Abstract Shipping carton liner and method for making the same, which consists of a unitary sheet of synthetic plastic foam composed of a pluality of panels separated by grooves or score lines of sufficient depth and of a configuration to enable the panels to be swung from coplanar to mutually perpendicular orientation. A resilient layer is applied to the foam, at least along the score line portions thereof and is characterized by a tear strength and flexibility greater than said foam. In one embodiment, the resilient layer is obtained by forming a densified skin on the surface of the foam. The layer of resilient material and the score lines form a hinge for the pivotal movement of the panels. Apparatus is also provided for fabricatng such liners or cartons.
Method of fabricating protective cartons and liners therefor comprising the steps of applying a thermoplastic resin, heated to its melt temperature, to a synthetic plastic foam sheet to form thereon an overall layer, cooling said resin to solidify the same and to form a resiliently flexible layer which has a tear strength and flexibility substantially greater than said foam, cutting grooves into said sheet of foam on the surface thereof opposite said resilient layer without cutting into said layer to form a plurality of panels delineated by said grooves, which are of sufficient depth and configuration to enable said panels to be swung into mutually perpendicular orientation, said resilient layer and foam forming a composite laminar structure in which said layer and grooves form flexible hinges for the pivotable movement of said panels into and out of said mutually perpendicular orientation.
Claim 2
Dependent Claim
141 words
Method of fabricating protective cartons and liners therefor comprising the steps of applying a thermoplastic resin, heated to its melt temperature, to a synthetic plastic foam sheet to form thereon an overall layer, cooling said resin to solidify the same and to form a resiliently flexible layer which has a tear strength and flexibility substantially greater than said foam, cutting grooves into said sheet of foam on the surface thereof opposite said resilient layer without cutting into said layer to form a plurality of panels delineated by said grooves, which are of sufficient depth and configuration to enable said panels to be swung into mutually perpendicular orientation, said resilient layer and foam forming a composite laminar structure in which said layer and grooves form flexible hinges for the pivotable movement of said panels into and out of said mutually perpendicular orientation.
Claim 3
Dependent Claim
22 words
Method of making protective cartons and liners therefor as set forth in claim 1, in which said thermoplastic layer includes an elastomer.