WO2025217618A1

WO2025217618A1 - Packaging materials with heat-activated bonds between intermittent inter-layer attachment points

Info

Publication number: WO2025217618A1
Application number: PCT/US2025/024431
Authority: WO
Inventors: Thomas D. Wetsch; Rachell L. Slovik
Original assignee: Pregis LLC
Current assignee: Pregis LLC
Priority date: 2024-04-11
Filing date: 2025-04-11
Publication date: 2025-10-16
Anticipated expiration: 2026-10-11

Abstract

A packaging material includes a first layer having an extensive flat surface, a second layer having a plurality of embossments, flutes, or other protrusions formed therein, and a bonding layer that includes a heat-activatable material fixing the extensive flat surface of the first layer to the second layer intermittently at a plurality of attachment locations.

Description

PACKAGING MATERIALS WITH HEAT-ACTIVATED BONDS BETWEEN INTERMITTENT INTER-LAYER ATTACHMENT POINTS

CROSS-REFERENCE TO RELEATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 63/632,973, filed April 11, 2024, the contents of which are incorporated by reference herein in their entirety.

BACKGROUND

[0002] Packaging materials are in widespread use to protect small to medium-sized items being shipped in e-commerce and other applications. The packaging materials typically are placed within the shipping box or other container holding the item and may be used to cushion or thermally insulate the item during shipping.

[0003] Many common protective packaging materials, such as inflatable cushions or pillows, are formed from plastic material such as polyethylene. Paper-based protective packaging materials are gaining popularity due to the environmentally friendly characteristics of paper, such as its recyclability. In some applications, however, it may be difficult to achieve a degree of protection from a paper packaging material comparable to that available from a packaging material formed from inflated plastic film.

SUMMARY

[0004] In one aspect of the disclosed technology, packaging material includes a first layer; and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer. [0005] In another aspect of the disclosed technology, the heat sealable material is applied as a flood coating to the first layer and/or second layer.

[0006] In another aspect of the disclosed technology, the first and second layers are made of a paper material.

[0007] In another aspect of the disclosed technology, at least some of the peaks or valleys are affixed to the first layer a plurality of attachment locations on the second layer.

[0008] In another aspect of the disclosed technology, the attachment locations are spaced from each other.

[0009] In another aspect of the disclosed technology, the second layer is periodically free of attachment to the first layer.

[0010] In another aspect of the disclosed technology, the protrusions extend from a principal surface of the second layer in a first direction, and the protrusions space the first layer from the principal surface in the first direction to define a thickness of the packaging material in the first direction.

[0011] In another aspect of the disclosed technology, the principal surface, the projections, and the first layer define gaps between the projections.

[0012] In another aspect of the disclosed technology, the first and second layers are made of a paper material.

[0013] In another aspect of the disclosed technology, the first layer is substantially flat.

[0014] In another aspect of the disclosed technology, the first layer is free of protrusions and complex bends.

[0015] In another aspect of the disclosed technology, the first layer has a plurality of three- dimensional protrusions defining peaks and valleys on the first layer, and at least some of the peaks or valleys on the second layer are affixed to at least some of the peaks or valleys on the first layer by the heat seals.

[0016] In another aspect of the disclosed technology, the packaging material further includes a third layer located on an opposite side of the second layer from the first layer, wherein at least some of the peaks or valleys of the second layer are affixed to the third layer by heat seals formed from the heat sealable material applied to each of the second layer and the third layer.

[0017] In another aspect of the disclosed technology, a packaging material includes a first layer having a flat surface, a second layer having a plurality of embossments formed therein, and a first bonding layer including a heat-activated material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

[0018] In another aspect of the disclosed technology, the attachment locations are spaced from each other.

[0019] In another aspect of the disclosed technology, the second layer is periodically free of attachment to the first layer.

[0020] In another aspect of the disclosed technology, the embossments extend from a principal surface of the second layer in a first direction, and the embossments space the first layer from the principal surface in the first direction to define a thickness of the packaging material in the first direction.

[0021] In another aspect of the disclosed technology, the principal surface, the embossments, and the first layer define gaps between the projections.

[0022] In another aspect of the disclosed technology, at least some of the attachment locations are located on peaks of the embossments. [0023] In another aspect of the disclosed technology, peaks of at least some of the embossments are detached from the first layer.

[0024] In another aspect of the disclosed technology, the embossments are disposed in repeating patterns along at least one of a length and a width of the second layer.

[0025] In another aspect of the disclosed technology, the heat-activatable material is a heat- sealable material, and the packaging material further comprises a second bonding layer including the heat sealable material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

[0026] In another aspect of the disclosed technology, the first bonding layer is applied to the first layer as a flood coat and/or the second bonding layer is applied to the second layer as a flood coat.

[0027] In another aspect of the disclosed technology, the heat-activatable material is a hot-melt adhesive.

[0028] In another aspect of the disclosed technology, the first and second layers are made of a paper material.

[0029] In another aspect of the disclosed technology, the attachment locations are located on a first side of the second layer, and the packaging material further includes a third layer having a flat surface and a second bonding layer including a heat-activated material bonding the extensive flat surface of the third layer to the second layer at a plurality of attachment locations on a second side of the second layer so that the packaging material is configured as a double-face packaging material. [0030] In another aspect of the disclosed technology, some of the embossments extend from the second layer and toward the first sheet in a first direction, and others of the embossments extend from the second layer in a second direction opposite the first direction.

[0031] In another aspect of the disclosed technology, the extensive flat surface of the first layer is attached to a first side of the second layer, and an extensive area on a second side of the second layer is substantially free of attachment to another layer to form a padding area within the packaging material.

[0032] In another aspect of the disclosed technology, an envelope includes a first sidewall, and [0033] a second sidewall fixed to the first sidewall and opposing the first sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope. At least one of the first and second sidewalls includes a packaging material including a first layer, and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer.

[0034] In another aspect of the disclosed technology, the protrusions are embossments or flutes.

[0035] In another aspect of the disclosed technology, a packaging material includes a first layer having an extensive flat surface, a second layer having a plurality of protrusions formed therein, and a first bonding layer including a heat-activated material bonding the extensive flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer, the first bonding layer extending continuously between at least some of the protrusions.

[0036] In another aspect of the disclosed technology, the protrusions are embossments. [0037] In another aspect of the disclosed technology, protrusions are flutes.

[0038] In another aspect of the disclosed technology, the attachment locations are spaced from each other.

[0039] In another aspect of the disclosed technology, the second layer is periodically free of attachment to the first layer.

[0040] In another aspect of the disclosed technology, the heat-activatable material is a heat- sealable material, and the packaging material further includes a second bonding layer including the heat sealable material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

[0041] In another aspect of the disclosed technology, the first bonding layer is applied to the first layer as a flood coat and/or the second bonding layer is applied to the second layer as a flood coat.

[0042] In another aspect of the disclosed technology, the heat-activatable material is a hot-melt adhesive.

[0043] In another aspect of the disclosed technology, the first and second layers are made of a paper material.

[0044] In another aspect of the disclosed technology, a method for forming an envelope includes providing a first and a second sidewall, at least one of the first and second sidewalls being formed from a packaging material including a first sidewall, and a second sidewall fixed to the first sidewall and opposing the first sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope. At least one of the first and second sidewalls includes a packaging material including a first layer, and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer. [0045] The method further includes overlaying the first sidewall onto the second sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope, and fixing the first sidewall to the second sidewall by forming a first seal extending in a generally lengthwise direction along respective side portions of the first and second sidewalls, and a second seal extending in a generally transverse direction across the first and second sidewalls.

[0046] In another aspect of the disclosed technology, a method for producing a packaging material includes providing a first web made from a first stock material, providing a second web made from a second stock material including a plurality of protrusions, and providing a first bonding element on the first web and/or the second web, the bonding element comprising a heat- activatable material.

[0047] The method further includes heating the first bonding element sufficiently to allow the heat-activatable material to bond, and pressing peaks of the protrusions against a surface of the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web, to provide a padded packaging material.

[0048] In another aspect of the disclosed technology, the method further includes forming the protrusions in the second web.

[0049] In another aspect of the disclosed technology, the method further includes embossing the second web to form the protrusions in the form of embossments. [0050] In another aspect of the disclosed technology, forming the embossments includes locally displacing portions of the second web away from a principal surface of the second web to stretch and plastically deform material within the embossments in relation to its initial state.

[0051] In another aspect of the disclosed technology, the method further includes forming the protrusions in the form of flutes.

[0052] In another aspect of the disclosed technology, the heat-activatable material is a hot-melt adhesive.

[0053] In another aspect of the disclosed technology, the heat-activatable material is a heat- sealable material.

[0054] In another aspect of the disclosed technology, at least one of the first and second stock materials is paper.

[0055] In another aspect of the disclosed technology, the method further includes providing the heat-activatable material on an entirety of one side of the first web and/or the second web.

[0056] In another aspect of the disclosed technology, pressing peaks of the protrusions against the surface of the first web includes directing the first and second webs between a first pressing member and a second pressing member, the first pressing member and the second pressing member configured to press the peaks of the protrusions against the surface of the first web.

[0057] In another aspect of the disclosed technology, forming the protrusions in the second web includes directing the second web between the first pressing member and a third pressing member, the first and third pressing members configured to locally displace portions of the second web away from a principal surface of the second web so as to stretch and plastically deform material within the second web in relation to its initial state to form embossments on the second web. [0058] In another aspect of the disclosed technology, forming the protrusions in the second web includes directing the second web between the first pressing member and a third pressing member, the first and third pressing members configured to locally displace portions of the second web without locally stretching or plastically deform material within the second web in relation to its initial state, to form flutes in the second web.

[0059] In another aspect of the disclosed technology, the method further includes providing a third web made from a third stock material, providing a second bonding element on the second web and/or the third web, the second bonding element including the heat-activatable material; heating the second bonding element sufficiently to allow the heat-activatable material in the second boding element to bond; and pressing additional peaks of the protrusions against a surface of the third web with the heated bonding element disposed therebetween to form bonds that fix the surface of the third web to the second web at a plurality of attachment locations on the second web.

[0060] In another aspect of the disclosed technology, the method further includes heating the heat-activatable material before pressing the peaks and the surface against each other.

[0061] In another aspect of the disclosed technology, the method further includes heating the heat-activatable material while pressing the peaks and the surface against each other with the heated bonding element disposed therebetween.

[0062] In another aspect of the disclosed technology, the method further includes applying the bonding layer to the first web and/or the second webs.

[0063] In another aspect of the disclosed technology, the surface of the first layer is a flat surface. [0064] In another aspect of the disclosed technology, the first bonding element is a heat sealable material applied to the first web and the second web, and heating the first bonding element sufficiently to allow the heat-activatable material to bond and pressing peaks of the protrusions against a surface of the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web includes applying sufficient heat to the first bonding element and pressure to the peaks of the protrusions and the surface of the first web to pressure the bonding element on the first and second layers against each other, so that the heat sealable material melts and becomes welded together upon cooling.

[0065] In another aspect of the disclosed technology, a device for forming a packaging material includes a heating device configured to heat a heat-activatable material on a first and/or a second web of stock material, and a sealer configured to press peaks of protrusions on the second web into a surface on the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web.

[0066] In another aspect of the disclosed technology, the device further includes a former configured to form the protrusions.

[0067] In another aspect of the disclosed technology, the former is an embosser configured to emboss the second web.

[0068] In another aspect of the disclosed technology, the embosser is configured to locally displace portions of the second web away from a principal surface of the second web to stretch and plastically deform material within the embossments in relation to its initial state. [0069] In another aspect of the disclosed technology, the former is configured to form flutes in the second web.

[0070] In another aspect of the disclosed technology, the former is configured to locally displace portions of the second web without substantially stretching or plastically deforming material within the flutes in relation to its initial state.

[0071] In another aspect of the disclosed technology, the heating device is positioned on or within the sealer.

[0072] In another aspect of the disclosed technology, the heating device is configured to heat the first or the second pressing member.

[0073] In another aspect of the disclosed technology, the sealer includes a first and a second pressing member configured to receive the first and second webs of stock material therebetween and to press the peaks of protrusions on the second web into the surface on the first web.

[0074] In another aspect of the disclosed technology, the first pressing member is a first roller and the second pressing member is a second roller, the device further includes a third roller, and the first roller and the third rollers are configured to receive the second web of stock material therebetween and to form the protrusions on the second web of stock material.

[0075] In another aspect of the disclosed technology, the second roller has a substantially smooth outer surface.

[0076] In another aspect of the disclosed technology, the third roller has a plurality of projections formed on an outer surface thereof, the first roller has a plurality of recesses formed therein, and each of the projections becomes disposed in a corresponding recess in the first roller as the second web passes between the first roller and the third roller so that the projections locally displace and stretch portions of the second web to plastically deform the portions of the second web to form embossments on the second web.

[0077] In another aspect of the disclosed technology, the first roller and the third roller each has a plurality of undulations formed on outer surfaces thereof; the undulations define a series of peaks and valleys; and each of the peaks of the first roller and the third roller becomes disposed in a corresponding valley in the other first roller or third roller as the second web passes between the first roller and the third roller so that the undulations form the flutes in the second web.

[0078] In another aspect of the disclosed technology, the heat-activatable material is a heat sealable material applied to the first web and the second web; and the heating device and the sealer are configured to apply sufficient heat to the first bonding element and pressure to the peaks of the protrusions and the surface of the first web to pressure the bonding element on the first and second web against each other, so that the heat sealable material melts and becomes welded together upon cooling.

[0079] In another aspect of the disclosed technology, a system for forming a packaging material includes the above, a supply of the first web of stock material, and a supply of the second web of stock material.

[0080] In another aspect of the disclosed technology, the first web and/or the second web is paper.

[0081] In another aspect of the disclosed technology, the first supply of stock material and/or the second supply of stock material has a rolled configuration.

[0082] In another aspect of the disclosed technology, the heat-activatable material is a hot-melt adhesive. [0083] BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[0085] FIG. 1 is a perspective view of a device for forming a packaging material;

[0086] FIG. 1A is a magnified view of the noted area in FIG. 1;

[0087] FIG. 2 is a perspective view of the single-face corrugated packaging material formed by the device shown in FIG. 1;

[0088] FIG. 3 is a top view of a web used to form the packaging material shown in FIG. 2;

[0089] FIG. 4 is a top view of an alternative embodiment of the web shown in FIG. 4;

[0090] FIG. 4A is a magnified view of the noted area in FIG. 4;

[0091] FIG. 5 is a perspective view of an alternative embodiment of the device shown in FIG. i;

[0092] FIG. 6 is a perspective view of a packaging material made of an embossed layer disposed between two substantially smooth layers;

[0093] FIG. 7 is a perspective view of an envelope formed from the packaging material shown in FIG. 2;

[0094] FIG. 8 is a perspective view of an envelope formed from a packaging material produced by the device shown in FIG. 5;

[0095] FIG. 9 is a perspective view of another alternative embodiment of the device shown in

FIG. 1; and [0096] FIG. 10 is a flow diagram depicting a method for forming the packaging material shown in FIG. 2 using the device shown in FIG. 1.

DETAILED DESCRIPTION

[0097] The inventive concepts are described with reference to the attached figures, wherein like reference numerals represent like parts and assemblies throughout the several views.

Several aspects of the inventive concepts are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the inventive concepts. One having ordinary skill in the relevant art, however, will readily recognize that the inventive concepts can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the inventive concepts.

[0098] Packaging containers can include parcel packaging and other containers to package items. Packaging containers are configured to contain and hold an item, typically enclosing the item, during shipping or storage of the item. Parcel packaging is configured for shipping and/or storing products, such as for storage in warehouse or retail shelves and displays. Examples of parcel packaging include flexible shipping containers such as envelopes, which can have varying degrees of flexibility and typically are used to ship or mail small or relatively flat items or smaller items around which the walls of the container can conform envelopes. Flexible shipping containers such as envelopes can be padded or non-padded, can be made of materials such as paper and flexible cardboard, can be configured with or without sidewalls or gussets, and can include larger envelopes such as mailers. Examples of parcel packaging also include bags, such as paper or poly bags, which can have a self-sealing capability and are typically used to ship small to medium-sized items; boxes, which can be formed from paperboard, cardboard, wood, or plastic, and typically have a rigid or semi-rigid structure suitable for holding medium to large- size items and heavier items; and shipping tubes or tube mailers, typically used to ship documents and paper items.

[0099] Protective packaging articles are configured for placement within a packaging container or between packaging containers or items being shipped or stored, to protect items, fill void space within a container, such as a packaging container, and/or prevent or inhibit the items from moving around within the container. Cushioning articles are a type of protective packaging article configured to provide cushioning to the packaged items and protection to various degrees against shocks and impact. Examples of cushioning materials include inflatable air pillows and cushions, bubble wrap, paper dunnage with a loft structure capable of withstanding moderate shocks and impact, foam sheets, and packing peanuts. Typically, cushioning articles are provided as a plurality of units of one or more similar sizes, typically common predetermined sizes, although in some applications the cushioning articles can be made to custom sizes. Some cushioning articles are also packaging containers, such as padded mailers or other containers with a padded wall.

[00100] The cushioning articles typically are selected to sufficiently fill the void space within the container to serve the desired protective function. Some cushioning articles can be used to enclose or otherwise surround an item, such as expandable-paper or bubble wrap that can be used to wrap an item, such as a bottle.

[00101] FIGS. 1 and 2 depict a single-face packaging material 12 with a corrugated layer, and a device 10 for forming the packaging material 12. FIG. 10 is a flow diagram depicting a method for forming the packaging material 12. [00102] The packaging material 12 can be used, for example, as a cushioning article to cushion an object within a box, envelope, or other container in which the object is being packaged for shipping, storage, etc. For example, the packaging material 12 can be wrapped around the object, or can be used to line the interior surfaces of the container. The packaging material 12 can be used in other applications. For example, the packaging material 12 can be configured as a sleeve that can be placed around a beverage container to thermally insulate the user’s hand from the container. Also, the packaging material 12 can be used in cold chain packaging applications in which the packaging material lines some or all of the interior of a container used to ship items that need to be maintained at a reduced temperature. As discussed below, the packaging materials disclosed herein are not limited to single-face cushioning articles.

[00103] The packaging material 12 includes a smooth layer 14, and a fluted layer 16 fixed to the layer 14. The layer 16 has protrusions in the form of flutes 18 formed therein. The smooth layer 14 is a flexible sheet that is generally flat, i.e., the smooth layer 14 is free of flutes, embossments, other protrusions, and complex bends. When the smooth layer 14 is attached to the fluted layer 16 as discussed below, the smooth layer 14 can be bent locally along a single bending axis, with no complex bending about multiple axes.

[00104] In alternative embodiments, one side of the smooth layer 14 has a generally flat surface that can lie in a plane, and the other side can have disconnected embossments, flutes, or other protrusions that extend in one direction, leaving the flat surface on the other side to which to attach the fluted layer 16.

[00105] The smooth layer 14 and the fluted layer 16 can be formed from regular kraft paper. The smooth layer 14 and/or the fluted layer 16 can be formed from other types of paper, such as extensible paper or carboard, and from other types of materials in alternative embodiments. The side of the fluted layer 16 opposite the smooth layer 14 is not covered, so that the smooth layer 14 forms the single face of the packaging material 12.

[00106] The flutes 18 are open-ended protrusions that extend transversely across the packaging material 12, i.e., in a direction substantially perpendicular to the machine direction. The transverse and machine directions are denoted by the respective arrows 20, 22 in FIGS. 1 and 2. The flutes 18 undulate in the machine direction, relative to an initial plane defined by the undeformed stock material from which the layer 16 is formed, such that flutes 18 have a generally wave-shaped profile. The material within the flutes 18 undergoes no substantial stretching or plastic deformation when the flutes 18 are formed. As shown in FIGS. 1 and 2, the flutes 18 have a profile that varies sinusoidally in the machine direction. The flutes 18 can have other shapes, such as stepped, angular, or triangular, in the alternative. The amplitude or height of the flutes 18, the length of the flutes 18 in the machine direction, and other characteristics of the flutes 18 are application-dependent and can vary with factors such as the flexibility and crush resistance of the packaging material 12 needed for a particular application, the stiffness and other characteristics of the stock material form which the layer 16 is formed, etc.

[00107] The device 10 includes a supply roller 32 and a supply roller 34. A supply of stock material in the form a web 36 is disposed on the supply roller 32. The web 36 includes the single layer 38 of stock material in the form of regular kraft paper. As discussed below, the paper layer 38 is formed into the fluted layer 16 of the packaging material 12. The stock material from which the layer 16 is formed, i.e., the paper layer 38, can be a material other than regular kraft paper. The web 36 can be suppled in a fan-folded configuration or other configurations in lieu of a rolled configuration in alternative embodiments. [00108] Another supply of stock material in the form a web 40 is disposed on the supply roller 34. The web 40 includes a layer 42 of stock material in form of regular kraft paper, and a bonding element in the form of a layer 44 of heat-activatable material disposed on the paper layer 42. As discussed below, the paper layer 42 forms the smooth layer 14 of the packaging material 12, and the heat-activatable material fixes the smooth layer 14 to the fluted layer 16 of the packaging material 12 at a plurality of attachment locations located within an attachment region on the fluted later 16. The stock material from which the smooth layer 14 is formed, i.e., the paper layer 42, can be a material other than regular kraft paper. The web 40 can be suppled in a fan-folded configuration or other configurations in lieu of a rolled configuration in alternative embodiments.

[00109] The layer 44 of heat-activatable material can be applied as a flood coat to an entire side of the paper layer 42 of the web 40, as depicted in FIG. 3. In alternative embodiments, the heat- activatable material can be applied in bands corresponding to the locations at which the flutes 18 will be attached to the paper layer 42. For example, FIG. 4 depicts an alternative embodiment of the web 40 in the form of a web 100. The web 100 has bands 104 of heat-activatable material disposed on a paper layer 102, at locations where the flutes 18 of the web 36 will be attached to the paper layer 102. In other alternative embodiments, the device 10 can include a spraying device or other type of applicator configured to apply the heat-activatable material to the paper layer 42 as or after the paper layer 42 is unwound from the supply roller 34.

[00110] The heat-activatable material can be, for example, a hot-melt adhesive. The hot-melt adhesive can have minimal, or no tackiness at room temperature, so that the adhesive layer 44 does not need to be covered by a release layer within the rolled web 40. In alternative embodiments, the hot-melt adhesive can be tacky at room temperature, and the adhesive layer 44 can be covered by a release layer within the web 40.

[00111] Hot-melt adhesives are thermoplastic polymers that are solid at room temperature, become molten when heated to an activation temperature above their softening point, and resolidify upon loss of heat at a temperature below a solidifying point, which may be the same as or different than the activation temperature, increasing in strength as they re-solidify. Most hot- melt adhesives, upon melting into a molten state and re-solidifying, do not undergo any chemical reaction such as cross-linking or removal of a carrier, e.g., evaporation of water. Thus, hot-melt adhesives typically can be reactivated, i.e., re-melted and re-solidified, after initially being applied to a substrate.

[00112] The hot-melt adhesive, after being applied to the surface to be bonded, can be in a low- tackiness state in which it has a low, or no tackiness in a lower range of temperatures. The hot- melt adhesive is applied hot, and cools and cures in the converting process. The hot-melt adhesive is reactivated by re-heating the hot-melt adhesive up to an activation temperature within a lower range of temperatures. This lower range of application temperatures in some embodiments, for example, is below about 140 °F. In other embodiments, for example, the lower range of temperatures is below about 120 °F, below about 125 °F, or below about 130 °F. [00113] The re-heating of the hot-melt adhesive to the activation temperature causes the hot- melt adhesive to become molten. The subsequent cooling of the hot-melt adhesive, in combination with the application of pressure, causes the hot-melt adhesive to bond to the opposing surface, forming a seal between the surfaces.

[00114] Other types of heat-activatable materials can be used in lieu of a hot-melt adhesive in alternative embodiments. For example, a heat-sealable material can be disposed on the web 36 and the web 40 in lieu of the hot-melt adhesive, in which case both the web 36 and the web 40 each would have a layer of heat-activatable material thereon. The heat sealable material is preapplied on the opposing surfaces of the substrates that are to be sealed together, typically as a coating applied to each surface. In some embodiments, the heat sealable material can be applied as a tape. The heat sealable material, after application, typically is solid in form.

[00115] An example of a heat sealable coating material is a weldable polymer provided in a thickness and with a composition such that upon applying sufficient heat to the coating and pressure to the substrates to pressure the opposing coatings against each other, the heat sealable material of the coatings melts and becomes welded together upon cooling, thereby forming a heat-seal of one substrate to the other. Typical heat sealable coatings are made of thermoplastics. The heat sealable material on the opposing surfaces of the substrates typically is identical. In some embodiments, non-identical materials can be used in the coating provided the materials are similar enough such that the materials can melt and combine to become welded together upon cooling.

[00116] In some embodiments, the heat-sealable material can include emulsion-based polymers and polymer dispersions. The one or more polymers can include one or more of vinyl acetate ethylene, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymers, polyvinyl alcohol copolymers, dextrin stabilized polyvinyl acetate, vinyl acetate copolymers, ethylene copolymers, vinylacrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane, polyolefins, and biodegradable materials (e g., cellulose and starch). For example, the heat-activatable material can be a polyvinyl alcohol (PVOH) coating. In some applications, the PVOH can be coated with polyethylene (PE) or polylactic acid (PLA) to prevent the PVOH from sticking, or from absorbing moisture which causes sticking. [00117] In some embodiments, the heat-sealable material can include a polyolefin-based dispersion. The polyolefin dispersion can include polyethylene and/or polypropylene, thermoplastic polymers, polymeric stabilizing agents including at least one polar polymer, water, and/or other suitable polyolefin dispersions. A suitable polyolefin dispersion can include, for example HYPOD™, from Dow Chemical, or other suitable polyolefin dispersions.

[00118] In some embodiments, the heat-sealable material can be water-based. The water-based heat-sealable material may include a water-based polymer. The use of a water-based heat- sealable material can enhance the recyclability of the packaging material 12, since the waterbased heat-sealable material can be dissolved and separated easily from the paper pulp during the recycling process.

[00119] As another example, the heat-activatable material can be an expandable material that expands when subjected to an elevated temperature. The expandable material, when expanded, can provide an additional cushioning effect to the packaging material 12. For example, an expandable material can be provided by depositing an expansion element on to the surface of a fluid adhesive. When activated, the expansion element creates voids in the adhesive, producing a foamed adhesive. Microspheres filled with a gas, such as nitrogen, for example, can be used as the expansion element. When heated, such as by subjecting the microspheres to microwave or other radiation, the expandable material expands and can provide a cushioning effect.

[00120] Referring to FIG. 1, the device 10 also includes a pressing member in the form of a forming roller 50 and another pressing member in the form of a forming roller 52. The forming rollers 50, 52 are configured to form the flutes 18 in the web 36. Each of the forming rollers 50, 52 has an outer surface with undulations 54 formed therein. The undulations 54 define a repeating series of peaks 56 and valleys 58 around the outer circumference of each roller 50, 52. The rollers 50, 52 are positioned in close proximity to each other, and can be driven in a synchronized manner so that each peak 56 on the rollers 50, 52 becomes disposed in a corresponding valley 58 in the other roller 50, 52 as the rollers 50, 52 rotate past each other. The supply roller 32 can be freewheeling, so that the web 36 is drawn from the supply roller 32 by the rollers 50, 52. In alternative embodiments, the supply roller 32 can be driven in a synchronized manner with the rollers 50, 52.

[00121] During operation of the device 10, the web 36 is drawn from the supply roller 32 and passes between the rollers 50, 52 as depicted in FIG. 1. The paper layer 38 of the web 36 is deformed as it passes between each corresponding peak 56 and valley 58 in the rollers 50, 52. The deformation of the layer 38 results in the formation of the flutes 18 on the layer 38. The flutes 18 have peaks 70 and valleys 72 similar in shape and dimensions to the respective peaks 56 and valleys 58 of the rollers 50, 52, as can be seen in FIGS. 1 and 2. The flutes 18 can be formed using pressing members other than rollers, such as stamping dies, in alternative embodiments.

[00122] The device 10 also includes a heated pressing member in the form of a heated roller 60. The roller 60 has a substantially smooth outer surface 62. The roller 60 is positioned opposite the forming roller 52 as shown in FIG. 1, so that the web 40 passes between the rollers 52, 60 after being drawn from the supply roller 34.

[00123] The roller 60 can be driven in a synchronized manner with the rollers 50, 52. The roller 60 draws the web 40 from the supply roller 34. The web 40 is oriented so that the paper layer 42 of the web 40 contacts the outer surface 62 of the roller 60 after leaving the roller 34, with the layer 44 of hot-melt adhesive on the web 40 facing outward, away from the surface 62 as shown in FIG. 1. [00124] The web 40 subsequently converges with the web 36 as the web 40 and the web 36 are drawn between the rollers 52, 60, so that the outward-facing layer 44 of hot-melt adhesive contacts the adjacent peaks 70 of the flutes 18 in the web 36.

[00125] The device 10 includes a heater configured to heat the roller 60. The heater can be integrated with the roller 60. The heater maintains the outer surface 62 of the roller 60 at a temperature sufficient to cause the hot-melt adhesive on the web 40 to reach or exceed its softening point as the web 40 converges with the web 36 and passes between the rollers 52, 60. The temperature at which the outer surface 62 of the roller 60 is maintained is application dependent, and is related to factors such as the thickness of the paper layer 42 of the web 40, the softening point of the hot-melt adhesive in the layer 44, the speed at which the web 40 is drawn over the roller 60, etc.

[00126] Alternative embodiments of the device 10 can include an additional roller or other provision to heat, or pre-heat the web 40 before the web 40 reaches the roller 60. For example, FIG. 9 depicts an alternative embodiment of the device 10 in the form of a device 10b. The device 10b is substantially identical to the device 10, with the exception that the device 10b includes a roller 63 configured to heat the web 40 before the web 40 reaches the roller 60. In other alternative embodiments, the heating device can be a stand-alone heater in the form of a blower, infrared heater, etc. that heats the web 40 before the web 40 reaches the roller 60.

[00127] The rollers 52, 60 are closely spaced so that the peaks 70 of each flute 18 and the opposing portion of the web 40 are pressed into each other upon passing between the rollers 52, 60. The combination of heat and pressure to which the layer 44 of hot-melt adhesive on the web 40 is subjected at this point are sufficient to form a bond 74 between each peak 70 and the opposing surface of the paper layer 42 of the web 40 when the hot-melt adhesive subsequently cools and re-solidifies.

[00128] The resulting packaging material 12 leaves the device 10 as a web that includes the smooth layer 14, which has been formed from the paper layer 42 of the web 40; and the fluted layer 16, which has been formed from the paper layer 38 of the web 36 and is intermittently attached to the smooth layer 14 by the bonds 74 formed from the layer 44 of hot-melt adhesive, so that the fluted layer 16 and the smooth layer 14 intermittently contact each other at the respective peaks 70 of the flutes 18, and the flutes 18 and the inwardly-facing surface of the smooth layer 14 define gaps between adjacent flutes 18. The peaks 70 thus define spaced-apart attachment locations on the web 36, with the attachment locations located within an attachment region on the web 38. As can be seen in FIG. 1, the attachment region is located over a substantial entirety of the web 36. In alternative embodiments, the attachment region can be spaced from an entirety or a portion of the perimeter of the web 36.

[00129] The web, upon leaving the device 10, can be wound into a roll, folded, cut into relatively small segments, formed into the envelope 13 shown in FIG. 7.

[00130] Alternative embodiments of the device 10 can be configured as a desktop device. More specifically, the device 10 can be configured in a compact form and can be disposed within a housing configured to rest on an elevated surface such as the working surface of a packing table. In such applications, for example, the device 10 can be configured to dispense the packaging material in response an operator input. The packaging material 12 can be produced, for example, in discrete predetermined lengths, or in variable lengths determined by the duration of the input provided by the operator. In some embodiments, the desktop device 10 can be provided with a cutting device to configured to sever the packaging material 12 after it has been dispensed. [00131] In alternative embodiments, the layer 44 of hot-melt adhesive can be disposed on the paper layer 38 of the web 36 instead of the paper layer 42 of the web 40, and the forming roller 52 can be heated to soften the layer 44 of hot-melt adhesive.

[00132] In alternative embodiments of the packaging material 10, another fluted layer 16 can be used in lieu of the smooth layer 14, and the peaks 70 of the flutes 18 of the two layers 16 can be attached to each other by the bonds 74.

[00133] In alternative embodiments of the packaging material 10 in which a heat-sealable material is used in lieu of a hot-melt adhesive, a layer of the heat-sealable material can be applied to both the paper layer 42 of the web 40 and the paper layer 38 of the web 36.

[00134] As noted above, the packaging material 12 can be formed into an envelope 13, as shown in FIG. 7, in which two sheets of the packaging material 12 can be joined by longitudinal, or side seals extending along the respective sides of the envelope 13, and by a transverse seal extending transversely across the bottom of the envelope 13, with the fluted layers 16 facing inward, toward the interior pocket of the envelope 13. Alternatively, a vertically-oriented web of the packaging material 12 can be C-folded about its longitudinal axis and sealed by an automated bagging machine to form a front-loaded envelope that can be cut or otherwise separated from the web once the envelope 13 has been loaded and sealed. The longitudinal and transverse seals can be formed, for example, by a layer of heat-activatable material (or other type of bonding element) on all, or a portion of one or both opposing surfaces of the fluted layers 16 of the opposing sheets. A bonding element can be disposed on the closure flap of the envelope 13 to form a closure seal between the flap and a side of the envelope 13 after the envelope 13 has been loaded and the closure flap has been folded over and onto the side of the envelope 13.

Alternative embodiments of the envelope 13 can be formed without a closure flap. In such embodiments, a heat activatable material (or other type of bonding element) can be disposed on one or both opposing surfaces of the fluted layers 16 of the opposing sheets, at or near the top of the envelope 13, to form a closure seal.

[00135] In alternative embodiments of the envelope 13, the fluted layers 16 can face outward. In other alternative embodiments, the envelope 13 can be formed using embodiments of the packaging material 12 in which smooth layers 14 are affixed to both sides of the fluted layer 16 to form a double-face packaging material.

[00136] FIG. 5 depicts an alternative embodiment of the device 10 in the form of a device 10a. The device 10a is substantially identical to the device 10, with the below-noted exceptions.

Unless otherwise indicated, the above description of the device 10 applies equally to the device 10a.

[00137] The device 10a is configured to produce a packaging material 12a, shown in FIGS. 5 and 6. The packaging material 12a includes a substantially smooth layer 14a that is substantially identical to the smooth layer 14 of the packaging material 12. The packaging material 12a also includes an embossed layer 16a fixed to the smooth layer 14a. The smooth layer 14a and the embossed layer 16a can be formed from regular kraft paper. One or both layers 14a, 16a can be formed from extensible paper or other types of materials in alternative embodiments.

[00138] The embossed layer 16a has protrusions in the form of embossments 80 formed therein. The embossments 80 can be arranged in rows that extend transversely across the packaging material 12a, and in rows that extend in the machine direction of the packaging material 12a.

The embossments 80 can be arranged in other patterns in alternative embodiments.

[00139] The embossments 80 are regions of the web 36a that are displaced relative to a region of the web 36a that forms a principal surface 83 of the embossed layer 16a, with the principal surface 83 located between and connecting the embossments 80. The material within each embossment 80 becomes stretched as the embossment 80 is formed, resulting in plastic deformation of the stock material, an increase in the surface area compared to the original flat configuration of the stock material, and consequently the formation of a bulging three- dimensional area that extends proud of the principal surface 83. Some thinning, tearing, and/or shifting of the fibers in the material can occur from the embossing depending on the thickness, stiffness, and other characteristics of stock material and on the height, shape, and other characteristics of the embossments.

[00140] Embossments typically are formed using a pressing member, such as a die, having projections that locally displace the material out of its initial plane to effect the stretching and increase in surface area that define the embossments. In some applications, another die having recesses that receive a corresponding one of the projections can be used in conjunction with the die containing the projections.

[00141] The embossments 80 extend in a first direction from the adjacent, planar portions of the embossed layer 16a, resulting in raised features on one side of the embossed layer 16a and recesses on the other side of the embossed layer 16a. In alternative embodiments, the embossments 80 can extend from both the first and second sides of the embossed layer 16a, resulting in raised features and recesses on both sides of the embossed layer 16a.

[00142] The embossments 80 have the shape of a spherical dome. The embossments 80 can have other shapes in alternative embodiments. For example, the embossments 80 can have non- curvilinear surfaces, and can have an oval, stepped, ridged, elongated, or other shape in alternative embodiments. The height of the embossments 80, the density of the embossments 80 on the layer 16a, and other characteristics of the embossments 80 are application-dependent and can vary with factors such as the flexibility and crush resistance of the packaging material 12a needed for a particular application, the stiffness and other characteristics of the stock material form which the layer 16a is formed, etc.

[00143] The device 10a includes the supply roller 32 and the supply roller 34 as described above in relation to the device 10. A web 36a, which can be substantially identical to the web 36 described above, is disposed on the supply roller 32. As discussed below, a paper layer 38a of the web 36a forms the embossed layer 16a of the packaging material 12a.

[00144] A web 40a, which can be substantially identical to the web 40 described above, is disposed on the supply roller 34. As discussed below, a paper layer 42a of the web 40a forms the smooth layer 14a of the packaging material 12a, and a layer 44a of heat-activatable material of the web 40a fixes the embossed layer 16a to the smooth layer 14a.

[00145] The layer 44a of heat-activatable material can be applied as a flood coat to an entire side of the paper layer 42a of the web 40a. In alternative embodiments, the heat-activatable material can be applied in bands or dots corresponding to the locations at which the embossments 80 will be attached to the paper layer 42a.

[00146] The device 10a also includes a pressing member in the form of a forming roller 50a, and another pressing member in the form of a forming roller 52a. The forming rollers 50a, 52a are configured to form the embossments 80 in the web 36a. The forming roller 50a has a plurality of hemispherical projections 82 formed on an outer surface 84 thereof, with each projection 82 having a peak 86, or area of greatest height above the adjacent portion of the outer surface 84. [00147] The forming roller 52a defines a plurality of hemispherical recesses 88 that extend downward, into the roller 52a, from an outer surface 90 of the roller 52a. Each recess 88 is sized to receive a corresponding projection 82 with minimal clearance.

[00148] The rollers 50a, 52a are in close proximity to each other, and can be driven in a synchronized manner so that each projection 82 on the roller 50a becomes disposed in a corresponding recess 88 in the roller 52a as the rollers 50a, 52a rotate past each other. The supply roller 32 can be freewheeling, so that the web 36a is drawn from the supply roller 32 by the rollers 50a, 52a. In alternative embodiments, the supply roller 32 can be driven in a synchronized manner with the rollers 50a, 52a.

[00149] During operation of the device 10a, the web 36a is drawn from the supply roller 32 and is locally displaced out of its original plane and stretched as it is pressed into the recesses 88 by the corresponding projections 82. The resulting plastic deformation and increases in the surface area of the layer 38a result in the formation of the embossments 80 on the layer 38a. The embossments 80 are similar in shape and dimensions to the projections 82 and the recesses 88 on the respective forming rollers 50a, 52a. The embossments 80 can be formed using pressing members other than rollers, such as stamping dies, in alternative embodiments.

[00150] In alternative embodiments, the web 36a can have two or more layers with a heat- activatable material disposed on or more of the layers. One or both of the forming rollers 50a, 52a can be heated so the heat-activatable material forms bonds between the layers of material within each embossment 80 as the embossments 80 are formed, resulting in embossments 80 with two or more layers bonded to each other.

[00151] The device 10a also includes a pressing member in the form of the roller 60 as described above in relation to the device 10. The roller 60 is positioned opposite the forming roller 52a as shown in FIG. 5, so that the paper layer 38a of the web 36a passes between the rollers 52a, 60 after the embossments 80 have been formed in the layer 38a.

[00152] The roller 60 can be driven in a synchronized manner with the rollers 50a, 52a. The roller 60 draws the web 40a from the supply roller 34. The web 40a is oriented so that the paper layer 42a of the web 40a contacts the outer surface 62 of the roller 60 after leaving the roller 34, with the layer 44a of hot-melt adhesive on the web 40a facing outward, away from the surface 62.

[00153] The web 40a subsequently converges with the web 36a as the web 40a and the web 36a are drawn between the rollers 52a, 60, so that the outward-facing layer 44a of hot-melt adhesive contacts peaks 91 of the embossments 80 in the web 36a, as shown in FIG. 5.

[00154] The outer surface 62 of the roller 60 is maintained at a temperature sufficient to cause the hot-melt adhesive on the web 40a to reach or exceed its softening point as the web 40a converges with the web 36a and passes between the rollers 52a, 60. The temperature at which the outer surface 62 of the roller 60 is maintained is application dependent, and is related to factors such as the thickness of the paper layer 42a of the web 40a, the softening point of the hot- melt adhesive in the layer 44a, the speed at which the web 40a is drawn over the roller 60, etc. [00155] The rollers 52a, 60 are closely spaced so that the peaks 91 of each embossment 80 and the opposing portion of the web 40a are pressed into each other upon passing between the rollers 52a, 60. The combination of heat and pressure to which the layer 44a of hot-melt adhesive on the web 40a is subjected at this point are sufficient to form a bond 92 between each peak 91 and the opposing surface of the paper layer 42a of the web 40a when the hot-melt adhesive subsequently cools and re-solidifies. [00156] The resulting packaging material 12a is a single-faced packaging material with an embossed layer. The packaging material 12a is configured as a web that includes the smooth layer 14a, which has been formed from the paper layer 42a of the web 40a; and the embossed layer 16a, which has been formed from the paper layer 38a of the web 36a. The embossed layer 16a is intermittently attached to the smooth layer 14a at a plurality of intermittent attachment locations positioned within an attachment region on the embossed later 16a, by the bonds 92 formed from the layer 44a of hot-melt adhesive, so that the embossed layer 16a and the smooth layer 14a are attached to each other intermittently at the respective peaks 91 of the embossments 80, the embossments 80 and the inward-facing surface of the smooth layer 14a define gaps 85 between adjacent embossments 80, and valleys 87 are defined on the principal surface 83 between the embossments 80. The peaks 91 thus define spaced-apart attachment locations on the web 36a, with the attachment locations located within an attachment region on the web 36a. Also, as a result of the intermittent attachment of the peaks 91 to the smooth layer 14a, the embossed layer 16a is periodically fee of attachment to the smooth layer. The projection of the embossments 80 from the principal surface 83 spaces the principal surface from the smooth layer 14a, providing loft to the packaging material 10 which helps the packaging material 10 to exert a cushioning or thermal insulating effect.

[00157] As can be seen in FIG. 5, the attachment region is located over a substantial entirety of the web 36a. In alternative embodiments, the attachment region can spaced from an entirety or a portion of the perimeter of the web 36a.

[00158] In some embodiments, the peaks 91 of all the embossments 80 within the attachment region can be attached to the smooth layer 14a. In alternative embodiments, the peaks 19 of less than all of the embossments 80 within the attachment region can be attached to the smooth layer 14a. In embodiments in which the packaging material has localized protective regions, i.e., localize portions of the packaging material 12a that are intended to provide a padding or thermal insulating effect, the peaks 91 of most or all of the embossments 80 can be attached to the smooth layer 14a, and the only attachment of the embossed layer 16a to the smooth layer can occur at the peaks 91 of the embossments 80.

[00159] The web, upon leaving the device 10a, can be wound into a roll; folded or cut into relatively small segments; formed into an envelope 94 in a manner similar to the envelope 94, as shown in FIG. 8; and/or subject to other processing operations.

[00160] In alternative embodiments of the packaging material 10a, another embossed layer 16a can be used in lieu of the smooth layer 14a, and the peaks 91 of the embossments 80 of the two layers 16a can be attached to each other by the bonds 92.

[00161] In alternative embodiments of the packaging material 10a in which a heat-sealable material is used in lieu of a hot-melt adhesive, a layer of the heat-sealable material can be applied to both the paper layer 42a of the web 40a and the paper layer 38a of the web 36a.

[00162] FIG. 6 depicts a double-faced packaging material 110 that can be formed from the single-faced packaging material 12a with the embossed layer 16a. The packaging material 110 can be formed by adhering or otherwise fixing the paper layer 42a of another web 40a to the side of the embossed layer 16a opposite the side to which the initial paper layer 42a originally was fixed to form the substantially smooth layer 14a of the packaging material 12a, to thereby form another substantially smooth layer 14b on the opposite side of the embossed layer 16a. (A double-faced corrugated packaging material can be formed in a similar manner from the singlefaced packaging material 12.) [00163] As noted above, the packaging material 12a can be formed into an envelope 94, as shown in FIG. 8, in which two sheets of the packaging material 12a can be joined by longitudinal, or side seals extending along the respective sides of the envelope 94, and by a transverse seal extending transversely across the bottom of the envelope 94, with the recesses on the embossed layers 16a facing inward, toward the interior pocket of the envelope 94. Alternatively, a vertically-oriented web of the packaging material 12a can be C-folded about its longitudinal axis and sealed by an automated bagging machine to form a front-loaded envelope that can be cut or otherwise separated from the web once the envelope 94 has been loaded and sealed. The longitudinal and transverse seals can be formed, for example, by a layer of heat- activatable material (or other type of bonding element) on all, or a portion of one or both opposing surfaces of the embossed layers 16a of the opposing sheets. A bonding element can be disposed on the closure flap of the envelope 94 to form a closure seal between the flap and a side of the envelope 94 after the envelope 94 has been loaded and the closure flap has been folded over and onto the side of the envelope 94. Alternative embodiments of the envelope 94 can be formed without a closure flap. In such embodiments, a heat activatable material (or other type of bonding element) can be disposed on one or both opposing surfaces of the embossed layers 94 of the opposing sheets, at or near the top of the envelope 94, to form a closure seal.

[00164] In alternative embodiments of the envelope 94, the recesses on the embossed layers 16a can face outward. In other alternative embodiments, the envelope 94 can be formed using sheets of the double-faced packaging material 1 10.

[00165] Other alternative embodiments can include protrusions other than the flutes 18 and the embossments 80. [00166] Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.

Claims

What is claimed is:

1. A packaging material, comprising: a first layer; and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer.

2. The packaging material of claim 1, wherein the heat sealable material is applied as a flood coating to the first layer and/or second layer.

3. The packaging material of claim 1, wherein the first and second layers are made of a paper material.

4. The packaging material of claim 1, wherein at least some of the peaks or valleys are affixed to the first layer a plurality of attachment locations on the second layer.

5. The packaging material of claim 4, wherein the attachment locations are spaced from each other.

6. The packaging material of claim 1, wherein the second layer is periodically free of attachment to the first layer.

7. The packaging material of claim 1, wherein: the protrusions extend from a principal surface of the second layer in a first direction; and the protrusions space the first layer from the principal surface in the first direction to define a thickness of the packaging material in the first direction.

8. The packaging material of claim 7, wherein the principal surface, the projections, and the first layer define gaps between the projections.

9. The packaging material of claim 1, wherein the first and second layers are made of a paper material.

10. The packaging material of claim 1, wherein the first layer is substantially flat.

11. The packaging material of claim 10, wherein the first layer is free of protrusions and complex bends.

12. The packaging material of claim 1, wherein: the first layer has a plurality of three-dimensional protrusions defining peaks and valleys on the first layer; and at least some of the peaks or valleys on the second layer are affixed to at least some of the peaks or valleys on the first layer by the heat seals.

13. The packaging material of claim 1 , further comprising a third layer located on an opposite side of the second layer from the first layer, wherein at least some of the peaks or valleys of the second layer are affixed to the third layer by heat seals formed from the heat sealable material applied to each of the second layer and the third layer.

14. A packaging material, comprising: a first layer having a flat surface; a second layer having a plurality of embossments formed therein; and a first bonding layer including a heat-activated material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

15. The packaging material of claim 14, wherein the attachment locations are spaced from each other.

16. The packaging material of claim 14 wherein the second layer is periodically free of attachment to the first layer.

17. The packaging material of claim 14, wherein: the embossments extend from a principal surface of the second layer in a first direction; and the embossments space the first layer from the principal surface in the first direction to define a thickness of the packaging material in the first direction.

18. The packaging material of claim 17, wherein the principal surface, the embossments, and the first layer define gaps between the projections.

19. The packaging material of claim 14, wherein at least some of the attachment locations are located on peaks of the embossments.

20. The packaging material of claim 14, wherein peaks of at least some of the embossments are detached from the first layer.

21. The packaging material of claim 14, wherein the embossments are disposed in repeating patterns along at least one of a length and a width of the second layer.

22. The packaging material of claim 14, wherein: wherein the heat-activatable material is a heat-sealable material; and the packaging material further comprises a second bonding layer including the heat sealable material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

23. The packaging material of claim 22, wherein the first bonding layer is applied to the first layer as a flood coat and/or the second bonding layer is applied to the second layer as a flood coat.

24. The packaging material of claim 14, wherein the heat-activatable material is a hot-melt adhesive.

25. The packaging material of claim 14, the first and second layers are made of a paper material.

26. The packaging material of claim 14, wherein: the attachment locations are located on a first side of the second layer; and the packaging material further includes a third layer having a flat surface and a second bonding layer including a heat-activated material bonding the extensive flat surface of the third layer to the second layer at a plurality of attachment locations on a second side of the second layer so that the packaging material is configured as a double-face packaging material.

27. The packaging material of claim 26, wherein: some of the embossments extend from the second layer and toward the first sheet in a first direction; and others of the embossments extend from the second layer in a second direction opposite the first direction.

28. The packaging material of claim 1, wherein: the extensive flat surface of the first layer is attached to a first side of the second layer; and an extensive area on a second side of the second layer is substantially free of attachment to another layer to form a padding area within the packaging material.

29. An envelope comprising: a first sidewall; and a second sidewall fixed to the first sidewall and opposing the first sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope, wherein at least one of the first and second sidewalls include a packaging material including: a first layer; and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer.

30. The envelope of claim 29, wherein the protrusions are embossments or flutes.

31. A packaging material, comprising: a first layer having an extensive flat surface; a second layer having a plurality of protrusions formed therein; and a first bonding layer including a heat-activated material bonding the extensive flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer, the first bonding layer extending continuously between at least some of the protrusions.

32. The packaging material of claim 31, wherein the protrusions are embossments.

33. The packaging material of claim 31, wherein the protrusions are flutes.

34. The packaging material of claim 31, wherein the attachment locations are spaced from each other.

35. The packaging material of claim 31 wherein the second layer is periodically free of attachment to the first layer.

36. The packaging material of claim 31, wherein: wherein the heat-activatable material is a heat-sealable material; and the packaging material further comprises a second bonding layer including the heat sealable material bonding the flat surface of the first layer to the second layer at a plurality of attachment locations on the second layer.

37. The packaging material of claim 36, wherein the first bonding layer is applied to the first layer as a flood coat and/or the second bonding layer is applied to the second layer as a flood coat.

38. The packaging material of claim 31 , wherein the heat-activatable material is a hot-melt adhesive.

39. The packaging material of claim 31, the first and second layers are made of a paper material.

40. A method for forming an envelope, the method comprising: providing a first and a second sidewall, at least one of the first and second sidewalls being formed from a packaging material including: a first sidewall; and a second sidewall fixed to the first sidewall and opposing the first sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope, wherein at least one of the first and second sidewalls includes a packaging material including: a first layer; and a second layer having a plurality of three-dimensional protrusions defining peaks and valleys on the second layer, wherein at least some of the peaks or valleys are affixed to the first layer by heat seals formed from a heat sealable material applied to each of the first layer and the second layer; overlaying the first sidewall onto the second sidewall so that the first and second sidewalls define an envelope pocket configured to receive an item to be held in the envelope; and fixing the first sidewall to the second sidewall by forming a first seal extending in a generally lengthwise direction along respective side portions of the first and second sidewalls, and a second seal extending in a generally transverse direction across the first and second sidewalls.

41. A method for producing a packaging material, comprising: providing a first web made from a first stock material; providing a second web made from a second stock material including a plurality of protrusions; providing a first bonding element on the first web and/or the second web, the bonding element comprising a heat-activatable material; heating the first bonding element sufficiently to allow the heat-activatable material to bond; and pressing peaks of the protrusions against a surface of the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web, to provide a padded packaging material.

42. The method of claim 41, further comprising forming the protrusions in the second web.

43. The method of claim 42, further comprising embossing the second web to form the protrusions in the form of embossments.

44. The method of claim 43, wherein forming the embossments includes locally displacing portions of the second web away from a principal surface of the second web to stretch and plastically deform material within the embossments in relation to its initial state.

45. The method of claim 42, further comprising forming the protrusions in the form of flutes.

46. The method of claim 41, wherein the heat-activatable material is a hot-melt adhesive.

47. The method of claim 41, wherein the heat-activatable material is a heat-sealable material.

48. The method of claim 41, wherein at least one of the first and second stock materials is paper.

49. The method of claim 41, further comprising providing the heat-activatable material on an entirety of one side of the first web and/or the second web.

50. The method of claim 42, wherein pressing peaks of the protrusions against the surface of the first web includes directing the first and second webs between a first pressing member and a second pressing member, the first pressing member and the second pressing member configured to press the peaks of the protrusions against the surface of the first web.

51. The method of claim 50, wherein forming the protrusions in the second web includes directing the second web between the first pressing member and a third pressing member, the first and third pressing members configured to locally displace portions of the second web away from a principal surface of the second web so as to stretch and plastically deform material within the second web in relation to its initial state to form embossments on the second web.

52. The method of claim 50, wherein forming the protrusions in the second web includes directing the second web between the first pressing member and a third pressing member, the first and third pressing members configured to locally displace portions of the second web without locally stretching or plastically deform material within the second web in relation to its initial state, to form flutes in the second web.

53. The method of claim 41, further comprising: providing a third web made from a third stock material providing a second bonding element on the second web and/or the third web, the second bonding element including the heat-activatable material; heating the second bonding element sufficiently to allow the heat-activatable material in the second boding element to bond; and pressing additional peaks of the protrusions against a surface of the third web with the heated bonding element disposed therebetween to form bonds that fix the surface of the third web to the second web at a plurality of attachment locations on the second web.

54. The method of claim 41, further comprising heating the heat-activatable material before pressing the peaks and the surface against each other.

55. The method of claim 41, further comprising heating the heat-activatable material while pressing the peaks and the surface against each other with the heated bonding element disposed therebetween.

56. The method of claim 41, further comprising applying the bonding layer to the first web and/or the second webs.

57. The method of claim 41, wherein the surface of the first layer is a flat surface.

58. The method of claim 41, wherein: the first bonding element is a heat sealable material applied to the first web and the second web; and heating the first bonding element sufficiently to allow the heat-activatable material to bond and pressing peaks of the protrusions against a surface of the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web includes applying sufficient heat to the first bonding element and pressure to the peaks of the protrusions and the surface of the first web to pressure the bonding element on the first and second layers against each other, so that the heat sealable material melts and becomes welded together upon cooling.

59. A device for forming a packaging material, the device comprising: a heating device configured to heat a heat-activatable material on a first and/or a second web of stock material; and a sealer configured to press peaks of protrusions on the second web into a surface on the first web with the heated bonding element disposed therebetween to form bonds that fix the surface of the first web to the second web at a plurality of attachment locations on the second web.

60. The device of claim 59, further including a former configured to form the protrusions.

61. The device of claim 60, wherein the former is an embosser configured to emboss the second web.

63. The device of claim 61, wherein the embosser is configured to locally displace portions of the second web away from a principal surface of the second web to stretch and plastically deform material within the embossments in relation to its initial state.

64. The device of claim 59, wherein the former is configured to form flutes in the second web.

65. The device of claim 64, wherein the former is configured to locally displace portions of the second web without substantially stretching or plastically deforming material within the flutes in relation to its initial state.

66. The device of claim 59, wherein the heating device is positioned on or within the sealer.

67. The device of claim 59, wherein the heating device is configured to heat the first or the second pressing member.

68. The device of claim 60, wherein the sealer includes a first and a second pressing member configured to receive the first and second webs of stock material therebetween and to press the peaks of protrusions on the second web into the surface on the first web.

69. The device of claim 68, wherein: the first pressing member is a first roller and the second pressing member is a second roller; the device further includes a third roller; and the first roller and the third rollers are configured to receive the second web of stock material therebetween and to form the protrusions on the second web of stock material.

70. The device of claim 69, wherein the second roller has a substantially smooth outer surface.

71. The device of claim 69, wherein: the third roller has a plurality of projections formed on an outer surface thereof; the first roller has a plurality of recesses formed therein; and each of the projections becomes disposed in a corresponding recess in the first roller as the second web passes between the first roller and the third roller so that the projections locally displace and stretch portions of the second web to plastically deform the portions of the second web to form embossments on the second web.

72. The device of claim 69, wherein: the first roller and the third roller each has a plurality of undulations formed on outer surfaces thereof; the undulations define a series of peaks and valleys; and each of the peaks of the first roller and the third roller becomes disposed in a corresponding valley in the other first roller or third roller as the second web passes between the first roller and the third roller so that the undulations form the flutes in the second web.

73. The device of claim 59, wherein: the heat-activatable material is a heat sealable material applied to the first web and the second web; and the heating device and the sealer are configured to apply sufficient heat to the first bonding element and pressure to the peaks of the protrusions and the surface of the first web to pressure the bonding element on the first and second web against each other, so that the heat sealable material melts and becomes welded together upon cooling.

74. A system for forming a packaging material, comprising: the device of claim 59; a supply of the first web of stock material; and a supply of the second web of stock material.

75. The system of claim 74, wherein the first web and/or the second web is paper.

76. The system of claim 74, wherein the first supply of stock material and/or the second supply of stock material has a rolled configuration.

77. The system of claim 74, wherein the heat-activatable material is a hot-melt adhesive.