NZ525041A - Wrapping material comprising a layer of non woven synthetic material and a layer of bubble film - Google Patents

Abstract

An extruded multi-layer protective film product comprises at least one first layer of plastic bubble sheet and at least one second layer of non-woven synthetic material wherein the synthetic material is a 100% spun-bonded non-woven polypropylene fabric having a weight of 30g/m2 or higher.

Description

52 NEW ZEALAND SEALED AIR (NZ) LIMITED COMPLETE SPECIFICATION Invention Title: INTELLECTUAL PROPERTY OFFICE OF N.Z MAR 2004 RECEIVED Wrapping material The following statement is a full description of this invention including the best method of performing it known to us:- m:\speci\110000\116-117\117335cmpnzbal.doc 2 "Wrapping material" Field of the Invention The present invention relates to a multi-layer film product and in particular to such a product that is suitable for use in the protection of furniture and other articles.

Background to the Invention Multi-layer film products can be used in a wide range of products. One area where the products are particularly useful is in the protection of articles. For example, multi-layer film can be used to cover all or at least the vulnerable areas of furniture that is being transported following manufacture or by furniture removalist companies.

One example of a known multi-layer film comprises a layer of bubble sheet bonded to a layer of brown Kraft paper. While providing good protection, the paper can tear at sharp corners of the furniture and is also relatively difficult to recycle following use.

The present invention is directed to a multi-layer film that provides protection of furniture and other articles while also not suffering some of the disadvantages of the prior art.

Any discussion of documents, acts, materials, devices, articles or the like which 25 has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

Summary of the Invention Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated 35 element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. m:\speci\110000\116-117\117335cmpnzbal.doc According to a first aspect, the present invention is an extruded multi-layer protective film product comprising at least one first layer of plastic bubble sheet and at least one second layer of a non-woven synthetic material, wherein the synthetic material is a 100% spun-bonded non-woven polypropylene fabric having a weight of 5 about 30g/m2 or higher.

In one embodiment, the film can be suitable for use in the at least partial wrapping and protection of articles. Such articles include items of furniture.

The layers of the film product are preferably contiguous over the length and/or width of the product.

In a further embodiment, the plastic bubble sheet is preferably formed from a suitable polyethylene, polyethylene blend, or copolymer of polyethylene and another material.

The plastic bubble sheet preferably comprises a plurality of sealed cavities or bubbles disposed in a plane, each cavity having air entrapped therein. Each of the 15 sealed cavities preferably extend outwardly from a substantially planar base layer. The cavities each preferably extend outwardly a substantially equal distance from the planar base layer. The cavities can extend outwardly by a distance from the base layer of between about 0.3 and 20mm, more preferably about 2mm and 7mm, and most preferably about 4mm.

The polymeric film used to form the cavities preferably has a thickness between about 20 and 100 microns, more preferably about 40 microns. Examples of the shapes of sealed cavities can include squares, circles, rectangles, ellipses and triangles.

Each sealed cavity is preferably substantially circular with a substantially planar base. Each cavity preferably has a diameter between about 4mm and 25mm, more 25 preferably between 4mm and 20mm, and most preferably about 10mm. Each cavity can be spaced from each of its adjacent cavities by an approximately equal minimum distance. The distance can be between about 1mm and 10mm, more preferably between about 1mm and 5mm, and most preferably about 2mm.

In one dimension, hereinafter the "x-dimension", the sealed cavities can be 30 linearly aligned. In another dimension, hereinafter the "y-dimension", each sealed intellectual property office of n.z. 16 NOV 20M RECEIVED cavity can be off-set from its immediate neighbours in the y-dimension. In this case, every alternate sealed cavity in the y-dimension can be longitudinally aligned.

The plastic bubble sheet is preferably formed from transparent or translucent 5 film. It will be appreciated that the bubble sheet could be formed from opaque film and have a colour, such as black.

In a further embodiment, the film can comprise a further layer. The layer is preferably formed over a face of the bubble sheet distal said at least one second layer. 10 The further layer can comprise a layer of a thermoplastic polymeric film. The further layer can be opaque. In one embodiment, the further layer can be white in colour. In one embodiment, the further layer can have a thickness between about 10 and 200 microns, more preferably about 100 microns. In a still further embodiment, an additional layer can be disposed between said one face of the bubble sheet and the 15 further layer. The further layer can be a thermoplastic polymeric film.

In one embodiment, the second layer can have a thickness between about 10 and 200 microns, more preferably about 100 microns.

In a still further embodiment, the non-woven synthetic material of the second layer can be formed from a polyester or polyolefin material. In one embodiment, the material can be selected from the group comprising polypropylene and polyethylene. In a particularly preferred embodiment, the material is a 100% spun-bonded non-woven polypropylene fabric having a specification of about 30g/m2 or higher. The second 25 layer is preferably opaque and can be white in colour.

The protective film can be formed in a one-step lamination process. In this regard, the respect layers can be fed through an in-line heat lamination device to form the protective film.

The protective film can be formed in relatively bulky quantities suitable for use in the wrapping of furniture items. For example, the protective film can be formed into rolls from which a suitable quantity of protective film can be drawn off as required to wrap an article of furniture. In one embodiment, the roll can have a diameter between 35 about 50cm and 150cm, more preferably about 100cm. m:\speci\110000\116-117\117335cmpnzbal.doc The present invention provides a protective film that is suitable for the wrapping of furniture. The film is designed to wrap the furniture with the second layer abutting the surface of the furniture. The nature of the second layer serves to reduce and preferably minimise the likelihood of marking to the furniture. A key advantage of the 5 present invention over the prior art is that the second layer also preferably acts to absorb moisture so ensuring that any moisture build-up is wicked away from the surface thereof and into the film. This ensures that the furniture is not damaged by moisture build-up during transport and storage.

The film is also preferably relatively durable and relatively resistant to puncture and tearing thereby making it suitable for wrapping around corners and protrusions that often exist on furniture.

The all-polymer nature of the protective film also makes it more readily 15 recyclable than prior art products. This is particularly important as large quantities of the film can need to be disposed following safe delivery of the furniture.

A still further advantage of the present invention is the fact that the protective film has been formed without the need for an additional adhesive to be employed to 20 bond the first layer and second layer of the film. Rather, the application of heat is sufficient to ensure the formation of a protective film having the desired properties.

Brief Description of the Drawings By way of example only, preferred embodiments of the invention are now described with reference to the accompanying drawings, in which: Fig. 1 is a cross-sectional view of one embodiment of a protective film according to the present invention; Fig. 2 is a cross-sectional view of another embodiment of a protective film according to the present invention; Fig. 3 is a cross-sectional view of a still further embodiment of a protective film 35 according to the present invention; and m:\specl\110000\116-117\117335cmpnzbal.doc 6 Fig. 4 depicts one arrangement of the sealed cavities making up the bubble sheet that can be used in the film.

Preferred Mode of Carrying out the Invention One embodiment of an extruded multi-layer protective film product according to the present invention is depicted generally as 10 in Fig. 1.

The protective film 10 comprises one first layer of plastic bubble sheet 11 and 10 one second layer of a non-woven synthetic material 12.

The depicted plastic bubble sheet is formed from a polyethylene material and comprises a plurality of circular sealed cavities or bubbles 14 disposed in a plane, with each cavity having air entrapped therein. Each of the sealed cavities extend outwardly 15 a substantially equal distance from a substantially planar base layer 13. In the depicted embodiment, the cavities or bubbles extend outwardly by a distance from the base layer 13 of about 4mm and have a diameter of about 10mm. Each cavity is also spaced from each of its adjacent cavities by an approximately equal minimum distance of about 2mm. The centre to centre distance of the cavities is therefore 12mm.

The polymeric film used to form the cavities preferably has a thickness of about 40 microns.

As depicted in Fig. 4, the plastic bubble sheet 11 has a series of sealed cavities 25 14 that are linearly aligned in what is nominally termed the x-direction while being offset from its immediate neighbours in the y-dimension. In the depicted embodiment, every alternate sealed cavity in the y-dimension is in alignment.

The depicted bubble sheet 11 is formed from transparent film. It will be 30 appreciated that the bubble sheet could be formed from opaque film and have a desired colour.

In the embodiment depicted in Fig. 1, the non-woven layer 12 is formed from a 100% spun-bonded non-woven polypropylene fabric having a specification of 30g/m. 35 The depicted layer 12 is opaque and white in colour. m:\speci\110000\116-117\117335cmpnzbal.doc 7 A further embodiment of a protective film is depicted generally as 20 in Fig. 2. In this embodiment, the film 20 has, in addition to the features of film 10, a further layer 15 formed over a face of the bubble sheet 11 distal the non-woven polypropylene layer 12.

The depicted further layer 15 comprises a layer of an opaque and white thermoplastic film. This layer has a thickness at least substantially the same as the second layer 12. As is the case in Fig. 1, the film 20 can have the layer of bubble sheet as depicted in Fig. 4. This layer 15 serves to further strengthen the protective film 20. 10 It also provides a surface that can be more readily written or drawn upon directly.

A still further embodiment of a protective film is depicted generally as 30 in Fig. 3. In this embodiment, the further layer 15 is laminated to an additional layer 16.

Each of the protective films 10, 20 and 30 are preferably formed in a one-step lamination process.

The protective films 10, 20 and 30 are generally formed in rolls having dimensions that make the film suitable for being drawn off the roll and then used to 20 wrap the furniture items.

The present invention provides a protective film 10, 20, and 30 that is suitable for the wrapping of furniture. The film can be readily formed without the need for additional adhesive to be used to bond the layers together. The film 10, 20 and 30 is 25 also designed to wrap the furniture with the second layer 12 abutting at least some of the surface of the furniture. The nature of the second layer 12 serves to minimise the likelihood of marking to the furniture. It is also importantly acts to absorb moisture so ensuring that any moisture build-up is wicked away from the surface thereof and into the film 10, 20 and 30. The film 10, 20 and 30 is also relatively durable and relatively 30 resistant to puncture and tearing thereby making it suitable for wrapping around corners and protrusions that often exist on furniture.

The all-polymer nature of the protective film 10, 20 and 30 also makes it more readily recyclable than prior art products. This is particularly important as large 35 quantities of the film 10, 20 and 30 can need to be disposed following safe delivery of the furniture that has had the film 10,20 and 30 wrapped therearound. m:\speci\110000V116-117\117335cmpnzbal.doc 8 It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. m:\speci\110000\116-117\117335cmpnzbal.doc

Claims (24)

CLAIMS:

1. An extruded multi-layer protective film product comprising at least one first layer of plastic bubble sheet and at least one second layer of a non-woven synthetic 5 material, wherein the synthetic material is a 100% spun-bonded non-woven polypropylene fabric having a weight of about 30g/m or higher.

2. The extruded multi-layer protective film product of claim 1 wherein the plastic bubble sheet is formed from a polyethylene, a polyethylene blend, or a copolymer of 10 polyethylene and another material.

3. The extruded multi-layer protective film product of claim 2 wherein the plastic bubble sheet comprises a plurality of sealed cavities or bubbles disposed in a plane, each cavity having air entrapped therein. 15

4. The extruded multi-layer protective film product of claim 3 wherein each of the sealed cavities extend outwardly from a substantially planar base layer.

5. The extruded multi-layer protective film product of claim 4 wherein the cavities 20 each extend outwardly a substantially equal distance from the planar base layer.

6. The extruded multi-layer protective film product of claim 5 wherein the cavities extend outwardly by a distance from the base layer of between about 0.3 and 20mm. 25

7. The extruded multi-layer protective film product of claim 6 wherein the cavities extend outwardly by a distance from the base layer of about 4mm.

8. The extruded multi-layer protective film product of any one of claims 3-7 wherein the polymeric film used to form the cavities has a thickness between about 20 30 and 100 microns.

9. The extruded multi-layer protective film product of claim 9 wherein the polymeric film used to form the cavities has a thickness of about 40 microns. 35

10. The extruded multi-layer protective film product of any one of claims 3-9 wherein each cavity has a diameter between about 4mm and 25mm. intellectual property office of n.z. 16 NOV 2004 RECEIVED 10

11. The extruded multi-layer protective film product of claim 10 wherein each cavity has a diameter of about 10mm.

12. The extruded multi-layer protective film product of any one of claims 3-11 5 wherein each cavity is spaced from each of its adjacent cavities by an approximately equal minimum distance.

13. The extruded multi-layer protective film product of claim 12 wherein the distance is between about 1mm and 10mm. 10

14. The extruded multi-layer protective film product of claim 13 wherein the distance is about 2mm.

15. The extruded multi-layer protective film product of any one of the preceding 15 claims wherein the plastic bubble sheet is formed from a transparent or translucent film.

16. The extruded multi-layer protective film product of any one of the preceding claims wherein the product comprises a further layer formed over a face of the bubble 20 sheet distal said at least one second layer.

17. The extruded multi-layer protective film product of claim 16 wherein the further layer comprises a layer of a thermoplastic polymeric film. 25

18, The extruded multi-layer protective film product of claim 17 wherein the further layer is opaque.

19. The extruded multi-layer protective film product of claim 17 or claim 18 wherein the further layer has a thickness of between 10 and 200 microns. 30

20. The extruded multi-layer protective film product of any one of claims 16-19 wherein an additional layer is disposed between said one face of the bubble sheet and the further layer. 35

21. The extruded multi-layer protective film product of claim 20 wherein the additional layer is formed from a thermoplastic polymeric film. m:\speci\110000\116-117\117335cmpnzbal.doc 11

22. The extruded multi-layer protective film product of claim 20 or 21 wherein the additional layer has a thickness of between 10 and 200 microns.

23. The extruded multi-layer protective film product of any one of the preceding 5 claims wherein the second layer has a thickness between about 10 and 200 microns.

24. The extruded multi-layer protective film product of claim 23 wherein the second layer has a thickness of about 100 microns. OP <*4IMS ABSTRACT An extruded multi-layer protective film product for furniture and other articles. The product comprises at least one first layer of plastic bubble sheet and at least one second layer of a non-woven synthetic material. The plastic bubble sheet can be formed from a suitable polyethylene, polyethylene blend, or copolymer of polyethylene and another material. The non-woven synthetic material of the second layer can be formed from a polyester or polyolefin material such as a 100% spun-bonded non-woven polypropylene fabric having a specification of about 30g/m2 or higher. m:\speci\110000\116-117\117335cmpnzbal.doc