A packaging material includes a web of pouches and an outer skin. One panel of the web has an inflation pattern that is not inflated. The web has a continuous inflation channel that is in fluid communication with the inflation pattern. Each of the pouches of the web can be inflated by inflating the inflation pattern while the outer skin already attached to the outside of the web. The outer skin is attached to the web only along edge lines of the pouches. The outer skin is detached from the web between the edge lines of the pouches. The outer skin is attached to the outside of the web such that the continuous inflation pattern extends above the outer skin.

A wrapping material includes a substrate and a buffer layer, wherein the substrate has a first lateral edge and a second lateral edge, and the buffer layer has a third lateral edge and a fourth lateral edge. The buffer layer is stacked on the substrate. The first lateral edge of the substrate is tightly merged with the third lateral edge of the buffer layer, and the second lateral edge of the substrate is tightly merged with the fourth lateral edge of the buffer layer. A method of making a wrapping material includes: providing a substrate; stacking a buffer layer on the substrate; using a thermal cutting tool to cut the stacked substrate and buffer layer so that the substrate and the buffer layer are tightly merged at where they are cut as being melted by heat.

A wrapping material includes a substrate and a buffer layer, wherein the substrate has a first lateral edge and a second lateral edge, and the buffer layer has a third lateral edge and a fourth lateral edge. The buffer layer is stacked on the substrate. The first lateral edge of the substrate is tightly merged with the third lateral edge of the buffer layer, and the second lateral edge of the substrate is tightly merged with the fourth lateral edge of the buffer layer. A method of making a wrapping material includes: providing a substrate; stacking a buffer layer on the substrate; using a thermal cutting tool to cut the stacked substrate and buffer layer so that the substrate and the buffer layer are tightly merged at where they are cut as being melted by heat.

A foldable template for forming an envelope includes a central panel, a top glue flap, a bottom glue flap, a first intermediate panel, a second intermediate panel, a first back panel, and a second back panel. The first intermediate panel extends from a first side of the central panel and is separated therefrom by a first curved crease. The second intermediate panel extends from a second side of the central panel and is separated therefrom by a second curved crease. The first back panel extends from the first intermediate panel and is separated therefrom by a third curved crease. The second back panel extends from the second intermediate panel and is separated therefrom by a fourth curved crease.

An inflatable packaging web (3201) includes a continuous web of preformed pouches (3200) and an outer skin (612). The continuous web of preformed pouches is defined by two panels (18) connected together along first and second side edges (14) and either connected together or folded along a bottom edge (20). At least one of the panels is inflatable. The outer skin is disposed over at least one of the inflatable panels. The outer skin is attached to the at least one of the inflatable panels along at least a portion of the height of the first and second side edges. The preformed pouch includes at least one fold such that a folded portion (3215) of the two panels is folded over a first portion of the two panels.

An inflatable packaging web (3201) includes a continuous web of preformed pouches (3200) and an outer skin (612). The continuous web of preformed pouches is defined by two panels (18) connected together along first and second side edges (14) and either connected together or folded along a bottom edge (20). At least one of the panels is inflatable. The outer skin is disposed over at least one of the inflatable panels. The outer skin is attached to the at least one of the inflatable panels along at least a portion of the height of the first and second side edges. The preformed pouch includes at least one fold such that a folded portion (3215) of the two panels is folded over a first portion of the two panels.

The present disclosure relates to a recyclable, padded paper mailer that is water resistant, heat sealable, and provides padded protection. The mailers in accordance with this disclosure find utility as padded mailing envelopes such as e-commerce mailers, bubble packaging pillows, or any other protective shipping packaging.

The present disclosure relates to a recyclable, padded paper mailer that is water resistant, heat sealable, and provides padded protection. The mailers in accordance with this disclosure find utility as padded mailing envelopes such as e-commerce mailers, bubble packaging pillows, or any other protective shipping packaging.

A method of forming a cushioning sheet includes 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.

A method of forming a cushioning sheet includes 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.