SHIPPING PACKAGING AND ITS MANUFACTURING PROCESS

Abstract

A shipping packaging including a front wall and a rear wall, assembled to define at least one inner compartment, and including an opening connecting with the at least one inner compartment for the introduction of at least one object, a flap featuring an open position wherein the inner compartment is accessible through its opening, and a closed position wherein the flap covers at least partially this opening. At least one of the front and rear walls includes at least two sheets, a first of the sheets being embossed forming a cushioning element and including ridges the at least a second of the sheets being substantially smooth, at least the portions of these two sheets being placed facing the at least one compartment, being assembled together only by at least some of the tops of the ridges of one side of the first sheet bonded to the second substantially smooth sheet.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 U.S.C. § 119 to French Patent Application No. 2302250, filed on Mar. 10, 2023, in the French Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

Field

The present disclosure relates to the field of shipping packaging such as envelopes, pouches or boxes.

Furthermore, it relates to shipping packaging that incorporates a cushioning element to protect one or more fragile objects during shipment and transport by mail.

It also relates to a method of manufacturing such shipping packaging.

Brief Description of Related Developments

Padded envelopes or pouches with a protective element have historically been used to ship fragile products.

By way of example, some envelopes or pouches with walls that are covered with a layer of transparent bubble film, which walls surround the inner compartment to hold the product to be protected.

These envelopes or pouches are advantageous as they are easier to use and more cost-effective than cardboard packaging, which tends to require one or more separate protective elements such as bubble wrap and/or wedge elements.

These air bubbles are also resistant and waterproof.

The advantage of padded envelopes or pouches is that they protect their contents well, which could otherwise be damaged during shipment and transport by mail services.

In particular, the bubble film layers or foam used in these padded envelopes or pouches are flexible and thus able to adapt to the shape of their contents to ensure better protection.

Although these products provide good results, there is still room for improvement.

Firstly, these padded envelopes or pouches include one or more layers of bubble film or foam that are made from plastic materials.

For example, the foam layer is often made from expanded low-density polyethylene (LDPE).

However, although it is widespread and standard to use such plastics in padded envelopes and pouches, this runs contrary to environmental protection requirements.

Various solutions have been suggested in recent years to reduce the effects of this problem. For example, there are now envelopes with an outer paper sleeve to hold an air bubble cover that can be removed once the envelope has been used and then reused with another sleeve.

However, the use of plastic in this packaging is an intrinsic part of this product, and a major drawback, particularly in terms of environmental pollution.

As such, it would be useful to have padded shipping packaging to protect fragile products during shipment with an original design that overcomes the aforementioned disadvantages.

SUMMARY

The present disclosure is intended for shipping packaging such as an envelope, with a simple design that is easy to use, economical and fully recyclable.

The objective of this present disclosure is to obtain shipping packaging that provides better impact protection.

A further objective of the present disclosure is to obtain shipping packaging that is particularly compact and lightweight in its unfolded form, and that forms a shipping box with adequate storage volume through an easy folding process.

It also relates to a manufacturing process for such shipping packaging that is particularly easy to implement.

To this end, the disclosure relates to shipping packaging comprising a front wall and a rear wall, assembled so as to delineate at least one inner compartment, the packaging comprising an opening connected with at least one inner compartment so that at least one object can be placed inside, and a flap with an open position wherein the inner compartment is accessible via its opening and a closed position wherein the flap at least partially covers this opening. According to the disclosure, at least one of the front and rear walls comprises at least two sheets, the first of these sheets being embossed to form a cushioning element. The first paper sheet has ridges on at least one of its sides corresponding to depressions on its other side. The packaging also comprises a second sheet that is smooth or substantially smooth, with at least a portion of these two sheets disposed facing at least one inner compartment. These are joined together by at least some of the tops of the ridges on one side of the first sheet attaching to the second sheet or the second smooth or substantially smooth sheet.

It should be noted that the present disclosure is not limited to the production of a padded envelope, but can be applied to any other shipping packaging, such as a bag, pouch or a pouch designed to form a shipping box by folding that incorporates a cushioning element to protect its contents.

Advantageously, this shipping packaging can be made entirely of paper with a natural, emission-free assembly glue that ensures the durability, such as a wheat starch-based glue. This packaging is therefore environmentally friendly.

Additionally, in tests carried out on the packaging discussed in the present disclosure, the applicant found significantly better results in terms of shock protection compared to bubble envelopes.

Indeed, joining the tops of the ridges of the first sheet to the second smooth or substantially smooth sheet allows the envelope's cushioning or spring effect to be maintained after an initial impact.
This cushioning effect was clearly degraded after a first impact when the tops of the ridges were not joined to the second smooth or substantially smooth sheet.

For illustrative purposes only, the basic shape of this shipping packaging is either rectangular or square.

The first sheet of paper is preferably fully embossed.

One advantage is that at least this first sheet of paper is made of vellum paper, kraft paper or cardboard.

Likewise, all the sheets of this shipping packaging can be made of paper, kraft paper or cardboard; with or without windows.

According to one specific aspect of this shipping packaging, at least the portions of these two sheets are placed opposite at least one inner compartment joined together solely by glue dots connecting at least some of the tops of the ridges of one side of the first sheet to the second smooth or substantially smooth sheet.

According to another specific aspect of this shipping packaging, the first paper sheet has alternating ridges and depressions on one of its sides, which correspond to respective depressions and ridges on the other side, the tops of these ridges being located in the same plane, or in more or less the same plane.

These ridges should preferably be aligned along lines that are oblique to the main axis of the package.

For example, since the first sheet is fully embossed, it may present a honeycomb configuration, as in an egg carton.

According to another specific aspect of this shipping packaging, the height H of its ridges is equal to at least 1 mm, and ideally 1.5 mm.

The first paper sheet has ridges on both sides, and the thickness of this first sheet providing the cushioning effect is at least 2.5 mm, and ideally at least 4 mm.

For illustrative purposes only, the number of ridges on both sides of the embossed sheet is approximately 0.5 per cm².

According to another particular aspect of this shipping packaging, at least forty percent (40%), and better at least sixty percent (60%), and ideally, at least seventy-five percent (75%) of the tops of the ridges of the first paper sheet are joined to the second smooth or substantially smooth sheet.

It is particularly advantageous if at least ninety percent (90%) of the tops of the ridges of the first sheet can be joined to the second smooth or substantially smooth sheet.

According to another particular aspect of this shipping packaging, the ridges have a shape selected from within a group comprising domes, cones, truncated cones and combinations thereof. Preferably, these ridges should form domes, or half-spheres, with a base diameter of at least 4 mm, and ideally at least 5 mm, giving a surface area of at least 12.5 mm², and ideally at least 20 mm².

According to another particular aspect of this shipping packaging, each of the front and rear walls comprises at least two sheets, a first of the sheets being embossed to form a cushioning element, the first paper sheet comprising ridges on at least one of its sides that correspond to the depressions on its other side, the second sheet, or at least a second of the sheets being smooth or substantially smooth, at least the portions of these two sheets placed facing at least one compartment that are assembled to one another solely by glue dots connecting at least some of the tops of the ridges on one side of the first sheet to the second smooth or substantially smooth sheet.

According to another specific aspect of this shipping packaging, the front and rear walls each comprise three sheets, the first embossed sheet being held between a smooth or substantially smooth sheet called the outer surface of the package and another smooth or substantially smooth sheet called the inner surface of the package, the portion of the first embossed sheet being placed facing at least one inner compartment, which is joined solely to the smooth or substantially smooth sheet forming the outer face of the package.

According to another specific aspect of this shipping packaging, the packaging comprises a first edge containing the opening and a second opposite edge defining the bottom of the package. The second edge forms a bottom gusset and the edges of the package connecting the first and second edges each contain a so-called side gusset. The gussets are configured to give the packaging a box shape when deployed or activated. The flap is shaped to ensure closure of this box when it is in the closed position.

Preferably, each of the lateral edges of this flap has a V-shaped cut and crease so that a portion of this flap can be placed between the lateral gussets by folding to close the package, the portion then forms a lateral side of the box.

A part of this flap containing a closure element such as an adhesive strip then comes into contact with the rear wall of the packaging to close it.

According to another specific aspect of this shipping packaging, it comprises at least one closure element designed to non-reversibly hold the flap in the closed position.

This closure element can be used to hold the flap in the closed position by non-reversible attachment of the inner surface of the flap to the outer surface of the rear wall of the shipping packaging.
For illustrative purposes only, this closure element can be an adhesive strip with a peel-off protective film.

The present disclosure also relates to a method for manufacturing shipping packaging such as an envelope or pouch, comprising at least the steps of creasing, folding and gluing a strip portion to part of its edges to define at least one inner compartment that connects with an opening to access the compartment.

According to the disclosure, this strip portion is previously obtained by unwinding a first paper strip, embossing it onto an embossing unit to form ridges on at least one of its sides that correspond to depressions on its other side, and then by unwinding a second smooth or substantially smooth paper strip, and superimposing the two strips beyond the embossing unit and joining the strips solely by gluing at least some of the tops of the ridges on one side of the first embossed strip to the smooth or substantially smooth strip.

Preferably, the embossing step aims to achieve an even distribution of ridges over the entire surface of the first paper strip.

According to another specific aspect of this shipping packaging, the step of embossing the first strip involves creating alternating ridges and depressions on one of the sides of the first strip corresponding to the respective depressions and ridges on its other side, the tops of these ridges on each side of the first strip are positioned in the same plane or more or less in the same plane.

According to another specific aspect of this shipping packaging, the embossing step gives the first cushioning strip a thickness of at least three times its initial thickness, and even better, at least five times its initial thickness.

According to another particular aspect of this shipping packaging, the embossing step involves heating the first strip to treat the constituent fibers of the paper of the first strip and enhance its cushioning effect, as well as its spring effect.

For illustrative purposes only, the heating temperature of the paper fibers of the first strip should be between 40° C. and 90° C., preferably between 50° C. and 60° C. and even more preferably between 50° C. and 55° C.

According to another particular aspect of this shipping packaging, after embossing, glue is deposited on at least 50%, and preferably at least 70%, and even more preferably at least 80%, of only the tops of the ridges of the first strip to ensure the assembly of the first and second strips.

According to another particular aspect of this shipping packaging, this method comprises a step of forming a so-called bottom gusset by folding and creasing on the edge opposite that delimiting the opening that communicates with the inner compartment, as well as a gusset on each of the lateral edges of the strip portion.

Preferably, this process should also include a V-shaped cutting and creasing step for the part of the strip portion that forms the flap of the packaging. This is done to ensure that this part of the flap can be folded and then inserted between the side gussets to close the package. This part forms a side of the box.

Preferably, the inner surface of the flap should come into contact with the outer surface of the rear wall of the packaging when the flap is in the closed position.

BRIEF DESCRIPTION OF THE FIGURES

Other advantages, purposes and special features of the present disclosure will be made apparent from the following description, provided for the purpose of explanation and by no means limited thereto, with reference to the appended drawings, wherein:

FIG. 1

FIG. 1 is a schematic representation of protective envelopes according to a specific aspect of the present disclosure;

FIG. 2

FIG. 2 is a partial perspective view and opening of a protective envelope shown in FIG. 1;

FIG. 3

FIG. 3 is a perspective view of a protective pouch forming a box when folded, according to another specific aspect of the present disclosure;

FIG. 4

FIG. 4 is another view of the protective pouch shown in FIG. 3;

FIG. 5

FIG. 5 shows the first of the various folding steps for the protective pouch shown in FIG. 3 resulting in the creation of a shipping box;

FIG. 6

FIG. 6 shows the second folding step for the protective pouch shown in FIG. 3 resulting in the creation of a shipping box;

FIG. 7

FIG. 7 shows the third folding step for the protective pouch shown in FIG. 3 resulting in the creation of a shipping box; and

FIG. 8

FIG. 8 shows the fourth folding step for the protective pouch shown in FIG. 3 resulting in the creation of a shipping box.

DETAILED DESCRIPTION

The following drawings and description contain, for the most part, elements of certainty. They may therefore not only serve to improve understanding of the present disclosure, but also contribute to its definition, where appropriate.

First, it should be noted that the figures are not to scale.

FIGS. 1 and 2 show schematically a protective envelope produced according to a specific aspect of the present disclosure.

This protective envelope 10 comprises a front wall 11 and a rear wall 12, joined together to form an inner compartment 13.

Protective envelope 10 is generally rectangular in shape and has an opening that connects with its inner compartment 13 to allow access to the latter.

Protective envelope 10 also comprises a flap 14, placed here in the extension of its front wall 11. Flap 14 can be moved between an open position, in which inner compartment 13 is accessible via its opening, and a closed position in which flap 14 at least partially covers this opening to close envelope 10.

In the closed position, the inner side of flap 14 is in contact with rear wall 12 of envelope 10. This inner side of flap 14 may include one or more glue lines or strips 15 to secure flap 14 to rear wall 12 of the envelope.

Front wall 11 and rear wall 12 of envelope 10 both are made up of two sheets of paper 16, 17 joined together around part of their perimeter.

First sheet 16 of these sheets is fully embossed to form a cushioning element. It thus features alternating ridges 18 and depressions on one side, corresponding to the respective depressions and ridges on the other side.

The inner side of first sheet 16 delimits inner compartment 13 of envelope 10, so that these ridges 18 and depressions are visible when this inner compartment is opened.

For example, first sheet 16 is made of vellum paper with a grammage of 90 or 120 g/m2.

Second paper sheet 17 is smooth or substantially smooth. It is made of white vellum paper, but could also be made in any other color, or in kraft paper or cardboard to give it a certain rigidity to the envelope.

To ensure the desired cushioning effect, two sheets 16, 17 are joined together solely by glue dots connecting all the tops of ridges 18 on the outer side of first sheet 16 to second smooth or substantially smooth sheet 17.

The adhesive used here is based on modified starch in an aqueous water solution.

Advantageously, during an embossing step, first sheet 16 is heated during its mechanical deformation to produce ridges 18 and depressions on its two sides, by means of heated cylinders. The temperature of the first sheet heated in this way is slightly above 55° C., which corresponds to this glue's gel point. This is done to ensure that the temperature of the first sheet is sufficient to adequately bond the two sheets together when they are assembled.

In addition, it has been found that heating the paper fibers of first sheet 16 advantageously enhances the cushioning effect of the ridges 18.

FIGS. 3 to 8 schematically show a protective pouch produced according to another specific aspect of the present disclosure.

This protective pouch 30 has a so-called unfolded configuration in which it is substantially flat, so it can be easily stored and stowed, and a folded configuration in which it conveniently forms a shipping box.

The front 31 and rear 32 walls of this pouch are identical in structure to those described for the envelope above. The front wall has a flap portion 33 for closing the pouch.

Protective pouch 30 has a side forming the bottom, which comprises a bottom gusset 34, and the side edges of the pouch each comprising a so-called side gusset 35.

Classically, these side edges connect the side forming the bottom of protective pouch 30 to its upper side comprising the opening that gives access to the inner compartment.

As shown in FIGS. 5 to 8, gussets 34, 35 are configured to give this pouch a box-shape when activated by folding.

Preferably, each of the lateral edges of flap 33 should have a V-shaped cut and crease 36 so that a portion of flap 33 can be placed between lateral gussets 35 by folding to close protective package 30.

This part of flap 33 then forms a side 37 of the box.

The inner surface of flap 33 also features a closure element 38, such as an adhesive strip, which, when flap 33 is in the closed position, faces the rear wall of the protective pouch 30 so that it can be closed.

Advantageously, the creasing and shaping method used to produce three gussets 34, 35 of protective pouch 30 enable the user to instantly shape this pouch to form a box, simply by exerting pressure (arrow 3) on the sides of protective pouch 30.

Claims

1. A shipping packaging of pouch or envelope type, comprising a front wall and a rear wall, assembled so as to define at least one inner compartment-, the package comprising an opening that engages with at least one inner compartment so that at least one object can be inserted, a flap with an open position in which the inner compartment is accessible through its opening, and a closed position in which the flap at least partially covers this opening, characterized in that at least one of the front and rear walls comprises at least two sheets, a first of the sheets of paper being embossed to form a cushioning element, the first sheet of paper has ridges on at least one of its sides corresponding to depressions on its other side, the second sheet or at least a second smooth or substantially smooth sheet, with at least the portions of these two sheets placed facing the inner compartment, and joined together solely by at least some of the tops of the ridges on one side of the first sheet being attached to the second smooth or substantially smooth sheet.

2. The shipping packaging according to claim 1, characterized in that at least a portion of these two sheets placed facing at least one inner compartment are joined together solely by glue dots connecting at least some of the tops of the ridges of one side of the first sheet to the second smooth or substantially smooth sheet.

3. The shipping packaging according to claim 1, characterized in that the first sheet of paper features alternating ridges and depressions on one of its sides corresponding to respective depressions and ridges on its other side, the tops of the ridges being located in the same plane or substantially in the same plane.

4. The shipping packaging according to claim 3, characterized in that a ridge height H is of at least 1 mm, and preferably 1.5 mm, so that the thickness of the first sheet forms a cushioning element of at least 2.5 mm in thickness, and ideally at least 4 mm.

5. The shipping packaging according to claim 1, characterized in that at least forty percent, and preferably at least sixty percent, and even more preferably at least seventy-five percent of the tops of the ridges of the first sheet of paper are joined with the second smooth or almost smooth sheet.

6. The shipping packaging according to claim 1, characterized in that the ridges feature a shape chosen from the group comprising domes, cones, truncated cones and combinations of these.

7. The shipping packaging according to claim 1, characterized in that each of the front and rear walls comprises at least two sheets, a first of the sheets being embossed to form a cushioning element, the first sheet of paper comprising ridges on at least one of its sides corresponding to depressions on the other of its sides, the second sheet or at least a second of the sheets being smooth or substantially smooth, at least the portions of the two sheets being placed facing the at least one compartment, being joined together only by points of glue connecting the tops of the ridges of one side of the first sheet to the second smooth or substantially smooth sheet.

8. The shipping packaging according to claim 1, characterized in that the front and rear walls each comprise three sheets, the said first sheet is embossed and is held between a smooth or substantially smooth sheet called the outer surface of the packaging and another smooth or substantially smooth sheet called the inner surface of the packaging, the portion of the first embossed sheet being placed facing at least one inner compartment which is joined solely to the smooth or substantially smooth sheet forming the outer surface of the packaging.

9. The shipping packaging according to claim 1, characterized in that the packaging comprising a first edge containing the opening and a second opposite edge defining the bottom of the packaging, the second edge comprising a bottom gusset and the edges of the packaging connecting the first and second edges each comprising a so-called side gusset, the gussets being configured to give the packaging a box shape when deployed, or activated, the flap being shaped to ensure this box closes in its closed position.

10. The shipping packaging according to claim 9, characterized in that each lateral edge of the flap has a V-shaped cut and crease so that a portion of the flap can be placed between the lateral gussets by folding to close the packaging, the portion then forming a lateral side of the box.

11. A method for manufacturing shipping packaging such as an envelope or pouch, comprising at least the steps of creasing, folding and gluing on part of its edges of a strip portion to define at least one inner compartment connecting with an opening to access the compartment, characterized in that the strip portion is previously obtained by unwinding a first paper strip, embossing it onto an embossing unit to form ridges on at least one of its sides that corresponds to depressions on its other side, and then by unwinding a second smooth or substantially smooth paper strip, and superimposing the two strips beyond the embossing unit and joining the strips solely by gluing at least some of the tops of the ridges on one side of the first embossed strip to the smooth or almost smooth strip.

12. The method for manufacturing shipping packaging according to claim 11, characterized in that the step of embossing the first strip involves creating alternating ridges and depressions on one of the sides of the first strip corresponding to the respective depressions and ridges on its other side, the tops of the ridges on each side of the first strip being positioned in the same plane or substantially in the same plane.

13. The method for manufacturing shipping packaging according to claim 11, characterized in that the embossing step involves heating the first strip to treat the constituent fibers and enhance its cushioning effect, as well as its spring effect.

14. The method for manufacturing shipping packaging according to claim 11, characterized in that, after embossing, glue is deposited on at least 50%, and even more preferably at least 70%, and even more preferably at least 80%, of only the tops of the ridges of the first strip to ensure the assembly of the first and second strips.

15. The method for manufacturing shipping packaging according to claim 11, characterized in that it comprises a step of forming a so-called bottom gusset by folding and creasing on the edge opposite the edge delimiting the opening that connects with the inner compartment-, as well as a gusset on each of the lateral edges of the strip portion.

16. The method for manufacturing shipping packaging according to claim 11, characterized in that it comprises a V-shaped cutting and creasing step for the part of the strip portion that forms the flap of the packaging to ensure that this part of the flap can be folded and then inserted between the side gussets to close the packaging.