Abstract: A tube having enhanced inner diameter stiffness is provided. The tube includes a wall having an inner zone, intermediate zone, and an outer zone. The intermediate zone includes a plurality of partially offset and overlapped plies that form a number of non-radial spokes and voids extending from the inner zone and the outer zone. The non-radial spokes of the tube facilitate the transmission of torque from the inner zone to the outer zone during winding and handling operations, while insulating the inner diameter from radial pressure on the outer zone. The spokes and voids may essentially extend around the entire circumference and length of the tube and thus provide for more consistent properties throughout the tube.

Abstract: An improved support post for cushioning and supporting large products is provided. The post is made from a non-rectangular sheet that is convolutely wound around a mandrel and shaped into a desired cross-sectional shape. The post has a higher axial compression strength than a conventional post.

Abstract: A pallet block includes an extruded inner core and an outer shell co-extruded with the inner core. The outer shell surrounds the inner core with respect to an extrusion axis defined by the inner core. The compositions of the inner core and outer shell differ by one or both of mass density and formula. For example, the outer shell may have a higher mass density than the inner core and may protect the inner core from impact and moisture ingression. Each of the inner core and outer shell may include product-packaging waste.

Abstract: A tube having enhanced inner diameter stiffness is provided. The tube includes a wall having an inner zone, intermediate zone, and an outer zone. The intermediate zone includes a plurality of partially offset and overlapped plies that form a number of non-radial spokes and voids extending from the inner zone and the outer zone. The non-radial spokes of the tube facilitate the transmission of torque from the inner zone to the outer zone during winding and handling operations, while insulating the inner diameter from radial pressure on the outer zone. The spokes and voids may essentially extend around the entire circumference and length of the tube and thus provide for more consistent properties throughout the tube.

Abstract: A tube includes a structural ply wrapped around an axis of the tube, and adhesive which adheres an outer surface of the structural ply to an inner surface. The inner surface is part of the structural ply, or it is part of a second ply of the tube. The outer surface confronts the inner surface, and the adhesive is arranged in a predetermined pattern so that only a predetermined percentage of the outer surface is substantially adhered to the inner surface (e.g., the tube is only “partially adhered”). The predetermined pattern can include three or more stripes of the adhesive, and the predetermined percentage can be substantially less than 100%. The predetermined pattern is preferably provided by apparatus for applying and/or arranging the adhesive on the ply in a predetermined pattern prior to the ply being formed into the tube.

Abstract: An improved support post for cushioning and supporting large products is provided. The post is made from a sheet that is convolutely wound around a mandrel and shaped into a desired shape. The improvement comprises making the sheet from multiple thicknesses of paper so that, upon winding the sheet into a tube, the middle layer of the tube is thicker than the outer layers. The post has a higher axial compression strength than a conventional post, but the same amount (weight) of material.

Abstract: A tube includes a structural ply wrapped around an axis of the tube, and adhesive which adheres an outer surface of the structural ply to an inner surface. The inner surface is part of the structural ply, or it is part of a second ply of the tube. The outer surface confronts the inner surface, and the adhesive is arranged in a predetermined pattern so that only a predetermined percentage of the outer surface is substantially adhered to the inner surface (e.g., the tube is only “partially adhered”). The predetermined pattern can include three or more stripes of the adhesive, and the predetermined percentage can be substantially less than 100%. The predetermined pattern is preferably provided by apparatus for applying and/or arranging the adhesive on the ply in a predetermined pattern prior to the ply being formed into the tube.

Abstract: The invention provides a method and apparatus for spirally winding a tube of enhanced spiral seam uniformity that is simple and reliable. The spirally wound tube is formed using a spiral pitch control surface that engages with an exterior or interior cylindrical surface of a spirally wound tube and constrains movement of the tube to a predetermined spiral rotation as it is formed on a cylindrical stationary mandrel. Preferably, the pitch control surface comprises a tube engaging surface positioned along at least one spirally aligned portion of the exterior portion of the tube forming mandrel.

Abstract: The invention provides a method and apparatus for spirally winding a tube of enhanced spiral seam uniformity that is simple and reliable. The spirally wound tube is formed using a spiral pitch control surface that engages with an exterior or interior cylindrical surface of a spirally wound tube and constrains movement of the tube to a predetermined spiral rotation as it is formed on a cylindrical stationary mandrel. Preferably, the pitch control surface comprises a tube engaging surface positioned along at least one spirally aligned portion of the exterior portion of the tube forming mandrel.