A packaging structure and methods of manufacturing a packaging structure. The packaging structure, for example, an edge protector, a corner board, etc., may generally include a first ply having a first width, a second ply having a second width, and a third ply having a third width wider than the first width and the second width. The second ply may be wrapped around at least one end of the first ply, and the third ply may be wrapped around the first ply and the second ply. The third ply may overlap at a portion (e.g., an intermediate portion, an apex, etc.) of the packaging structure.

In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.

In a method for processing a cushioning material strand, which is produced by a cushioning conversion machine from a web-shaped stock material (e.g. a roll or a leporello stack, for example of paper), the cushioning material strand is wound around a winding center into a cushioning material winding and is compressed during winding into the cushioning material winding.

In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.

An application mechanism is used to apply water to wet paper in a process for producing planar cushioning material and filler material made of paper having a spatial structure with embossing on each side. The water can be applied to the paper like ink, so as to keep it sufficiently moist for the embossing process. Likewise, it is possible to use ink to apply a two-dimensional imprint, whereby sufficient wetting can also take place, but at the same time an optical effect is achieved.

A packing material, its use, method of manufacture, and method of production creates a curl or spiral having elastic, cushioning, form-fitting, and coherent packing properties. The curl is created from a dimension-controlled strip of cohesive paper having a cohesive side and a non-cohesive side, and formed with a leading end that is folded upon itself such that a cohesive side of the leading end contacts the cohesive side of the dimension controlled strip of cohesive paper, and a trailing end opposite the leading end that is folded upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, wherein the dimensioned strip of cohesive paper is wound into a spiral with the cohesive side of the dimensioned strip of cohesive paper facing outward. A plurality of curls provides a clumped, cohesive mass around a packed item.

Pouch including an insulation pad (100) including two juxtaposed cellulose-based sheets (110, 112) and a cellulose-based insulation material (120). The two juxtaposed cellulose-based sheets are laminated together with the cellulose-based insulation material located therebetween. The pouch further includes transverse fold lines (134) in the insulation pad. The pouch further includes two W-shaped folds (140) in the insulation pad. The two W-shaped folds are formed by folding the insulation pad along the transverse fold lines. Portions of a first longitudinal edge (116) of the insulation pad are coupled to each other between the two W-shaped folds in the insulation pad.

An apparatus for the production a cushion product from a single- or multi-layer continuous paper strip includes a feed unit for drawing the paper strip into the apparatus, a cutting unit for cutting the cushion product from the paper strip, and control electronics for the activation of the cutting unit according to a predetermined motion profile. A sensor captures a rotation angle position of the feed unit. The control electronics are configured to activate the feed unit continuously and to start an activation of the cutting unit for a discontinuous cutting operation during capturing a predetermined actual rotation angle position of the feed unit.

Various embodiments of the present disclosure provide an improved edge protector having two plies wrapped around a core and a method of manufacturing the improved edge protector.

A method and system for forming domes or protruded structures in a flat material such as paper is disclosed. The method includes cutting one or more sheets; applying an adhesive between the one or more sheets, joining the one or more sheets together in a registered manner to form a substrate, encapsulating the one or more sheets in a container to prevent curing of the adhesive, opening the container, and pressing the adhesive under pressure to shape the substrate into a desired shape may include the domes or protruded structures.