US 12,005,685 B2
Method of forming a cushioning sheet
Greg Sollie, Sharpsburg, GA (US); and Christopher M. Stanton, Peachtree City, GA (US)
Assigned to Pratt Corrugated Holdings, Inc., Brookhaven, GA (US)
Filed by Pratt Corrugated Holdings, Inc., Brookhaven, GA (US)
Filed on Dec. 23, 2022, as Appl. No. 18/146,244.
Application 18/146,244 is a division of application No. 17/177,908, filed on Feb. 17, 2021.
Claims priority of provisional application 63/059,001, filed on Jul. 30, 2020.
Prior Publication US 2023/0130696 A1, Apr. 27, 2023
Int. Cl. B32B 3/30 (2006.01); B32B 3/08 (2006.01); B32B 7/12 (2006.01); B32B 29/00 (2006.01); B32B 37/00 (2006.01); B32B 37/10 (2006.01); B65D 27/14 (2006.01); B65D 81/02 (2006.01); B65D 81/03 (2006.01)
CPC B32B 3/08 (2013.01) [B32B 3/30 (2013.01); B32B 7/12 (2013.01); B32B 29/005 (2013.01); B32B 37/0053 (2013.01); B32B 37/10 (2013.01); B65D 27/14 (2013.01); B65D 81/02 (2013.01); B65D 81/03 (2013.01); B32B 2307/558 (2013.01); B32B 2439/40 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A method of forming a cushioning sheet comprising:
forming a plurality of first sockets in a first layer;
forming a plurality of second sockets in a second layer, each of the second sockets aligned with a corresponding one of the first sockets;
positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets; and
coupling the first layer to the second layer to retain the plurality of cushioning inserts within the voids;
wherein:
positioning the cushioning insert within the void comprises:
picking up the cushioning insert;
releasing the cushioning insert onto the first layer;
locating the cushioning insert in one of the first sockets; and
covering the first layer with the second layer;
picking up the cushioning insert comprises picking up the cushioning insert with a vacuum roller, the vacuum roller defining an insert indentation and a vacuum port formed in the insert indentation; and
releasing the cushioning insert onto the first layer comprises releasing the cushioning insert from the insert indentation of the vacuum roller.