Thermal insulation dunnage and method

Patent metadata

Field	Value
Publication number	US-10099836-B2
Application number	US-201414777274-A
Country	US
Kind code	B2
Filing date	Mar 14, 2014
Priority date	Mar 15, 2013
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

A method for making an insulating dunnage product ( 10 ) includes the steps of (a) permanently deforming at least one non-planar interior layer ( 12 ) that includes a paper sheet to form a plurality of air pockets ( 14 ), (b) surrounding the at least one interior layer ( 12 ) on all four sides and over the top and bottom sides of the at least one interior layer ( 12 ) with at least one outer layer ( 16 ) of sheet material and (c) peripherally sealing the at least one outer layer ( 16 ) to capture the at least one interior layer ( 12 ) therein such that the interior layer ( 12 ) has major portions that are free to shift relative to adjacent portions of the at least one outer layer ( 16 ).

First claim

What is claimed is:

1. A method for making an insulating dunnage product, comprising the following steps:
permanently deforming at least one non-planar interior layer that includes a paper sheet to form a plurality of air pockets;
surrounding the at least one interior layer on all four sides and over the top and bottom sides of the at least one interior layer with at least one outer layer of sheet material; and
peripherally sealing the at least one outer layer to capture the at least one interior layer therein such that the interior layer has major portions that are free to shift relative to adjacent portions of the at least one outer layer;
where the surrounding step includes surrounding the at least one interior layer with an outer layer of paper.

2. A method for making an insulating dunnage product, comprising the following steps:
permanently deforming at least one non-planar interior layer that includes a paper sheet to form a plurality of air pockets;
surrounding the at least one interior layer on all four sides and over the top and bottom sides of the at least one interior layer with at least one outer layer of sheet material;
peripherally sealing the at least one outer layer to capture the at least one interior layer therein such that the interior layer has major portions that are free to shift relative to adjacent portions of the at least one outer layer;
where the deforming step includes converting paper in roll or fan-fold form into a relatively less dense dunnage product.

3. A method as set forth in claim 1 , where the surrounding step includes placing the at least one interior layer between two layers of paper.

4. A method as set forth in claim 1 , where the surrounding step includes surrounding the at least one interior layer with a sheet material having a cohesive coating.

5. A method as set forth in claim 1 , where the surrounding step includes surrounding the at least one interior layer with two separate sheets on opposing sides of the at least one interior layer.

6. A method for making an insulating dunnage product, comprising the following steps:
permanently deforming at least one non-planar interior layer that includes a paper sheet to form a plurality of air pockets;
surrounding the at least one interior layer on all four sides and over the top and bottom sides of the at least one interior layer with at least one outer layer of sheet material;
peripherally sealing the at least one outer layer to capture the at least one interior layer therein such that the interior layer has major portions that are free to shift relative to adjacent portions of the at least one outer layer;
where the forming step includes forming fold lines in the at least one outer layer between portions of the at least one interior layer so as to separate the portions of the at least one interior layer with fold lines.

7. A method as set forth in claim 6 , where the forming step includes forming two fold lines to separate three sections of the at least one interior layer.

8. A method as set forth in claim 7 , comprising the step of placing the dunnage product within a container to cover three sides of the container.

9. A method as set forth in claim 8 , further comprising the step of repeating the placing step to cover all sides of the container when the container is closed.

10. A method comprising the following steps:
making a dunnage product by
permanently deforming at least one non-planar interior layer that includes a paper sheet to form a plurality of air pockets;
surrounding the at least one interior layer on all four sides and over the top and bottom sides of the at least one interior layer with at least one outer layer of sheet material; and
peripherally sealing the at least one outer layer to capture the at least one interior layer therein such that the interior layer has major portions that are free to shift relative to adjacent portions of the at least one outer layer;

placing the dunnage product in a container;
placing a cooling element in the container on the dunnage product; and
placing another dunnage product on the cooling element before adding an item to be shipped.

Assignees

• Ranpak Corp

Inventors

• Cheich Robert C

Classifications

• B31D5/0043 Primary

  including crumpling flat material · CPC title

• B31D5/006

  including controlled deformation of flat material, e.g. pleating, corrugating or embossing (including crumpling flat material B31D5/0043) · CPC title

• B65D81/052 Primary

  filled with fluid, e.g. inflatable elements · CPC title

• B31D5/0073

  including pillow forming · CPC title

• B65B63/08

  for heating or cooling articles or materials to facilitate packaging · CPC title