least a portion of the cavity, the cavity being a packaging interior cavity that is configured to house an object to be shipped.

10. The packaging material of claim 9 , wherein:

the corresponding first regions are sealed to each other by the first sealing material; and

the second sealing material is in an unsealed condition, forming an opening to the interior cavity, the opening being configured to receive the object into the interior cavity.

11. The packaging material of claim 10 , wherein the second sealing material is configured to seal closed the opening.

12. The packaging material of claim 10 , wherein, when the corresponding first regions are sealed to each other and the corresponding second regions abut each other.

13. The packaging material of claim 10 , wherein:

the at least one web layer includes a longer web layer and a shorter web layer;

the second region of the longer web layer is positioned on the longer web layer in a direction facing the interior cavity; and

the second region of the shorter web layer is positioned on the shorter web layer in a direction facing outwardly from the interior cavity.

14. The packaging material of claim 10 , further comprising an assembled web that includes the at least one web layer, which at least one web layer includes a plurality of said walls defining a plurality of said interior cavities, such that the assembled web includes a series of the packaging containers.

15. The packaging material of claim 14 , further comprising a region of weakness positioned between adjacent packaging containers in the series of packaging containers, wherein the region of weakness is configured to facilitate separation of the adjacent packaging containers.

16. The packaging material of claim 15 , wherein:

one of the walls is interrupted, forming the opening;

the region of weakness is positioned along the other remaining wall; and

the opening is overlaid over the region of weakness.

17. The packaging material of claim 14 , wherein the at least one web layer is part of a single web that is folded over itself to provide the at least one web layer on each side of the fold.

18. The packaging material of claim 14 , wherein the at least one web layer includes a plurality of webs that are overlaid.

19. Packaging material, comprising:

at least one web layer having a surface that includes first and second regions, wherein, when corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions cooperatively surrounding a cavity defined between the at least one web layer;

a first sealing material disposed in the first region and configured to seal together the corresponding first regions of the at least one web layer upon application of first conditions to the first sealing material; and

a second sealing material disposed in the second region and configured to seal together the corresponding second regions of the at least one web layer upon application of second conditions to the second sealing material;

wherein the first or second conditions include a required temperature or pressure;

wherein the second sealing material is configured such that the first conditions applied to the second sealing material do not cause the second sealing material to seal;

wherein the at least one web layer includes first and second overlaid plies including a hinge area disposed for folding the overlaid plies over each other at a hinge line that extends through the hinge area to divide the overlaid plies into first and second wall portions on opposite sides of the hinge line, such that the wall portions are folded about the hinge line to a folded configuration, defining the cavity therebetween, the cavity being an interior cavity configured to receive and house an object;

wherein the at least one web layer includes further includes an expandable material configured, when in an expanded configuration, to cushion the object, the expandable material being disposed between the first and second plies in a main padding area, wherein the hinge area between the plies has less of the expandable material than in the main padding area such that, in the folded configuration, the hinge area is thinner than the main padding area; and

wherein the first sealing material is disposed to affix the wall portions in the folded configuration such that the first and second walls define a packaging unit.

20. The packaging web material of claim 19 , wherein the hinge area is substantially free of the expandable material, providing a gap between portions of the main padding area on the first and second wall portions.

21. The packaging web material of claim 19 , wherein:

the first and second overlaid plies include a third wall portion; and

the hinge area comprises:

a first hinge area disposed between the first and second wall portions; and

a second hinge area disposed between the second and third wall portions; such that the first and third wall portions folded respectively about hinges in the first and second hinge areas each overlays the second wall portion, such that the second wall portion forms a first wall of a packaging container, and the first and third wall portions form a second wall of the packaging container overlaid on the first wall and defining the interior cavity between the walls;

wherein the first sealing material is disposed to seal the first wall to the third wall.

22. The packaging web material web of claim 21 , wherein first and third wall portions have longitudinal edges such that, in the folded configuration, the longitudinal edges are disposed above the second wall portion and are sealed together by the first sealing material.

23. Packaging material, comprising:

at least one web layer having a surface that includes first and second regions, wherein, when corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions cooperatively surrounding a cavity defined between the at least one web layer;

a first sealing material disposed in the first region and configured to seal together the corresponding first regions of the at least one web layer upon application of first conditions to the first sealing material; and

a second sealing material disposed in the second region and configured to seal together the corresponding second regions of the at least one web layer upon application of second conditions to the second sealing material;

wherein the first or second conditions include a required temperature or pressure;

wherein the second sealing material is configured such that the first conditions applied to the second sealing material do not cause the second sealing material to seal;

wherein the first conditions include a required first maximum temperature for the first sealing material;

wherein the second conditions include a required second minimum temperature for the second sealing material;

wherein the second minimum temperature is higher than the first maximum temperature; and

wherein the second sealing material is configured to remain unsealed at the first maximum temperature.

24. Packaging material, comprising:

at least one web layer having a surface that includes first and second regions, wherein, when corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions cooperatively surrounding a cavity defined between the at least one web layer;

a first sealing material disposed in the first region and configured to seal together the corresponding first regions of the at least one web layer upon application of first conditions to the first sealing material; and

a second sealing material disposed in the second region and configured to seal together the corresponding second regions of the at least one web layer upon application of second conditions to the second sealing material;

wherein the first or second conditions include a required temperature or pressure; where the second sealing material is configured such that the first conditions applied to the second sealing material do not cause the second sealing material to seal; and wherein the first conditions include a required first maximum temperature for the first sealing material; wherein the second conditions include a required second minimum temperature for the second sealing material; wherein the second minimum temperature is higher than the first maximum temperature, where the second sealing material; and

wherein the second sealing material is heat sealable, and application of the second conditions forms a heat seal between the corresponding second regions.

Assignments (5)

Cited By (8)

US 12,304,680 US 12,330,389 US 12,496,798 US 12,605,923 US 12,679,062 US 12,698,116 US 12,698,119 US 12,703,532