In accordance with a broad embodiment of the invention, a novel paper product is comprised of two or more slit sheet packing material layers, each layer having its own slit pattern design to create interlocking layers of expansion sheet packaging materials. Each layer expands to create a three dimensional open netting of cells of hexagons, and the like, and is designed to have limited nesting with its opposing layer, thereby maximizing the thickness of the combined layers as compared to nested layers. Adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer. Preferably the differing slit pattern produce when expanded, inclined land areas that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting.

A textured mailer includes a first panel comprising at least a first paper layer; a second panel coupled to and facing the first panel and comprising at least a second paper layer; and an inner cavity defined between the first panel and the second panel, wherein at least one of the first paper layer and the second paper layer is formed as a textured paper layer configured to provide cushioning to contents of the inner cavity.

A textured mailer includes a first panel comprising at least a first paper layer; a second panel coupled to and facing the first panel and comprising at least a second paper layer; and an inner cavity defined between the first panel and the second panel, wherein at least one of the first paper layer and the second paper layer is formed as a textured paper layer configured to provide cushioning to contents of the inner cavity.

The present disclosure relates generally to tension-activated, expanding articles that include single slit patterns. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.

The present disclosure relates generally to tension-activated, expanding articles that include single slit patterns. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.

A process of packaging includes providing a bottom support, providing a top film, and forming a closed chamber where a portion of the bottom support, a product and a portion of the top film are housed. The further includes sealing the portion of the bottom support to the portion of the top film along a sealing band circumscribing the product to sealingly house the product in a volume and forming one or more hollow structures by sealing a part of the portion of the top film to a part of the portion of the bottom support at one or more selected seal zones. Before forming the hollow structure, the part of the portion of the top film and of the portion of the bottom support destined to form the hollow structure are maintained separate at a distance the one from the other.

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 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.

The present disclosure relates generally to tension-activated, expanding articles that include compound slit patterns. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.

The present disclosure relates generally to tension-activated, expanding articles that include compound slit patterns. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.