GB2488509A - Paper or card bubblewrap. - Google Patents

Abstract

Method / apparatus / item produced, in which a cushioned packaging material 13 is produced from a sheet of paper, card, or similar material, excluding plastic, the surface of the paper being provided with an array of discrete structural portions 10a extending beyond the plane of the paper. These formations may be formed by embossing rollers (3,4 fig.1) during manufacturing. The use of paper or card instead of plastic may have cost and environmental benefits over plastic bubblewrap.

Description

CUSHIONED PACKAGING: MATERIALS

Field of the Inventon

The present invention relates in general to cushioned pa p er packing mäteriàlS: thld methods of rnanuft.Iturihg such.. In particu Jar the present invention relates to enVelopes and itiäiler b1.gs formed Usih. cu&iiOhed pëer pa�ka.ging mate:ri.I.$.

Background

During the transportation of Objects via mail or co.. urier services an object can be subject to mechanical stresses that can put the more fragile objects at fik. In order to help reduce:the. rc of an object being damagec ii transit objects may be wrapped in cushioned packaging materials or alternatively envelopes/bags comprising, such materials.

or.:E: of the most popular forms of cushioned packaging material air cushioned mailers, which are provided with bubble wrap on their interior surface. The bubble wrap provides a. cushioning layer Whih protects the contents'of the mailer from stresses Bubble Wrap is made primarily' from plastic, and. this tends to increase the manufacture costs of such packaging compared tO packaging. made solely from paper, fOr' example.

In adWtiqrt recent moves, towards more environmentally. friendly and: recyclable packaging have highlighted some disadvantages with these bubble wrap.:niailers in this regard. In particular there can be difficulties involved in.

removing the bubble wrap from the paper component of these air cushioned mAilers.. Ma result recycling can be. difficult, and economically. unattractive..

More enviionmentally friendly alternatives of air cushioned packaging are available. One such alte'rnatie.tEkes the form of an envelope/mailer bag which has a twin-wall cavity between. Which recycled paper fibers can be retained. However, whilst more easily recycled at the end of thOir lifespan, these. mailers to tend. to be heavier, which can mean that. negate: the benEfits

-

of their recyOlability are negated by the increased fLie! requirements for transporting such mailers.

Another aftemative form of.ccshioned packaging material makes use of corrugated card or paper to provide tllC required cushioning feature to VArious tyres of pAckaging, iriciuthng enVelopbs. AJth.ough the U'se of corrUgated card/paper allows for the eirmination of pastEcs horn the packaging material there are dIsad'vanages to. its use,.

One such disadvantage is the amount of card/paper material required to make a standard sized envelope, which is greater than is requited fat a standard sized, non-corrugated envelope because of the way in which corrugation Is forrned This increased material requirement of each envelopeTh.:ailer leads to an increase in the weight of the packaging, which again results, in increased fuel requirements when transporting the en ye lopes/m a Ue is ThE present invention Seeks to provide: an alternative to the: above- :mentiOhCd cushioned packaging containers which have, lower manufacture costs, are lightwcight and can be more easily recycled.

Summary of lbs Invention

The present invention �'rovides a mOthod of manufacturing a cushioned packaging material from paper, said method comprises forming an array of discrete pqrflons across the majority of the surface area of the paper, wherein each of the discrete portions in the array independently extends either above or below the plane of the paper: The array Of discrete portiohs that qover a majority of the pper sheet provides a cushioning. effect which, when wrapped aroun.d an object. provides a level of protection to such. object., It is appreciated that in order for the material to provide an adequate level of protection at least 5QP/ Of the surface area of the paper needs to be provided with discrete portions Although, of course, it is appreciated that greater surface area coverage could further irnprovethC cushioning effect..

Preferably the array may be fomled by embbs&ng the paper With 2 discrete portions..

Preferably the paper may be aelected from the grpup consting of: plain paper; chemically treated paper; laminated paper; and metalized paper.

It is appreciated that the type of paper used to produce the packaging mater!aJ of the present invention can. be Varied to suit; the requited characteristics of the end produci.

It s appreciated that the paper used to make the packaging material may cOmprise either a single piece of paper or multiple layers of paper. Thus.

depending on the quality of the paper berng used it is appreciated that it may bë prefëräble for multiple sheets of papet each having an array of discrete portions thereon, to be combined to form the cushioned paper packaging material In this regard, it is appreciated that multiple sheets of lower grade (i.e. lower density or gsm) paper could be used instead a single sheet of high grade (i.e.. higher density or gsm) paper.

Regardless of whether the' packaging aterial is thade.. from a si.hgle piece or multiple. layers of paper in one embodimentcf if e present invention.

is considered preferable that the. Paper' iS. provided with a,'n: :&ra.M! of discrete portions that. all, extend from the plane of the paper in the same direction. In another e'mbc.dirnent the paper may be. prOvided With an arrä9 of discrete portions that. alternately extehd abovE and below the piahe. oF th paper.

Further preferably, when the discrete portions extend in both directions the discrete p.c.rtiens. may be arranged i.h: an alternating pattern.

Preferably the shape of each discrete portion may be uniform.

Preferably the shape of the discrete portions may be selected from the group consisting of substantially hemi-spherical, pyramidal square triangular, circUtar, rectangular,. and diamond.. Other shapes. are considered p.ossble.

within the gpneral concept of the present invention, provided they can be arranged, in an array.

Prefer., bly the method of the present invention further includes the step of treating the papet with a hardening solution, such as starch, either after or before the array of discrete portions has' been forme d on the paper, in thIs.

way the array of discrete portions Can: be given structural strength that helps them retain theirshape overtime.

Preferably the method mayfurther involve strengthening the qushioned packaging material by affixing an a.'ditionàI layer to the papeL Further preferably the additional layer rr.ay be selected from the rnup: Oonistiflg Of paper, plastic, rubber metal, and fabnc By afhx!ng the addEbonal laye to the paper t s possible to strengthen the cushioned packaging material and also th. scrnecase.s ItaIp retain the shape. ofthedscrete portions cverti.me.Again, dëpeidinçj U:POfl the materi& Used. for the additional structur2l' layer, the additkriai layer can provide the packäçihg material with Iãdditiohal technical features for more specialized packaging requirements (e.g.: wátet resistance) The present invention also provides a cushioned pabkaging material comprising paper having an array of discrete portions provkied. O:VCI the majority of the surface area of the paper, and wherein each of the discrete portions independently extends either above or belOw the plane of the aer.

Ft will be' appreciated that the preferable features identified above in c.onn.ecticr; with the m.etho,d of manufá.cturihg the cushione packaging material are also applicable to the packaging matenal product Preferably: the distahce that the. discrete portions' extend from the plane of the $êrn1ay be such that the paper has an effective thickness of at least 2mm; By providing an array of discrete portions on the paper it is possible to increase the effective thickness, or, in other words, the amount of cushioning the. paper can provide. It is appreciated. that in order for.the packaging of the present imitAtion to have a meaningful, cushioning effect the minimum effective thickness needs to. be Ct least 2mm.

It' is' appreciated that the' cushioning effect, of the pad'kaging, material of the present invention may be incieased oy using either a single piece of high quality paper (e g 90-200gsm) which can sustain more pronounced discrete portions, O.r a combination cf multiple sheets of lower quality paper (:eg. 30-GOgsrn'), which are less capable: of retCiAiPg discrete pottiohs. As the aggregate effective thickness of multiple pieces of lower quality paper can equate to. the effective thickness of a single piece of higher qua dy paper, the use; ofsJngie Or multiple layers of pap& ca be, used provide the same qverali usjpning effect Depending on the quality of the paper used it is approcated that effective thicknesses of up to 6 to 8 mm are. achievable from singFe paper pieces. In ddition, it is envisaged that the Use of treated Or laminated paper can enable even high effective thicne.s.ses: t.p be achieved because of the increased ckstance that the discrete portions can be extended from the plane of the paperbefore the paper breaks...

In a preferred embodiment bfthe �resent invention.a cu'shibiied paper packaging. fermed from the packaging material of the present inventiOn..

Typical exarnpes of paper packaging jflCiE envelopes and mailer bags Ancthe.r preferred. .,mb,odirn.ent of the' present invention provides cushioned paper bag. or envelope formed from a cushioning' layer and a structural layer fixed in a Layered.reiat.ions:hip with one another, wherein: ff cushioning layer, which provides the inner surface, of the bag or envelope, comprtses one or more layers Cf paper having:an array of discrete portions' provided over the majority "�f the surface a rae thereof, wherein each.

of the'd,Stete portions independently extends either abOVe: or below the plane of the or bach layer Of pa�er; and the structural layer provides the.outer surface of the.bag.o envelope.

Preferably the structural layer may be made of paper It is envsagea that the.cu:shned paper bag or' envelope of the present Invention may have' additional features. Suitable additiOnal. featureswiii become aplpareri t from the detàilbd:dbscription of the. present: invention..

Bnef Descnption of the Drawings The.: preferred embodiments of the.' variou.s asp,.cts: of the present invention will row be described with reference: to the drawings, wherein; Figure 1 shows a manufacturing prOcess by which a first variant of the cushioned Paper packaging material k produced; Figure 2 shows a manufaotunng process by which a.se'cond variant pf the. cu:.shidfle.d paper packaging mateda'l. is preduqec.; FIgure 3 shows a manufacturing process by Which a third Variant of the cushioned paper packaging material is produced; FIgure 4a and 4b show The first va:riant of the cushic:ned packaging material th'atcan he produced by the process represented in Figure I Figure 5a and 5b shOw an ntëtmediate vari:Lnt, of the' cuShioned packaging mete.tiai; Figure 8a and 6b show the second variant of the cushioned packaging niaterial thatcan b.e produced by the process. reiresented n Hgure.2; Figure 7a and 7b show the third variant of the cushioned packaging material that can be produced by the process represented in Figure 3 and Figure 8 shows an envelope (or mailer bag) made from the cushioned paper packaging material of the present inveption..

Detailed Description of the Present Invention

Primarily the present invention relates to a paper-based cushioned packaging material and methods of manufacturing such The cushioning effect of the packaging material is essentially provided by paper -rather than plastic (ci bUbble wrap) for example which has been appropriately Shaped with an array of i.ndMd:u'at raised., or iddeed lowered,, portions that extend frOm, the plane of the paper The raised (or lowered) portions aie arranged across the plane of the paper in an array so as to provide the desired cushioning effect.

Whilst the packaging material of the present invention is essentially paper based, it is' appreciated that additionai materials, such as plastic, could be used.to supplement the properties of the paper in some situatidns.

ft IS' anticipated that, whilst: there will be a range of variants Of th.e cushioned packaging matenal of the present invention (see figs 4a-7b) they all share the essential fOatum that the, cushioning effect of the pacKaging material is provided primarily by a paper'struct'ure.

Figures 1, tO. 3 show v'arious arrangements of manufacturing roOess, éách Of which can be used tb produce One or more of' the product v'adä'nts shown in Figs 4a-7b.

Referring now to Figure 1 the various stages of the ni.nufacture process cart be appreciated. Hrstly, a roll of paper 1 provides the stock material from which the cushion.dpackaging material of the prese.ntinventi.on is prOducëd At its. most basicthepaper ia provided on the roll. 1 can: be: virgin or recycled plain paper (i e standard untreated paper made from wood pulp) It s appreciated however, that alternative types of papei including paper made.. from animal d.pg, crape. paper or pane*se knotweed,. could be used effectively within the, sccpe of the present invention for there. ovm indiVidual:charactedstics as required.

Although not essential to: the. ihvertion in its broadestsen.se, the paper source. material may also be pre-treated in some way depending upon what characteristics are requtred for the finished packaghig product. Specific examplS. ci. ways in which pie-treatment of the source paper a:n be used to enhance the finished packaging product include: a) applying.a hardening treatment. in the form of a starch additive for example, to. the paper material,s that when the paper is. shaped with array of discrete portions such shaping is more resiliently maintained by the paper.. It iS Eppreciated that such a hardening treatment might.alternE:tivelly he a�plidd after the paper is shaped with an array of discrete portioh.s.

b) laminating the paper viñth a layer of plastics material will increase the paper's tolerance to deformation, thus increasing the height that each discrete portion can extend from the plane of the paper without breaking.

The athount of plastic material required to produce the cush.ionin.g effect provided by the packaging m:ab.riai of the: present invention i. lower than i.s required for Bubble Wrap, for example, because the paper provides the :majc.rity c.f the structure... This: therefore reduces the material. cc.sts incurred during manufacture of a cushioned packaging material c) metalized paper may also be used to produce the packaging The: use. of metalized paper packaging may of particular use when trahsporhng electrical componC'nth,. far example.

In orde,r for the cushioned packaging material of the. present. invention to provide: a. useful. cushionIng effect it is appreciated. that the packaging matetiaI would preferably have ah effective thickness of at least2rnm, which is achieved by the discrete portions Stending from the plane of the paper. Ah effective thickness of between 6-8mm is considered more prefetable because of, th increased cushioning effeotHitaffords, It is appreciated that the lower the density (glrn' or gsm) of the source paper material the less capacity the source paper has to retain an array of discrete portions, which in turn effects the extent to which the disciete portions cari extenld from the plane *f the paper The m.in.irrwrn effective thickness of the packaging ma1eria can be achieved by using a single sheet (or ply) of source paper that has a density of around 9Th200gsm. Alternatively the effective thickness can b's achieved, by using a source paper that comprises multiple sheets (or plies) o lower density paper (e g 30-6Ogsm) Also, as mentioned above the extent to which discrete pottions can 1' . tend from the plane of the paper can be, ihcreased by pie-treating the paper, for example by lamination with plastic or spraying with starch.

Returning new to the process shown in Figure 1, the source pa�er la is supplied by the paper wIt I The paper la is shaped with an array of discrete portions and in this embodiment the. discrete: portions are embossed cnto the paper by an.e'rnbosser 2. It is, envisaged that alternative mechanisms for forming the array of disOrete po'rtion nay be adopted. The: embosser 2 shown in Figure. I comprises two rollers and 4 eadh of whidh has a pattern of raised portions and corresponding inde,ntaflons, The rollers 3 and 4 are po.stti.oned relailve to one another so that, when the. rollers come toether the raised portidns: Of. one roller are received within the indentations on the adjacent roller In this way when the rollcrs come together they impart a pattern of discrete portions which either extend upwards or downwards from the plane of the paper As the paper passes through the embosser 2 an array of discrete portions is formed on the paper The embossed paper 5. that exits: the embosser 2 therefore, has raised discrete pottidis 5a and lowered discrete pOrtions.5b. The embossed paper.5 is considered W a \triafltQfthe cUs:hiOfl1 packaging material of the present EnVentioft, n the process shown in Fgure I the embossed paper 5 s sprayed with a statch additive from a dispenser 6 to help strengthen and maintain the discrete pUrUbns 5a, Sb. Suitable fdrms of starch additive include oxidized acetyl and catronic starch although other suitable forms of hardening additive wifi be appreciated too n adthtion it is envisaged that alternative mechanisms for applying the additve to the paper include baths and wet rollers The Vadant of the cushioned packaging material that is produced by the process otshown in Figure. 1.issh:owfl in more detail in Figures 4a and 4b, The alternating arrangement of the raised and lowered discrete portions can be: .appre;oiate,d from. Figure. 4a, Figure 2. shows an altern:ative process for proc. ucing cushioned packaging materials of the present invention Once again a source paper roll 1 supplies a steady supply of paper ia, this time to an embo:ser 7. As mentione aIhoye. the exact form, of the paper la can vary depending upon what characteristiosthe: fiShed needs: to have.

The embosser 7 shown in Figure 2 has a different arrangement' of rOllers 8 àhd 9 to the embosser 2 shOwn in Figure 1. In contrast, the: embosser 7 shown in Figure 2 is arranged th fdftn discrete portions that only extend away from the plane of the paper in one direction lo this end one of the roRers is provided with a pattern of raised portions and the other roLler is provided with E: pattern of corresponding indentations,.. The rollers are aligned to ensure.thàt the raised portions ar receivable within the indentations: As the paper ia passes through the embosser 7 an array cf discrete portions IDa, all of which extend away froth the' plane of the papEr in the same direction, are formed on the embossed paper 10 This embossed paper 10 considered to be an intermediate variant of the packaging material of the presentinventiOn and is. shown fri mo:re:detaii in Figure 5a and b.

It i envisaged, that, although the intermediate variant. may not be as effective as the other varianth é$dribe:d herein, the embossed paper 10 can provide an e.ffctive cushioning effect When appfled to high densfty and/or pre: treated. source p Once again a dispenser 6 a.pp.Iies a h*arciefflng treatment Ip the embossed àper 10 to help strengther. and maintain the discrete. portions iDa.

it. i. apprec.ted that this step may hpt be necessary for higher density papec or indeed paper thathas been pre4reated,. for examp'e with [amnWon.

After the fbrmation of array of discrete portions I Os,. th. paper 1Q pasSes oVSr roLler 11 which appliesan adhesive to one side of the paper. It is.

envisaged that various types of adhesiVe' can effectively be UsGd, but suitable examples. incJuci cad starch glue:, FW glue and EVA glue.

Preferably, as is shown in FigUre the adh... esive is apphed to the underside cf the paper 1[s, The underside of the. paper is. considered to be: the. .t.pposite side of the paper fro ri. :whiich the. dlscrete portions extend and.

has accessible flat portions. It iS intended that the adhesive is.. primarily applk.,..d to the flat portions of the paper IDa, Qno:theadhes.ive is applied to the paper 1 0 it is caught together with a secondary source of paper 12a, which is supplied by roU 12 The adhesive ehables the tb paper strëähis tO cOn1bire: to produce thE: bushioned paper packaging thatCrial 13, which is the variaht of the packaging matdrial that is shown n Figures 6a and Sb. The secondary source paper 12a helps to reinforce the: .tructural integrity of the finished product.

ft is envisaged that a suitably shaped roller can be used, to' ensure: that the two sheets i.Oá., 12a are forced into adhesive contact with Oflê another without fiàttCning the raised discrete pdrtiohs on sheet 1 Oa.

it is also. envisaged that, wh:iist preferably the paper 10 is strengthened by applying the, second layer of pajer, the. strengthening function may be a.lte:rndvet9. provided by another suitable material. Suitable alternatives envisaged by the inventors are plastic rubber, metal and fabric Figure 3 shows another.aite:rna.tk,e process for iman:ufarturing cushioned packaging material of the present invention Ihe piocess shown in Figure 3 can be used to produce the variant of cushioned paper packaging material 14 that is. shown in ia end Tb. i 0-

The arrangement shown in Fiçjurè.3 Is similar to that shdwh in FIgLlre2 in* that the roll 1 supplies the source paper Ia to an embosser 7 whiOh produces embossed paper 1O. Hweyqr in the arrangement shown F:igure 3 a. Secohd toll 1 supplies a second source paper la' to a second erntos.se.r F whch prOthtcES asecond strëä'rn of embossed paper 10'.

The first and the second embossed paper streams are ahgned so that once a swtabe adhesive has been applied by rofler I I to at least one of the enibossed paper streams, the two *.strsams otembossed. paper ccme together to form a further variant of the cushoned paper packaging matenal 14 (see Figs 7a and 7b) As before the adhesive is appEied to the underside (i e the side wit.h axessIbieflat portiorts): and the two sheets are forced rtd adhesive contact by suitably shaped roIIers The alignment of the array of discrete portions formed on the first 10 arid Second 10' paper stream is such that when the streams come taçether each discrete portion on the first stream of embossed paper 10 lines up with a corresponding discrete portion on the second stream of embossed paper 1 0 In this way a bubble7 shape is formed at each point where the discrete portions align Providing the seal formed between the two paper streams is adequate th.e tuh.hles' can act in a similar way to Bubble Wrap.

Li Is envisaged that, although the Variants *of the *cushbned paper packaging: material shown in the:Fife all have discrete portions th:at have: a :substantiany hemi-spherical shape, the discrete portions may have alternative shapes. Examples of suitable alternative shapes for the discrete portions include pyramidal square, triangular, circular, rectangular and diamond shaped It is appreciated that any shape that can be embossed on to or in to paper in an array formation would be considered suitable Although not shown in any of Figures 1-3, it is envisaged that the finished cushioned packaging material (i e 5, 13 or 14) could be rolled up on to a roll (not shown) for easy transport and storage Alternatively the packaginç material could be formed intO: specific shapes and sites, preferabLy by a die cutfing machine, so that the pabkaging material can be formed into envelopes or mailer bags by an envelope forming machihe. It is also -it-envisaged that, if formed with the. correct dirnensins, the cushioned packaging material 13, in particular, could be used in place of Bubble VVrap in existing Jiffy mailer manufacturing rn achinery with onlymirior adaptation of the eXiSting equipment.

An example of an envelope 15 formed from a cushionea packaging material of the: preent invention is shown in Fjure 8. Of the: atove: d:&prEbcci variants of cushioned paper pk.gih'g niarid that are p.royided by the presEnt Invention that shbwti in Figure Ga and 6b is ccxisidere art ula.rIy suitáblë for the: fofl'flatiofl of éhvelo�es* arid/or mailer bag lUte that ShoWn in Figure ft The envelope I 5 is formed with the array of discrete portions located on the inne.r walls of the envelope. The discrete portions thereby combine to provide acushioned region 16 which h&psioprotect objects placed iithin the envelope 15 against mechanical stresses durIng transit. The: external wails of the envelope 17 are provided by the secondary layer of paper 1.2ä (see Figs Ha and Sb), which, gives theenv.eIope it strc,ctur,al integrity.. It: is envisaged that t:: per used to provide the eternal walls of the:envclope.: 1:7 way be pie-treated to give it improved strenth or water resistance, fOr exa'mçk.

The envelope. 15 is preferably formed frbm two: sheets of cushioned paper packaging material which are fixed together along three sides to fOrm the envelope. The two sheets can be: fixed together by a range' of fixing means, which include: cold starch glue, PVA glue, EVA glue, hot melt, heat sealing and stitching. It is envisaged that further fixing means might also be em�loyOd WithOut departing from the scope of the present invention.

Adjacent to the open side of the enyClope (Le. the side where the two sheets of cushioned paper packaging material are not fixed together) is provided a closure, flap' 19. The closure, flap: 19 fixEd to one of the sheets using a, similar suitable fking means: tO those used to: Uk the sheets of the ehvelope tOgether ($ee above).

In addition, the closure flap 19 is provided with at least one adhesive strip 20a, 20b: with a peelable coverstrip, which enables the clcsure flap to be secured across the opening of the envelope 15 thus retaining to contents 42-U within the envelope 15. Preferably: the clOsure flap 1 5 is pro'iided *WRh more than one: a.dhesve strip (Figure 8 shows an enveIpe with two adhesive strips):,, so that the envelope can be USS more than once.

It is e.n\,isägêd that th:eE cushioned, paper packaging rnteria.I. f the present invention can be Used to produt'ê a. uide variety of envelopes: and mailet bags Some examples of types of enve[opes'mailer bags which might suftably be H rQduced include: (i)Gusseted with a bottom flap an d extended. top for seiing; (2) Flat wfth a bOttom flap and extended top for seating:; (3) Block bottom with art attached flap for sealing (4) My size and length; and (5) Enclosed byeither sealing the side walls or bottom flap.

Ancthêt preferable feature of the ernie lopesimaiie.r bags provided by the present invention would be the addition of an individual number and bar code to the bag to aid tracking of a parcel in transit Also for security purposes, tamper proof security seals sirndar to those desuibed in UK patent application No. i006999.:5cOrild he provided, instead of standard firgc.r lift tape.

in situations where the cushioning paper packaging material of the present invention is to be used to form envelopes or mailer bags ft is envisaged: that, rather than completely forming envelopes/mailer bags of standard sizes, two streams of cushioned paper packaging material (e.g. vanant 13) could be cut to an appropnate width and then fixed together along the edges thereof to form what is essentially a length of packaging material in a tube Such tubing could then be stored on a roll and then cut from the roll in appropriate Lengths as required.

These bespoke lengths of packaging material tubing would then be sealed at one end to rorm the bespoke envelope The remaining open end of the: envelope would then be pi-o.vided with a suitable: c.lOswe flap. It is expected that this approach to envelope: formation would reduce the need for void fill where the object being transported is too small for the envelope.

Claims (5)

1. Claims 1. A method of manufacturing a cushioned packaging materiEl from paper, said method comprises providing the majority of the surface area of the paper with: at, array of discrete portions, wherein each of the discrete pprtions in the array.ind.ependently edOnd.eithe.r above or below the plane of the paper.
2. 2.. The: method of claim 1, wherein, the array of discrete portions is embossed onto the paper.
3. 3. The method of claim I or 2, wherein the paper is selected Irom the group consisting of: plain paper; chemically treated paper; laminated, paper: and metalized paper.
4. 4. The. method of claim 1, 2 or 3, wherein sAid paper comprises either a single: pIece of paper or multiplt layers of'paper 5. The method of claim 4, wherein' said single piece of paper or each of the multiple layers of caper is' proVided with: an array of discrete portions that all extend from the p!ane of the paper in the same d'irectbn.6. The method of claim 4, wherein said single piece of paper or each of the multiple layers of paper is provided. with. an. array of discrete. portions that alternately e>tOtid above and. .bel..:.w: the.platië.. Of the paper..7.. The: method. cf any of: the preceding claims:1 wherein.the:.sh.ape of each discrete: portion Is:. uniform..8. me. method of claim 7 wherelil: the. Shape cf the di'c'rete portions is selected from the group consiSting of: substantially.hemi-spher.ical:; pyramidal, square1 triangle,, circular, rectangle, and diamond.9, The': method of any of the preceding claims, wherein the paper is treated with a hardening solution after the array of discrete pardons has been formed: thereon.The method of any of the preceding claims further comprising strengthening the cushioned paper packaging material by affixing an additional Jay:erto. the. paper.11. The method of claim 10, wherein the additional. layer is s:lected froni the group consisting of paper plastic rubber, metal and fabric 12 A cushioned packaging material comprising paper having an array of discrete porhons provided over the majority of the surface area of the paper and Wherein each:f the discrete pOrtion independently extends either above or below the plane.of the paper 13. The packaging m'a.te:rim of claim 12:,. wherein, the array pf discrete pOrt is embossed onto the paper 14. The..: packaging material of claim 12 or 13, wherein the paper is s&ecte'd from the group consisting of: plain paper; chemically treated paper: laminated paper; and metalized paper 1.
5. 5. The pabkaging matérial of claim:12 13 or 14:, wherein said', paper comprises either a single piece of paper or multiple layers of paper 16 The packaging material of claim 15, wherein said single piece of papei or each of the multiple layers of paper is provided with an array of discrete podionsthat all extend from the plane of the paper in the saniedire..ction.17. The; packaging materia! of iai* 11; wherein nid. single pt of paper or each. of the multiple layers of is provided with nh array of discrete.portions that alternately extend abgyj.and.below the plane of fr:pwec: is, m:pa*ag:tngmatei1alofanybfoMrns.i2tai?whaminthcsuepatf fl The packagIng material of any otc!iafrIw 12 fl who re the tha ths dSete* portions is selectet from the 9:mtP oonsisfing. != subs tatIly hems-aph&td�t pyramidal, square tdaflçiSr CIrcular, rectan9ts,. at diam 20. TM: packaging material of any of claims 12 19, wherein distance that the distre S portions extend from the plane of the paper is suit:thatthe paper haS aii:étStI9t thickness of at.:least 2m(n 21 The packaging matenal of any of claims 12 to 20, further compnsing a *tfl!=SflD layer afft*ed to the paper, sad strong tflg layer b&ng çjp consisting of; papec pies tic; rubber; netal and tab$ A t'JSliiiOSi * p egg from the PSLg: Cf anyóEglJmai.2.to21, 23. A cu shkfled paper bag or envelope formed from a cushktntng layer and a: strut i te fixed in a layered reStonship with one anotheç wherein: jfr aushionm g layer3. fft pftht the inner swtte of pj: *etwelqpe1 fl1p:flSeS one;or rr,ore layet o.: paper having ih Err of disbtete ns pwvtdad: over: rnaqdw alto: suites.:.. area there where hi each rf the discrete portions independenOcextend. àlther abpve cor:be(ov:lhe ane Of the. ot each laA. bI pape and thestPu 1 layer prok the ouSnutface of the begoT envelope.24. The bag orenvetpe of claim 23, hdrëin the.sftuctUral:iàyêr is made of paper: 2& A method.°f manufactu.;rin;g a cushioned packaging material from: paper substantially as desctibed, herein with reference to the dmwings.26. A cushioned çackaçing material.substs:ritIaUy as described hereib with reference. to the drawings;.27: A. cushioned paper' bag or envelope SUbStantially as described herein with reference to the drawingS.