Field of the Invention

[0001 ] This invention relates generally to sheet packaging and, more particularly, this invention relates to a hyperflexible configuration of sheet packaging.

Background of the Invention

[0002] Cushioning sheet material is used for packaging and include a variety of configurations, including plastic bubble wrap.

[0003] Recyclable cardboard-based packaging alternatives to plastic bubble wrap is desirous however and, in this regard, US 2503874 A (Ives) 1 1 April 1950 proposes a planar reinforced layer having a corrugated layer bonded thereto. Ives teaches rows of straight notches being cut through the cardboard layer to confer flexibility across flutes of the cardboard layer.

[0004] The present invention seeks to provide sheet packaging, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0005] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Disclosure

[0006] There is provided herein sheet packaging comprising a corrugated ply bonded to a backing ply. The corrugated ply forms parallel flutes.

[0007] The packaging comprises voids through both the corrugated ply and the backing ply at intervals along the flutes.

[0008] The present voids formed through the corrugated ply and the backing ply at intervals along the flutes form a plurality of insular portions interconnected by flexures. Each insular portion comprising a flute portion and a backing portion between adjacent voids and bonded together at respective edges, and each flexure comprises bonded-together portions of the corrugated ply and the backing ply. [0009] These flexures confer hyper flexibility to the packaging wherein each flexure possesses an independent bend axis across which the flexure can both be twisted and bent. Furthermore, the flexures allow distortion of the packaging without compromising the cushioning structural integrity of the insular portions.

[0010] Unlike the arrangement of Ives for example which can only be bent along the flutes, across the flutes along the rows of voids or diagonally across diagonal voids, the present packaging can be twisted and bent across into arbitrary shapes and forms including across nonorthogonal and non-diagonal axes as is illustrated in Figures 7 and 8 and 9 and 10 for example.

[0011 ] The stiffness and flexibility of the present packaging may be controlled by the extent to which edges of insular portions of adjacent flutes overlap.

[0012] There are further provided embodiments herein wherein the sizing and respective positioning of the voids and insular portions can be adjusted to control the stiffness and other performance properties of the present packaging.

[0013] The corrugated ply and the backing ply preferably comprises cardboard and may be made in the manufacturing process wherein the corrugated ply is bonded to the backing ply whereafter the voids are punched, cut or formed through both simultaneously.

[0014] Other aspects of the invention are also disclosed.

Brief Description of the Drawings

[0015] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0016] Figure 1 shows a top plan view of sheet packaging in accordance with an embodiment;

[0017] Figure 2 shows a perspective view of the packaging of Figure 1 ;

[0018] Figure 3 illustrates bending of a flexure between insular portions of the packaging;

[0019] Figure 4 illustrates twisting of a flexure between insular portions of the packaging; [0020] Figure 5 illustrates both bending and twisting between insular portions of the packaging;

[0021] Figure 6 illustrates a quadrant of insular portions interconnected by respective flexures around a void when laid flat;

[0022] Figure 7 shows the embodiment of Figure 6 when the packaging is twisted and bent;

[0023] Figure 8 shows a further embodiment of the packaging illustrating the way in which the packaging can be arbitrarily twisted and bent;

[0024] Figure 9 shows packaging in accordance with an embodiment bent against the corrugated ply;

[0025] Figure 10 illustrates packaging in accordance with an embodiment bent against the backing ply;

[0026] Figure 11 shows a top plan view of the packaging in accordance with a further embodiment;

[0027] Figure 12 shows a perspective view of the packaging of Figure 11 ;

[0028] Figure 13 shows a top plan view of the packaging in accordance with a further embodiment;

[0029] Figure 14 shows a perspective view of the packaging of Figure 13;

[0030] Figure 15 shows a top plan view of the packaging in accordance with a further embodiment;

[0031] Figure 16 shows a perspective view of the packaging of Figure 15;

[0032] Figure 17 shows a top plan view of the packaging in accordance with a further embodiment;

[0033] Figure 18 shows a perspective view of the packaging of Figure 17;

[0034] Figure 19 shows a top plan view of the packaging in accordance with a further embodiment;

[0035] Figure 20 shows a perspective view of the packaging of Figure 19;

[0036] Figure 21 shows a top plan view of the packaging in accordance with a further embodiment;

[0037] Figure 22 shows a perspective view of the packaging of Figure 21 ; [0038] Figure 23 shows a top plan view of the packaging in accordance with a further embodiment;

[0039] Figure 24 shows a perspective view of the packaging of Figure 23. Description of Embodiments

[0040] Figures 1 and 2 shows packaging 100 comprising a corrugated ply 101 adhered to a backing ply 102. The corrugated ply 101 and the backing ply 102 are preferably cardboard. Furthermore, the packaging 100 preferably comprises biodegradable and/or compostable material.

[0041 ] The corrugated ply 101 forms parallel flutes 103. The corrugated ply 101 forms a generally wavelike pattern and may be generally sinusoidal and bonded to the backing ply 102 using adhesive or the like along apexes of an undersurface of the corrugated ply 101 . Other corrugated ply 101 shapes are envisaged, including the corrugated ply 101 being flat topped trapezoidal in cross sectional shape.

[0042] The packaging 100 comprises voids 104 through both the corrugated ply 101 and the backing ply 102 at intervals along the flutes 103, thereby forming a plurality of insular portions 105 interconnected by flexures 106 generally shown in Figure 1. [0043] With reference to Figure 2, each insular portion 105 comprises a flute portion 107 and a backing portion 108 bonded at respective edges along the respective flute 103.

[0044] Furthermore, each flexure 106 comprises bonded together portions of the corrugated ply 101 and the backing ply 102.

[0045] Figure 3 shows a flexure 106 bending between adjacent insular portions 105, Figure 4 shows a flexure 106 twisting between insular portions 105 and Figure 5 shows a flexure 106 both bending and twisting between insular portions 105.

[0046] Figure 6 shows a quadrant of insular portions 105 interconnected around a void 104 by respective flexures 106 when the packaging 100 is laid flat and Figure 7 shows the packaging of Figure 6 being twisted and bent, illustrating the hyper flexibility conferred by each flexure 106 having an independent bend axis. [0047] Figure 8 further illustrates how an elongate flexure 106A can itself bend under compression whilst in opposing flexure 106B can be under tension allowing the packaging 100 to be twisted and bent.

[0048] Figure 9 illustrates the packaging 100 in accordance with an embodiment hyper flexibly folded against the corrugated ply 101 whereas Figure 10 illustrates the packaging 100 in accordance with a further embodiment hyper flexibly folded against the backing ply 102.

[0049] According to the embodiment of Figure 1 , the voids 104 may be generally rectangular wherein each void 104 comprises straight edges 109 aligned along flute axes 110 and straight edges 11 1 orthogonally with respect to the flute axes 1 10. [0050] Figures 21 and 22 show wherein the voids 104 are non-rectangular. In accordance with the embodiment shown, each void 104 may yet comprise straight edges 109 along the flute axis 1 10 but wherein the voids 104 widen at opposite edges thereof along the flute axis 110 to increase the effective central cushioning width of the insular portion 105 along the flute axis 110 yet decrease the width of the flexures 106 along the flute axis 110 for increased flexibility. In this way, the horizontal cross section of the shapes of the voids 104 and/or the insular portions 105 may be adjusted to control the flexibility and/or the cushioning of the packaging 100.

[0051 ] In accordance with the embodiment shown in Figure 1 , the voids 104 of adjacent flutes 103 are alternately aligned along flute axes 1 10 so that each insular portion 105 is diagonally interconnected to a quadrant of adjacent insular portions 105.

[0052] According to the embodiment of Figure 1 , the insular portions 105 of adjacent flutes 103 overlap along flute axes 110 thereby increasing stiffness along flute axes 110. Furthermore, according to the embodiment of Figure 1 , the voids 104 of adjacent flutes 103 do not overlap across the flute axes 110, reducing stiffness across the flute axes 110.

[0053] According to the embodiment of Figures 11 and 12, edges of insular portions 105 of adjacent flutes 103 are aligned along flute axes 1 10, thereby reducing stiffness along the flute axes 110 and forming discrete fold lines across the flute axes 110 as compared to the embodiment of Figures 1 and 2.

[0054] According to the embodiment of Figure 13, the voids 104 are wider as compared to the insular portions 105 along flute axes thereby increasing flexibility. [0055] Furthermore, voids 104 of adjacent flutes 103 overlap along flute axes 1 10, thereby forming flexures 106 which have longitude along flute axes 1 10, thereby increasing flexibility thereof.

[0056] Figure 15 shows an embodiment wherein the voids 104 are narrower than the insular portions 105 along flute axes 110, thereby increasing stiffness along the flute axes 1 10. This is compared to the embodiment of Figure 13 which shows the voids

104 being wider than the insular portions 105 along the flute axis 110, thereby reducing stiffness along the flute axes 110.

[0057] Furthermore, Figure 15 shows wherein edges of the voids 104 along flute axes 110 of adjacent flutes 104 overlap, thereby conferring flexure 106 longitude across flute axes 110 have an increased flexibility across flute axes 110.

[0058] Figure 17 shows an embodiment wherein the voids 104 of parallel flutes 103 are alternately arranged overlapping and nonoverlapping along flute axes 110 thereby creating a pattern of shorter flexures 106C and longer flexures 106D along flute axes 110 thereby conferring nonuniform flexing properties to the packaging 100 along flute axes 110.

[0059] According to the embodiment of Figure 19, the voids 104 are aligned across the flute axes 110 so that flexures 106E are formed between adjacent insular portions

105 and flexures 106F are formed between adjacent voids 104.

[0060] Figures 23 and 24 show a similar embodiment but wherein the voids 104 are much narrower.

[0061 ] Manufacture of the packaging 100 may comprise adhering the corrugated ply 101 to the backing ply 102 and subsequently punching, forming or cutting the voids 104 through both layers.

[0062] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. Flowever, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.