PRODUCTS AND METHODS INCORPORATING EXTENSIBLE PAPER

Abstract

This disclosure includes various uses of extensible papers, for example to improve products typically made with conventional papers or as an alternative to plastic in products typically made with plastic. Examples of such products include bags such as retail shopping bags; primary product packaging; product bundle wraps; shipping products such as envelopes, pallet wrap, blocking, bracing, and cushioning; personal protection equipment (PPE) and medical products; food service products such takeaway wrappers for food; construction and landscape materials; and industrial and agricultural bags. In at least some of the present embodiments and configurations, the extensible paper has a machine direction (MD) extensibility of 10% or greater, and a cross-direction (CD) extensibility of 6% or greater.

Description

FIELD OF INVENTION

The present invention relates generally to extensible paper bags, and more specifically, to products (e.g., bags and other containers) and methods incorporating extensible papers with extensibility greater than 10% (e.g., 15% or greater).

BACKGROUND

Extensible papers have been known in the art. However, such extensible papers have largely been limited to machine direction (MD) extensibility of less than 15%, cross direction (CD) extensibility of 6% or less, and/or higher densities or basis weights than would otherwise be required for similar strength. U.S. Pat. Nos. 10,017,900; 10,724,178; and 11,390,994 to Georgio Trani et al. (the “Trani Patents”) disclose examples of methods for manufacturing paper with high extensibility (e.g., MD extensibility of 15% or greater, and CD extensibility of 6% or greater) that avoids the need for high-density refining. However, such highly-extensible papers have not yet achieved commercial production, which has limited development of end-uses for such highly-extensible (HE) papers.

SUMMARY

Highly-extensible (HE) papers, such as those produced by the methods disclosed in the Trani Patents, can be configured to—in addition to or as a result of extensibility—exhibit increased puncture resistance, energy absorption, flexibility and/or pliability, conformability, and/or drape. Additionally, the extensibility of such HE papers permits repeated deformation with less breakdown of fibers and bonds than with typical papers, meaning such HE papers may also exhibit increased durability and reusability. Additionally, such HE papers can be imparted with a wide range of other properties by adding various additives and treatments during manufacture of the paper, similarly to traditional papers. For example, additives, sizing, and/or the like can be applied during the manufacture of such HE papers to limit or impart a desired level of moisture vapor transmission rate (MVTR), oil and grease resistance (OGR), OTR (oxygen transmission rate), water resistance, wet strength, barrier properties (e.g., liquid impermeability), and/or the like. Such HE papers can also be configured to be heat-sealable, such as by adding a polymer coating to a region in which two layers of the paper may be heat sealed together via melting the polymer.

The extensibility (e.g., bi-directional—MD and CD—extensibility) of such HE papers, in some instances in combination with barrier properties, can enable such HE papers to function as an alternative to plastic, such as in bags, stand-up pouches, and other products, while maintaining the desirable recyclable and/or compostable properties of paper. Additionally, information (e.g., label information) can be printed directly on such HE papers, reducing the need for separate labels affixed to packaging. The drape, flexibility, and conformability of HE papers in some applications can mitigate and/or overcome limitations typically imposed by the stiffness and rigidity of conventional papers, for example, in the wrapping of individual food products.

Some of the present packages comprise: one or more sheets of paper defining an interior volume; where the paper has a machine direction (MD) extensibility of 10% or greater (e.g., 15% or greater), and a cross-direction (CD) extensibility of 6% or greater (e.g., 10% or greater).

In some of the present packages, the one or more sheets of paper define a bag. In such some configurations, the bag is a retail bag that includes a body and handles (e.g., handles that are unitary with the body). In some configurations, the bag is sealed.

In some of the present bags, dry goods are disposed in the bag. In others of the present bags, wet goods are disposed in the bag. In some of the present bags, the wet goods dry goods includes a food product.

In some of the present packages, the one or more sheets of paper define an envelope or mailer.

In some of the present packages, the one or more sheets of paper define a product bundle wrap.

Some of the present pallet wraps comprise: a roll of paper having a longitudinal direction extending in a circumferential direction of the roll; where the paper has a machine direction (MD) extensibility of 10% or greater (e.g., 15% or greater), and a cross-direction (CD) extensibility of 6% or greater (e.g., 10% or greater); where the MD of the paper is aligned with the longitudinal direction of the paper; and where the paper has a width in the cross direction of 12 inches or greater.

Some of the present assemblies comprise: a plurality of cut sheets of paper; and a package or wrap coupled to the plurality of cut sheets to resist separation of the cut sheets from each other; where the paper has a machine direction (MD) extensibility of 10% or greater (e.g., 15% or greater), and a cross-direction (CD) extensibility of 6% or greater (e.g., 10% or greater). In some such assemblies, the paper comprises an oil and grease resistance (OGR) treatment. In some of the present assemblies, the cut sheets of paper define individual food service wraps.

Some of the present medical gowns or aprons comprise: one or more sheets of paper defining at least a body configured to be worn by a human to cover at least a portion of the front of the human's torso; where the paper has a machine direction (MD) extensibility of 10% or greater (e.g., 15% or greater), and a cross-direction (CD) extensibility of 6% or greater (e.g., 10% or greater). In some such gowns or aprons, the one or more sheets of paper further define sleeves configured to receive the wearer's arms when the medical gown or apron is worn by the human.

The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed configuration, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

Further, an apparatus or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), and “include” (and any form of include, such as “includes” and “including”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

Any configuration of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.

The feature or features of one configuration may be applied to other configurations, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the configurations.

Some details associated with the configurations described above and others are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the configuration depicted in the figures.

FIG. 1 depicts a retail bag comprising HE paper and having a configuration similar to that of a traditional paper retail bag.

FIG. 2 depicts a retail bag comprising HE paper and having a configuration similar to that of a traditional plastic retail bag.

FIG. 3 depicts a wet goods package comprising HE paper and having a configuration similar that of flexible wet goods containers that traditionally comprise plastic.

FIG. 4 depicts a dry goods bag comprising HE paper and having a configuration similar to that of a conventional dry goods bag, such as is used for sugar.

FIG. 5 depicts a cement bag comprising HE paper and having a configuration similar to that of a conventional paper cement bag.

FIG. 6 depicts a product bundle wrap comprising HE paper and having a configuration similar to that of a conventional product bundle wrap, such as is used for paper towels.

FIG. 7 depicts a gusseted envelope comprising HE paper and having a configuration similar to that of a conventional TYVEK® gusseted envelope.

FIG. 8 depicts a flat mailing envelope comprising HE paper and having a configuration similar to that of a conventional flat mailing envelope.

FIG. 9 depicts a pallet wrap comprising HE paper and having a configuration similar to that of a conventional plastic pallet wrap.

FIG. 10 depicts a surgical gown comprising HE paper and having a configuration similar to that of a conventional surgical gown comprising plastic film or nonwoven, or conventional paper.

FIG. 11 depicts a box of food service wraps comprising HE paper and having a configuration similar to that of a box of conventional food service wraps.

FIG. 12 depicts an individual food service wrap comprising HE paper.

DETAILED DESCRIPTION

As described in more detail below, the present disclosure includes various uses of highly-extensible (HE) papers, both to improve similar products typically made with conventional papers or as an alternative to plastic in products typically made with plastic. Examples of such products include bags such as retail shopping bags; primary product packaging; product bundle wraps; shipping products such as envelopes, pallet wrap, blocking, bracing, and cushioning; personal protection equipment (PPE) and medical products; food service products such takeaway wrappers for food; construction and landscape materials; and industrial and agricultural bags.

Certain HE papers, such as those made by the methods disclosed in the Trani Patents, can be converted using conventional paper converting machinery and processes, in some instances with straightforward adjustments to tension and equipment settings to accommodate the extensibility of the HE papers.

1. Retail Shopping Bags

HE papers can be used in place of plastic or conventional paper in any of various bag configurations. For example, conventional bag configurations typically used in retail stores for groceries and other consumer goods can be manufactured from HE paper, resulting in bags that are more flexible, conformable, and durable than conventional paper bags while also being more recyclable and/or compostable than plastic bags (whether single-use or reusable).

Referring now to the drawings, and more particularly to FIG. 1, shown therein and designated by the reference numeral 10 is one example of a grocery or shopping bag comprising HE paper and having a configuration similar to that of a traditional paper grocery or shopping bag. More particularly, bag 10 includes a body 14 and handles 18 adhered to body 14. Body 14 defines an and interior 22 and a flat bottom 26 with a perimeter defined by folded edges 30. In the depicted embodiment, the machine direction (MD) of the paper itself extends circumferentially around the interior, and the cross direction (CD) of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the circumference of the bag may be provided with a greater degree of extensibility than the vertical direction of the bag. In other embodiments, the MD of the paper extends longitudinally and the CD of the paper extends circumferentially, such that the longitudinal (top-to-bottom) direction of the bag may have a greater degree of extensibility than the circumference of the bag. The use of HE paper instead of conventional paper allows the sides of bag 10 to flex and/or absorb forces/energy, and thereby resist tearing, when bag 10 is filled with items such as groceries, even when the HE paper is of the same or lower basis weight than is used in conventional paper grocery bags. Moreover, the use of HE paper can improve durability and toughness sufficiently for bag 10 to be reusable. By way of example, bag 10 can be provided with conventional dimensions (e.g., 12 inches×17 inches×7 inches) to ensure usability and/or compatibility with existing bag holders and fixtures. In at least some configurations, conventional kraft paper sacks/bags typically have a basis weight of from 90 grams per square meter (gsm) to 113 gsm, which corresponds to 70 lb paper. In at least some configurations, the present paper sacks or bags can comprise HE paper having a basis weight of from 70 gsm to 95 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar strength and carrying capacity as conventional kraft paper bags and exhibiting increased flexibility and conformability. As such, the use of HE papers can significantly reduce the amount of material needed for a sack or bag of comparable dimensions and carrying capacity.

FIG. 2 depicts a second example of retail bag 50 comprising HE paper and having a configuration similar to that of a traditional plastic retail bag. Bag 50 includes a body 54 and handles 58 that are unitary with body 54, and body 54 is closed on its bottom with a single lateral fold or seam 62 that allows for the bottom to conform to a flat surface on which the bag is placed. When formed from HE paper, bag 50 also include one or more vertical seams 66 to encircle and define the interior of the bag. In the depicted embodiment, the MD of the paper itself extends circumferentially around the interior, and the CD of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the circumference of the bag may be provided with a greater degree of extensibility than the vertical direction of the bag. In other embodiments, the MD of the paper extends longitudinally and the CD of the paper extends circumferentially, such that the longitudinal (top-to-bottom) direction of the bag may have a greater degree of extensibility than the circumference of the bag. In at least some configurations, such bags can comprise HE paper having a basis weight of from 70 gsm to 95 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength and carrying capacity as plastic retail or tee shirt bags while maintaining sufficient flexibility and conformability. As such, the use of HE papers can be used in place of conventional plastics, which may be less biodegradable and/or less recyclable than HE papers.

2. Primary Product Packaging

HE papers can also be used in place of plastic or conventional paper in any of various forms of primary packaging for wet goods or dry goods. HE papers enable the construction of product packaging that is more flexible, conformable, and durable than conventional paper packaging while also being more recyclable and/or compostable than plastic packaging (whether single-use or reusable/resealable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable.

For example, primary packaging for liquids and gels (e.g., cosmetic products like shampoo and conditioner, food products like yogurt and sour cream, and/or the like) can be made of HE paper, resulting in packages that are more recyclable and/or compostable than plastic packages (whether single-use or reusable). For such wet goods, HE paper can be treated and/or coated to impart barrier properties and thereby render the HE paper impervious to the liquid; for example, one side of the paper that will define the interior of such a package can be coated or laminated with a liquid-impervious material such as a biodegradable and/or heat-sealable polymers. In other embodiments, the interior of such a package can be lined with a plastic liner that is separate from the HE paper, such that the plastic liner can be removed from the paper package body to facilitate recycling of the paper. Even if the interior side of the paper is coated or lined with a conventional plastic that is not biodegradable, the use of HE paper as the primary packaging can substantially reduce the amount of plastic needed for the overall package. In at least some configurations, wet goods packaging can comprise HE paper having a basis weight of from 60 gsm to 90 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength and carrying capacity as plastic alternatives while, in at least some instances, maintaining similar or greater flexibility and conformability. As such, the use of HE papers can be used in place of conventional plastics, which may be less biodegradable and/or less recyclable than HE papers.

FIG. 3 depicts an example of a wet goods package 100 comprising HE paper and having a configuration similar that of flexible wet goods containers that traditionally comprise plastic. As will be familiar to those of ordinary skill in the art, package 100 has a body 104 including two sides 108 joined at a seam 112 around the upper periphery 116, and a bottom 120 joined to each of sides 108 at a seam 124 around the lower periphery 128. As described above, an interior surface of the HE paper defining body 104 is coated by or lined with a liquid-impervious material, or otherwise treated to impart barrier properties to contain a liquid or gel within the interior of the package. Another example of a wet goods package that can comprise HE papers is a configuration similar to that of a rectangular juice box or TETRA PAK® box of the type used for larger quantities of wet goods, such as stock and soups.

In the depicted embodiment, package 100 is configured to be repeatedly opened and closed. More particularly, package 100 includes a plastic neck 132 with a removable cap 136. Neck 132 is hollow and in fluid communication with the interior of body 104. Other embodiments may omit neck 132 and instead seal the entirety of upper periphery 116 such that the package is configured to be opened only once by tearing or cutting the package.

As a further example, primary packaging for dry goods (e.g., food products like chips, nuts, crackers, bread, sugar, coffee, candy, confectionaries, salads, prepared vegetables, cookies, or cereals; health & beauty products such as cotton balls, cotton swabs, or the like; industrial products such as cement, pellets, dry raw materials, or the like; and/or other consumer products) can be made of HE paper, resulting in packages that are that are more flexible, conformable, and durable than conventional paper packages while also being more recyclable and/or compostable than plastic packages (whether single-use or reusable). Some such dry goods packages (e.g., chip bags, cement bags) are configured to be opened once, emptied, and discarded without being closed or resealed; others of such dry goods packages are configured to be resealable (e.g., provided with a ZIP-LOC® or other type of reusable seal, for example, extending along at least a majority of the width of the package at or near an upper end of the package.

FIG. 4 depicts an example of such a dry goods package, in particular a food-product bag 150 comprising HE paper and having a configuration similar to that of a conventional sugar bag that have previously been made of plastic or conventional and/or multi-ply paper. Bag 150 has a body 154 formed by paper encircling an interior of the body 154 and joined along a longitudinal (vertical, in the depicted orientation) seam 158. In this configuration, an elongated HE paper tube can be formed, for example flattened and rolled, and then individual bags 150 defined by forming an upper seal 162 and a lower seal (not shown) and cutting—before or after forming one or both of the upper and lower seals—bag 150 from the rest of the HE paper tubing. In the depicted embodiment, the CD of the paper itself extends circumferentially around the interior, and the MD of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the vertical (top-to-bottom) direction of the bag may be provided with a greater degree of extensibility than the circumferential direction of the bag. In other embodiments, the CD of the paper extends longitudinally and the MD of the paper extends circumferentially, such that the circumference of the bag may have a greater degree of extensibility than the longitudinal direction of the bag. Conventional sugar bags typically have a dual-ply construction with a total basis weight of about 150 gsm, for example 154 gsm. In at least some configurations, the present dry goods bags can provide a comparable strength using a single-ply of HE paper having a basis weight as much as 35% lower, for example a basis weight of from 90 gsm to 120 gsm and/or MD extensibility of from 15% to 25%, while exhibiting similar strength and carrying capacity as conventional sugar bags and exhibiting increased flexibility and conformability. As such, the use of HE papers can significantly reduce the amount of material needed for a sugar bag or other dry goods bag of comparable dimensions and carrying capacity.

FIG. 5 depicts a further example of a dry goods package, in particular a cement bag 200 comprising HE paper and having a configuration similar to that of a conventional paper cement bag. Bag 200 has a body 204 formed by paper encircling an interior of the body 204 and joined along a longitudinal seam 208. In this configuration, an elongated HE paper tube can be formed, for example flattened and rolled, and then individual bags 200 defined by forming an upper seal 212 and a lower seal 216 and cutting—before or after forming one or both of the seals 212, 216—bag 200 from the rest of the HE paper tubing. In the depicted embodiment, the CD of the paper itself extends circumferentially around the interior, and the MD of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the vertical (top-to-bottom) direction of the bag may be provided with a greater degree of extensibility than the circumferential direction of the bag. In other embodiments, the CD of the paper extends longitudinally and the MD of the paper extends circumferentially, such that the circumference of the bag may have a greater degree of extensibility than the longitudinal direction of the bag. As will be appreciated by those of ordinary skill in the art, cement bags are typically made of heavy conventional paper, often will multiple plies or layers, to enable the bag to hold up to 50 pounds or more of cement powder and to be durable enough to survive handling and transport to a destination where the cement is ultimately used. In the present embodiments, utilizing HE paper instead of conventional paper allows for improved flexibility of bag 200, and similar levels of strength and durability, with a lower basis weight and/or reduced number of layers of HE paper relative to those required for conventional paper. As with the sugar bag example described above, conventional cement bags typically have a multi-ply construction. The present dry goods bags can provide a comparable strength using a fewer plies, for example a single ply, of HE paper having a basis weight as much as 35% lower than conventional cement bags while exhibiting similar strength and carrying capacity as conventional cement bags and exhibiting increased durability. In at least some configurations, the present cement (and other heavy dry goods) bags can provide a comparable strength using a single-ply of HE paper having a basis weight of from 120 gsm to 150 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar strength and carrying capacity as conventional cement bags and exhibiting increased flexibility and conformability.

3. Product Bundle Wrap

HE papers can also be used in place of plastic or conventional paper in any of various forms of product bundle wraps, such as, for example, those for bundles of toilet paper rolls, paper towel rolls, wrapping paper rolls, other paper goods, two-for-one bundles, product bundles in which a smaller product sample is added to a conventional-size primary product, and/or the like. HE papers enable the construction of product bundle wraps that are more flexible, conformable, and durable than conventional paper packaging while also being more recyclable and/or compostable than plastic product bundle wraps, for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable.

FIG. 6 depicts an example of a product bundle wrap 250 comprising HE paper and having a configuration similar to that of a conventional product bundle wrap, such as is used for paper towels. In particular, product bundle wrap 250 includes HE paper encircling a number of rolls 258 of paper towels to bundle the rolls together for display and sale. In the depicted embodiment, product bundle wrap 250 encircles six (6) rolls of paper towels; other embodiments can encircle any number of paper towel rolls (or other products). In the depicted embodiment, product bundle wrap 250 does not enclose the top and bottom of rolls 254; however, other embodiments, may enclose the top of the rolls, the bottom of the rolls, or both. In the depicted embodiment, the MD of the paper itself extends circumferentially around the rolls such that the product bundle wrap 250 may have a greater degree of extensibility than the vertical (in the depicted orientation) direction of the product bundle wrap 250, for example, so rolls can be encircled with the product bundle wrap under some tension to resist unintentional release of any of the rolls. In at least some configurations, the present product bundle wraps can comprise HE paper having a basis weight of from 50 gsm to 80 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar strength and carrying capacity as conventional product bundle wraps and exhibiting sufficient flexibility and conformability.

4. Shipping Products

HE papers can also be used in place of plastic (e.g., nonwovens such as TYVEK® mailers) or conventional paper in any of various forms of shipping products, such as, for example, envelopes and mailers, pallet wraps, shipping bags, tape substrates, and/or the like. HE papers enable the construction of shipping products that are more flexible, conformable, and durable than conventional paper shipping products while also being more recyclable and/or compostable than plastic shipping products (whether single-use or reusable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable.

FIG. 7 depicts an example of a shipping product, in particular a gusseted envelope 300 comprising HE paper and having a configuration similar to that of a conventional TYVEK® gusseted envelope. Envelope 300 has a body 304 formed by paper encircling an interior of the body 304 and joined along a longitudinal seam 308, and two folded gussets 310 on opposite longitudinal sides of the envelope. In this configuration, an elongated HE paper tube can be formed, for example flattened and rolled, and then individual envelopes 300 defined by forming a lower seal 312 and a upper flap 316 and cutting—before or after forming one or both of seals 312 and flap 316—envelope 300 from the rest of the HE paper tubing. In the depicted embodiment, the CD of the paper itself extends circumferentially around the interior, and the MD of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the vertical (top-to-bottom) direction of the bag may be provided with a greater degree of extensibility than the circumferential direction of the bag. In other embodiments, the CD of the paper extends longitudinally and the MD of the paper extends circumferentially, such that the circumference of the bag may have a greater degree of extensibility than the longitudinal direction of the bag. As will be appreciated by those of ordinary skill in the art, the depicted configuration of envelope is often formed of TYVEK® polymer nonwoven to be durable enough to survive handling and transport to a destination. In the present embodiments, utilizing HE paper instead of conventional polymer nonwoven allows for sufficient levels of strength and durability, while also being more recyclable and/or compostable than plastic packages (whether single-use or reusable). In at least some configurations, the present shipping envelopes can comprise HE paper having a basis weight of from 70 gsm to 100 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength and carrying capacity as traditional paper alternatives while, in at least some instances, exhibiting greater flexibility, conformability, and toughness or ability to absorb energy without tearing.

FIG. 8 depicts another example of a shipping product, in particular a flat mailing envelope 350 comprising HE paper and having a configuration similar to that of a conventional flat mailing envelope. Envelope 350 has a body 354 formed by paper folded along a bottom edge 358 to encircle an interior of the body 354 and joined along a pair of longitudinal side seams 362 with a closure flap 366. In this configuration, an elongated, HE paper construct can be formed with a longitudinal fold corresponding to bottom edge 358 (e.g., with the construct flattened and rolled) and an overlapping edge corresponding to closure flap 366, and then individual envelopes 350 defined by forming a side seals 362 and cutting—before or after forming one or both of side seals 362—envelope 350 from the rest of the HE paper construct. In the depicted embodiment, the MD of the paper itself extends circumferentially around the interior, and the CD of the paper itself extends longitudinally from bottom to top of the bag (vertically, in the depicted orientation of the bag). In this orientation, the circumferential direction of the bag may be provided with a greater degree of extensibility than the vertical (top-to-bottom) direction of the bag. In other embodiments, the CD of the paper extends circumference and the MD of the paper extends longitudinally, such that the circumference of the bag may have a greater degree of extensibility than the longitudinal direction of the bag. As will be appreciated by those of ordinary skill in the art, the depicted configuration of envelope is often formed of conventional paper. In the present embodiments, utilizing HE paper instead of conventional paper allows for paper envelopes that are more flexible, conformable, and durable than conventional paper envelopes, while maintaining recyclability and/or compostability. In at least some configurations, the present mailers can comprise HE paper having a basis weight of from 80 gsm to 120 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength and carrying capacity as plastic alternatives while, in at least some instances, maintaining similar or greater flexibility and conformability. As such, the use of HE papers can be used in place of conventional plastics, which may be less biodegradable and/or less recyclable than HE papers.

FIG. 9 depicts another example of a shipping product, in particular a pallet wrap 400 comprising HE paper and having a configuration similar to that of a conventional plastic pallet wrap. In the depicted embodiment, HE paper with a width 404 is rolled on a tube 408, with the MD of the paper itself extending in the longitudinal direction of the wrap (circumferentially around the tube) such that the longitudinal direction of the wrap may have a greater degree of extensibility than its width. Width 404 may be any dimension suitable for wrapping stacked products or boxes 412 on a pallet 416, such as, for example, greater than any one of or between any two of: 12 inches, 18 inches, 24 inches, 30 inches, 36 inches, 42 inches, and/or 48 inches. Forming wrap 400 from HE paper allows for sufficient extensibility and flexibility for stabilizing a load on a pallet, with improved recyclability and/or compostability relative to conventional plastic film pallet wraps. In at least some configurations, wet goods packaging can comprise HE paper having a basis weight of from 100 gsm to 150 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength and carrying capacity as plastic alternatives while, in at least some instances, maintaining sufficient flexibility and conformability.

5. Personal Protection Equipment (PPE) and Medical Products

HE papers can also be used in place of plastic (e.g., nonwovens or films) or conventional paper in any of various forms of personal protection equipment (PPE) and medical products, such as, for example, surgical gowns, drapes, bibs, aprons, gloves/mittens, hospital (patient) gowns, table cloths, examination bed covers, and/or the like. HE papers enable the construction of PPE and medical products that are more flexible, conformable, and durable than conventional paper products while also being more recyclable and/or compostable than plastic products (whether single-use or reusable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable.

FIG. 10 depicts an example of a PPE product, in particular a surgical gown 450 comprising HE paper and having a configuration similar to that of a conventional surgical gown comprising plastic film or nonwoven, or conventional paper. Gown 450 includes a body 454 and sleeves 458 sized for a human wearer (e.g., physician, nurse, or other healthcare provider), and a rear closure 462 to retain the gown on a wearer. In at least some configurations, such PPE products can comprise HE paper having a basis weight of from 60 gsm to 90 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength as plastic alternatives while, in at least some instances, maintaining similar or greater flexibility and conformability. As such, the use of HE papers can be used in place of conventional plastics, which may be less biodegradable and/or less recyclable than HE papers.

6. Food Service Products

HE papers can also be used in place of plastic (e.g., nonwovens or films) or conventional paper in any of various forms of food service products, such as, for example, bulk food bundling wraps and packages, foils, liners, food handling, take-away bags and food wraps (hamburgers, sandwiches, taco, fries, etc.), and/or the like. HE papers enable the construction of such food service products that are more flexible, conformable, and durable than conventional paper products while also being more recyclable and/or compostable than plastic products (whether single-use or reusable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable. As noted above, such HE papers may also be treated or otherwise configured for oil and grease resistance (e.g., for fast food wraps), barrier properties, water resistance, and/or the like to adapt HE paper to a particular application. In at least some configurations, the present food service products (e.g., wraps) can comprise HE paper having a basis weight of from 40 gsm to 70 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar or greater strength as plastic alternatives while, in at least some instances, maintaining similar or greater flexibility and conformability. As such, the use of HE papers can be used in place of conventional plastics, which may be less biodegradable and/or less recyclable than HE papers.

FIG. 11 depicts a box 500 of food service wraps 504 comprising HE paper and having a configuration similar to that of a box of conventional food service wraps.

FIG. 12 depicts an individual food service wrap 504 comprising HE paper and shown with a hamburger 508 as one example of a food service item that wrap 504 is suitable for wrapping.

7. Construction and Landscape Materials

HE papers can also be used in place of plastic (e.g., nonwovens or films) or conventional paper in any of various forms of construction and landscape materials, such as, for example, geotextiles, weed/mulch barrier, agricultural films for growing vegetables and fruits, and/or the like. HE papers enable the construction of such construction and landscape materials that are more flexible, conformable, and durable than conventional paper products while also being more recyclable and/or compostable than plastic products (whether single-use or reusable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable. As noted above, such HE papers may also be treated or otherwise configured for oil and grease resistance (e.g., for temporary construction and shop surface covers), barrier properties, water resistance, and/or the like to adapt HE paper to a particular application. In at least some configurations, the present construction and landscape materials can comprise HE paper having a basis weight of from 120 gsm to 150 gsm, and/or MD extensibility of from 15% to 25%.

8. Industrial & Agricultural Bags

HE papers can also be used in place of plastic (e.g., nonwovens or films) or conventional paper in any of various forms of industrial and agricultural bags, such as, for example, refuse or trash bags, waste collection bags, bin/container liners, protective coverings (dry cleaning bags, disposable seat covers, furniture covers, drape cloth, etc.), dunnage, disposable collection bags for fruits and vegetables, and/or the like. HE papers enable the construction of such industrial and agricultural bags that are more flexible, conformable, and durable than conventional paper products while also being more recyclable and/or compostable than plastic products (whether single-use or reusable), for example, enabling the use of a recyclable and/or compostable HE paper material where conventional paper may not be sufficiently flexible or durable. As noted above, such HE papers may also be treated or otherwise configured for oil and grease resistance, barrier properties, water resistance, and/or the like to adapt HE paper to a particular application. In at least some configurations, the present industrial and agricultural bags can comprise, for example, a single ply of, HE paper having a basis weight of from 120 gsm to 150 gsm, and/or MD extensibility of from 15% to 25%, while exhibiting similar strength and carrying capacity as conventional industrial and agricultural bags and exhibiting sufficient flexibility and conformability.

The above specification and examples provide a complete description of the structure and use of illustrative configurations. Although certain configurations have been described above with a certain degree of particularity, or with reference to one or more individual configurations, those skilled in the art could make numerous alterations to the disclosed configurations without departing from the scope of this invention. For example, certain features of one configuration can be replaced or added to other configurations. To illustrate, a configuration having a handle can be also include an aperture in addition to or in place of the handle. The modifications are not limited to these two features and a skilled person would understand multiple aspects of the described configurations can be utilized in other configurations.

The previous description of the disclosed implementations is provided to enable a person skilled in the art to make or use the disclosed implementations. Various modifications to these implementations will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other implementations without departing from the scope of the disclosure. Thus, the present disclosure is not intended to be limited to the implementations shown herein but is to be accorded the widest scope possible consistent with the principles and novel features as defined by the following claims.

The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.

Claims

1. A package comprising: one or more sheets of paper defining an interior volume;where the paper has a machine direction (MD) extensibility of 10% or greater, and a cross-direction (CD) extensibility of 6% or greater.

2. The package of claim 1, where the one or more sheets of paper define a bag.

3. The package of claim 2, where the bag is a retail bag that includes a body and handles.

4. The package of claim 3, where the handles are unitary with the body.

5. The package of claim 2, where the bag is sealed.

6. The package of claim 5, where dry goods are disposed in the bag.

7. The package of claim 5, where wet goods are disposed in the bag.

8. The package of claim 6, where a food product is disposed in the bag.

9. The package of claim 1, where the one or more sheets of paper define an envelope or mailer.

10. The package of claim 1, where the one or more sheets of paper define a product bundle wrap.

11. A pallet wrap comprising: a roll of paper having a longitudinal direction extending in a circumferential direction of the roll;where the paper has a machine direction (MD) extensibility of 10% or greater, and a cross-direction (CD) extensibility of 6% or greater;where the MD of the paper is aligned with the longitudinal direction of the paper; andwhere the paper has a width of 12 inches or greater.

12. An assembly comprising: a plurality of cut sheets of paper; anda package or wrap coupled to the plurality of cut sheets to resist separation of the cut sheets from each other;where the paper has a machine direction (MD) extensibility of 10% or greater, and a cross-direction (CD) extensibility of 6% or greater.

13. The assembly of claim 12, where the paper comprises an oil and grease resistance (OGR) treatment.

14. The assembly of claim 13, where the cut sheets of paper define individual food service wraps.

15. A medical gown or apron comprising: one or more sheets of paper defining at least a body configured to be worn by a human to cover at least a portion of the front of the human's torso;where the paper has a machine direction (MD) extensibility of 10% or greater, and a cross-direction (CD) extensibility of 6% or greater.

16. The medical gown or apron of claim 15, where the one or more sheets of paper further define sleeves configured to receive the wearer's arms when the medical gown or apron is worn by the human.