Cushioning panel

Application filed April 5, 1930. Serial No. 441,761.

The present invention relates to sheet material adapted to constitute a protective cushion for objects supported or covered thereby, and has for its object to produce a material of this kind which shall be inexpensive and at the same time highly efficient.

In its broader aspects my improved product may be used wherever so-called corrugated board is now used and therefore, coni sidered in one of its aspects, my invention may be said to have for its object to produce a cushioning material possessing advantages over such board.

In packing eggs and other fragile articles 15 in cellular structures open at the top and bottom and spaced apart by means of sheets known as flats, it is desirable that the sheets serve as effective cushions for the articles resting thereon and also that the sheets be ²⁰ interlocked with the Avails or partitions of the cellular structures in order to brace the same. Viewed in another of its aspects, my invention may be said to have for its object to produce a simple and novel cushioning ²⁵ and interlocking flat.

In accordance with my invention, I produce a sheet or panel having numerous more or less yielding bulges on at least one face, these bulges forming outer walls of sealed ³⁰ air pockets within the sheet, whereby an article resting on the bulges is supported by air Cushions. Therefore, viewed in a specific aspect, my invention may be said to have for its object to produce a simple and novel cushion³³ ing sheet which shall provide air cushions to protect objects supported thereby or covered therewith.

Since my improved composite sheet is in the nature of a hollow panel, the interior of ⁴⁰ which is divided into numerous air cells, it may be used to advantage as an insulation against heat or cold. Therefore, viewed in another of its aspects, the present invention may be said to have for its object to produce ⁵ a simple, novel and inexpensive sheet mate rial possessing the property of efficiently insulating against heat or cold.

The various features of novelty whereby my invention is characterized will hereinafter be pointed out with particularity in 50 the claims; but, for a full understanding of my invention and of its objects and advantages, reference may be had to the following detailed description taken in connection with the accompanying drawings wherein: 55

Figure 1 is a plan view of a fragment of a panel embodying my invention; Fig. 2 is a section on line 2—2 of Fig. 1, on a larger scale; Fig. 3 is a section on line 3—3 of Fig. 2; and Figs. 4 and 5 are views similar to Fig. 60 3, showing two modifications.

In the drawings I have illustrated my invention as embodied in structures composed of a plurality of sheets joined together and shaped to serve as flats for use in packaging 65 eggs or other fragile articles and, for the sake of brevity, the detailed description will be confined to these particular forms, although my invention is not, of course, limited thereto. . ⁷⁰

Referring to Figs. 1 to 3 of the drawings, 1 represents a sheet of yieldable and preferably fibrous material of substantially uniform thickness throughout, molded, pressed or otherwise, made so as to divide it into square ⁵raised sections or plateaus 2. These raised sections are closely spaced and arranged in two sets of rows at right angles to each other. The spaces between the plateaus constitute two series of narrow, uniformly spaced, deep ⁸⁰valleys 3 and 4 extending entirely across the sheet in two directions at right angles to each other. Each plateau is deformed to produce cushioning elements which also serve to reenforce and brace the side walls of the pla- ³teau. These elements, as illustrated, are parallel ribs or corrugations 5.'

It will therefore be seen that the sheet has on the upper side numerous bulges or con- _bovexities and on the under side numerous con1,853,374 cavities. Underlying the sheet_; and joined thereto by a suitable adhesive 6, is a flat sheet 7 which seals the concavities and transforms them into closed pockets in which air is con^e fined. Consequently, my improved product has a cushioning effect due not Only to the inherent qualities of the shaped paper or other material, but also to the confined air.

. Where the sheets are made of fibrous mate¹⁰ rial, such as a paper product, they are preferably waterproofed so that moisture will not affect them. The waterproofing also makes the enclosures for the pocketed air more air tight and prevents or retards the flattening of the air cushions under external pressure.

In Fig. 4 there is shown a modification in which two sheets 10 and 11, similar to the sheet 1, are fastened together back to back, ⁰ with their concavities registering with each other, thus making very deep air pockets. Whereas the sheet 7 in Figs. 1 to 3 may be much thinner than the sheet 1 if desired, the sheets 10 and 11 are preferably both to be of heavy or thick material.

In Fig. 5 the construction combines the features of the other two forms, the two similar sheets 10 and 11 being secured together with a flat sheet interposed between them. There are of course two layers of adhesive, one between the sheet 7 and each of the other sheets.

In using my invention, in the form shown, for packaging eggs, for example, the partitions are set in the valleys or grooves, so that the bottom of each cell consists of an air cushion and the partitions are locked against lateral displacement. The action in other uses will be evident without further explana⁴⁰ tion. ^F

While I have illustrated and described with particularity only a few simple forms of my invention, I do not desire to be limited to the exact structural details thus illustrat⁴⁵ ed and described; but intend to cover all forms and arrangements which come within the definitions of my invention constituting the appended claims.