PACKAGING ASSEMBLY COMPRISING AN INTERIOR BOND

Abstract

A packaging assembly including a flexible outer shell layer and a flexible inner cushioning layer in overlapping relation with each other and comprising at least one interior bond that bonds an interior area of the outer shell layer to an interior area of the inner cushioning layer.

Description

BACKGROUND

Packaging assemblies, e.g., shipping containers, padded mailers, and the like, have found increasing use as more and more items are purchased online and are shipped to the end-user.

SUMMARY

In broad summary, herein is disclosed a packaging assembly including a flexible outer shell layer and a flexible inner cushioning layer in overlapping relation with each other and comprising at least one interior bond that bonds an interior area of the outer shell layer to an interior area of the inner cushioning layer. These and other aspects will be apparent from the detailed description below. In no event, however, should this broad summary be construed to limit the claimable subject matter, whether such subject matter is presented in claims in the application as initially filed or in claims that are amended or otherwise presented in prosecution.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary packaging assembly with an item disposed in a ready-for-packaging condition.

FIG. 2 is a side view of an exemplary packaging assembly with an item disposed in a ready-for-packaging condition.

FIG. 3 is a side view of an exemplary packaging assembly as disclosed herein.

FIG. 4 is a side view of an exemplary packaging assembly and illustrating methods of packaging an item within the construction.

FIG. 5 is a side view of another exemplary packaging assembly as disclosed herein.

Like reference numbers in the various figures indicate like elements. Some elements may be present in identical or equivalent multiples; in such cases only one or more representative elements may be designated by a reference number but it will be understood that such reference numbers apply to all such identical elements. All figures and drawings in this document are not to scale and are chosen for the purpose of illustrating different embodiments of the invention. In particular the dimensions of the various components are depicted in illustrative terms only, and no relationship between the dimensions of the various components should be inferred from the drawings, unless so indicated. Although terms such as first and second may be used in this disclosure, it should be understood that those terms are used in their relative sense only unless otherwise noted.

Terms such as outward and inward are defined in relation to the packaging assembly as packaged (e.g., wrapped) around an item, with inward denoting toward the item and with outward denoting away from the item. For clarity of description, these terms are retained even in descriptions of the packaging assembly and components thereof, prior to the assembly being packaged around an item.

As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring a high degree of approximation (e.g., within +/−20% for quantifiable properties). The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within +/−10% for quantifiable properties). The term “essentially” means to a very high degree of approximation (e.g., within plus or minus 2% for quantifiable properties; it will be understood that the phrase “at least essentially” subsumes the specific case of an “exact” match. However, even an “exact” match, or any other characterization using terms such as, e.g., same, equal, identical, uniform, constant, and the like, will be understood to be within the usual tolerances or measuring error applicable to the particular circumstance rather than requiring absolute precision or a perfect match.

DETAILED DESCRIPTION

Disclosed herein is a packaging assembly 1. Packaging assembly 1 comprises a flexible outer shell layer 20 and a flexible inner cushioning layer 10, as shown in exemplary embodiment in perspective view in FIG. 1 and in side view in FIG. 2. By flexible is meant that layers 10 and 20, when manipulated individually and/or if manipulated simultaneously as a stacked pair of layers, can be easily bent, folded, and so on, by hand by a human user, without the use of any special tools or the like.

Flexible layers 10 and 20 are in overlapping relation with each other, as shown in exemplary embodiment in FIGS. 1 and 2. By overlapping relation is meant that, when layers 10 and 20 are in a ready-for-packaging condition (e.g., flat on a suitable horizontal surface, as in FIGS. 1 and 2) at least 40% of the total area of layer 10 overlaps layer 20, and vice versa. In various embodiments, at least 60, 80, 90 or 95% of the total area of layer 10 overlaps layer 20, and vice versa. In some convenient embodiments, layers 10 and 20 are coextensive, meaning that they share the same shape and size with essentially 100% of their area in overlapping relation with each other, as in the exemplary arrangement of FIG. 1. In many convenient embodiments, packaging assembly 1 and layers 10 and 20 thereof may be at least generally rectangular and may exhibit four major terminal edges. In some specific embodiments, layers 10 and 20 may be at least generally square, as shown in exemplary embodiment in FIG. 1.

Packaging assembly 1 comprises at least one interior bond 30 that is located between inner cushioning layer 10 and outer shell layer 20, as shown in exemplary embodiment in FIGS. 1 and 2. As shown in further detail in FIG. 3, interior bond 30 bonds an interior area 21 of outer shell layer 20 to an interior area 11 of inner cushioning layer 10. Other area(s) 22 of outer shell layer 20 and area(s) 12 of inner cushioning layer 10 remain unbonded as evident in FIG. 3. The provision of at least one interior bond 30 in this manner allows shell layer 20 and cushioning layer 10 to be provided to an end user and handled by the end user as a multilayer stack that is held together by the at least one interior bond 30. However, the unbonded areas 22 and 12 of the shell layer 20 and the cushioning layer 10 can be manipulated separately and individually, which is advantageous as discussed later herein.

By at least one interior bond is meant a bond (i.e., one or more bonds, whether direct or indirect) between the shell layer 20 and the cushioning layer 10, that is located in an interior area of each layer. In other words, no portion of bond 30 will extend to a terminal edge of layer 10 or layer 20. Rather, each layer will include a “picture-frame” border of unbonded material (areas 12 and 22, in FIG. 3). Left, right, fore and aft unbonded areas, that are not bonded by interior bond 30 and that collectively comprise an unbonded picture-frame border, are also indicated (as 1, r, f and a) in FIG. 1.

In some embodiments, an interior bond will occupy (in terms of total actual bonded area) less than 40% of the total area of each layer. In various embodiments, an interior bond 30 may occupy less than 35, 30, 25, 20, 15, 10, 8, 6, 4 or 2% of the total area of each layer. In further embodiments, an interior bond 30 may occupy at least 0.5, 1.0, 1.5, 3.0, 5.0, 7.0, 13, 18, 23, or 28% of the total area of each layer. By way of a specific example, the exemplary interior bond 30 depicted in FIG. 1 occupies approximately 3% of the total area of each layer.

In some embodiments the at least one interior bond 30 will overlap with the geometric center of shell layer 20 and/or the geometric center of cushioning layer 10 (in either case, this means that with the packaging assembly 1 in a ready-for-packaging configuration, the geometric center of the layer will pass through some portion of interior bond 30). In some such embodiments, the at least one interior bond will overlap with the geometric center 5 of packaging assembly 1 as indicated in exemplary manner in FIG. 2. In some such embodiments, the geometric center of layer 10, layer 20, and/or packaging assembly 1 will pass through (i.e., will coincide with) the geometric center of interior bond 30, again as in FIG. 2. In instances in which the at least one interior bond 30 is provided by multiple individual bonds with unbonded areas in between (as discussed below), for purposes of establishing a condition of the geometric center of bond 30, the geometric center of the total area occupied by the multiple bonded areas that collectively make up bond 30 will be used. Thus, in some instances the geometric center of interior bond 30 may, e.g., pass through an unbonded area, e.g., in between two adjacent bonded areas. An interior bond 30 may have any suitable shape; e.g., generally rectangular (e.g., square) as in the exemplary embodiment of FIG. 1.

In some embodiments, an at least one interior bond may take the form of a single, continuous bond (e.g., as shown in exemplary embodiments in FIGS. 1 and 2). In other embodiments, an at least one interior bond may take the form of multiple discrete bonds that are provided in a desired pattern along selected areas of layers 10 and 20, with the multiple discrete bonds serving as the at least one interior bond 30 and collectively exhibiting a total bonded area that meets the requirements listed above.

In some embodiments an at least one interior bond may take the form of a melt-bond between the shell layer 20 and the cushioning layer 10. A melt bond may be achieved, e.g., by way of temperature, ultrasonic energy, or any suitable means, combined, e.g., with appropriate pressure as needed. Thus in some embodiments an at least one interior bond 30 may take the form of a pattern of ultrasonic welds between layers 10 and 20.

In some embodiments an adhesive may be used to provide interior bond 30, e.g., a liquid adhesive, a glue, a hot melt adhesive, or the like, applied, e.g., as a strip, as a set of dots, and so on. In some convenient embodiments an at least one interior bond 30 may be provided by a double-faced pressure-sensitive adhesive, e.g., a piece, patch or strip of such an adhesive, as indicated in FIGS. 1-3. In such embodiments a major inward surface 33 of adhesive 30 may face toward, and be bonded to, a major outward surface 14 of cushioning layer 10; a major outward surface 34 of adhesive 30 may face toward, and be bonded to, major inward surface 24 of shell layer 20.

A packaging assembly 1 as disclosed herein may be used according to the general method depicted in generic, exemplary embodiment in FIG. 4. As a preliminary step, packaging assembly 1 can be positioned generally flat (e.g., on any suitable horizontal surface) with cushioning layer 10 facing up, and an item 100 to be packaged may be positioned as desired (typically, centered over the geometric center 5 of packaging assembly 1) atop cushioning layer 10 as shown in FIGS. 2 and 4. With reference to the side view of FIG. 4, as a first (“A”) step of packaging item 100 within packaging assembly 1, areas 12 of cushioning layer 10, which are not bonded to shell layer 20 and are thus free to be moved independently of shell layer 20, are folded over the top surface of item 100 in the general manner indicated by block arrows A of FIG. 4. At this point, the folded-over areas of cushioning layer 10 may be secured (e.g., with pressure-sensitive tape or the like) to each other, and/or to item 100, if desired.

An additional A step can then be performed with the remaining unbonded areas of cushioning layer 10. It will be understood that FIG. 4 is a cross-sectional view that can only show the folding of certain areas of the layers. Thus, with reference to the top, perspective view of FIG. 1, the above-described first A step may involve folding over the left (l) and right (r) areas of cushion layer 10. The additional A step will then involve folding over the fore (f) and aft (a) areas of cushion layer 10, noting that folded-over portions of the left and right areas may be present atop the fore and aft areas as the result of the first A step, and will accordingly be folded along with the fore and aft areas in the second A step.

The result of performing these steps is that cushioning layer 10 becomes wrapped around the item 100 in a protective configuration, by which is meant that layer 10 surrounds item 100 on all sides so that no portion of item 100 is reachable from the outside along a line that does not pass through at least a portion of cushioning layer 10. (Depending on, e.g., the size of the item relative to cushioning layer 10, there may be multiple layers of cushioning layer 10 on at least one side of the item 100).

In some embodiments, the cushioning layer can be secured (e.g., with pressure-sensitive adhesive tape, or with mechanical means such as string or staples) in the protective configuration. However, in some embodiments the cushioning layer may merely be held in this configuration while subsequent manipulations are performed with shell layer 20, so that shell layer 20, when in its final configuration as described below, holds and maintains cushioning layer 10 in its protective configuration.

After inner cushioning layer 10 has been wrapped around item 100 into a protective configuration as described above, a “B” packaging step can be performed in which areas 22 of outer shell layer 20 that are not bonded to inner cushioning layer 10 (and that thus remained undisturbed during the above-described steps of folding the cushioning layer), can be folded over the outward surface of the portions of cushioning layer 10 that are atop item 100, in the general manner indicated by block arrows B of FIG. 4. An additional B step can then be performed with any remaining unbonded areas of outer shell layer 20, in similar manner as discussed above for remaining unbonded areas of cushioning layer 10.

The result of the above-described steps of wrapping outer shell layer 20 around inner cushioning layer 10 will be that outer shell layer 20 is now in an encapsulating configuration. By this is meant that the outer shell layer 20 completely surrounds the inner cushioning layer on all sides so that no portion of inner cushioning layer 10 (or item 100) is reachable from the outside along a line that does not pass through at least a portion of shell layer 20. After the outer shell layer has been folded into an encapsulating configuration, outer shell layer 20 can be secured (e.g., with pressure-sensitive adhesive tape) in the protective configuration.

It will be understood that the above arrangements may be modified in any suitable manner. For example, in some embodiments the edges of the cushioning layer and/or the shell layer may be cut by an end user, e.g., with scissors, to reduce the total area of the layer(s) and/or or to modify the shape of the layer(s) in view of the size and/or shape of the item to be packaged. In some embodiments, multiple items 100, rather than a single item 100, may be packaged in a single packaging assembly of the general type described herein.

In some embodiments packaging assembly 1 may optionally comprise at least one area of pressure sensitive adhesive 40 that is provided on a major inward surface 13 of cushioning layer 10 that faces away from outer shell layer 20, as shown in exemplary embodiment in FIG. 5. Pressure-sensitive adhesive 40 can comprise a major adhesive surface that faces away from outer shell layer 20; an item 100 to be packaged can be contacted with (e.g., disposed on) the major adhesive surface of adhesive 40. Adhesive 40 thus can hold item 100 so that item 100 has less tendency to shift or slide during the above-described packaging process. Any such adhesive 40 need not necessarily be extremely strong, or need to hold item 100 permanently; rather, the adhesive may only serve to momentarily tack down item 100 until item 100 is secured within packaging assembly 1 as described above. If desired, adhesive 40 may be a pressure-sensitive adhesive of the type typically described as repositionable, so that item 100 can be separated from adhesive 40 when desired, without damaging or marring the surface of item 100.

An adhesive 40 may be provided by, for example, a piece of double-faced adhesive tape or the like. Such an adhesive can have any suitable size or shape, and/or can be provided by a single piece of adhesive tape or by several pieces working in combination. If desired, packaging assembly 1 may be provided to an end user with a release liner in place over the major adhesive surface of adhesive 40 (i.e., the “top” surface as shown in FIG. 5); such a release liner can be removed by the end user when an item is ready to be contacted with the adhesive.

In some embodiments, any such adhesive 40 will occupy (in terms of total actual bonded area) less than 40% of the total area of outer shell layer 20. In various embodiments, any such adhesive 40 may occupy less than 35, 30, 25, 20, 15, 10, 8, 6, 4 or 2% of the total area of each layer. In further embodiments, any such adhesive may occupy at least 0.5, 1.0, 1.5, 3.0, 5.0, 7.0, 13, 18, 23, or 28% of the total area of each layer.

A packaging assembly 1 as disclosed herein may be provided in any suitable format. In some embodiments, multiple packaging assemblies 1 can be provided, e.g., stacked into a batch, e.g., in a box or other suitable container, from which successive packaging assemblies 1 can be removed for use. In some embodiments, multiple packaging assemblies 1 may be provided as a roll good in which outer shell layer 20 and inner cushioning layer 10 are co-rolled with each other. The presence of the at least one interior bond between these two layers will retain the layers in their proper configuration (e.g., minimizing any tendency of the layers to slip, shift, telescope or the like) relative to each other. An end user can merely cut off a desired section of the roll good for use in packaging any particular item. In various embodiments, packaging assembly 1 may exhibit a total thickness of between about 1/32 inch and about 2 inches, or between about 7/64 inch and about 2 inches, or between about ¼ inch and about 1 inch.

Flexible outer shell layer 20 can be any desired layer that provides at least some of the features described herein. In some embodiments, the outer layer is a single layer. In some embodiments, the outer layer includes multiple layers. As is described in greater detail below, in some embodiments, the outer layer is at least one of single-ply, double-ply, or triple-ply and/or single layer or multi-layer. The multi-layer constructions can include any desired number of layers.

In embodiments where the outer layer is single ply, the outer layer material may be a heavy weight paper (such as, for example, kraft paper or the like), a plastic film (such as, for example, MYLAR™), a nonwoven material (such as, for example, TYVEK™), or a treated paper (such as, for example, aluminized paper).

In some embodiments, the outer layer includes a paper layer, which can be coated paper, Kraft paper, or higher quality paper such as Bond or white paper. In some embodiments, the paper may be printable and/or metallized to obtain a decorative packaging material. In some embodiments, the metallized paper layer may also be provided with graphics thereon.

In some embodiments, the outer layer includes a plastic. In some embodiments, the plastic is printed, embossed, structured, or reinforced. In some embodiments, the plastic includes at least one of polypropylene, polyethylene, polyurethane, polyester, and/or a copolymer of any of these. In some embodiments, the polyethylene is at least one of a low density polyethylene, a metallocene linear low density polyethylene, linear low density polyethylene, a low density polyethylene, polypropylene, olefinic block copolymer(s), a high density polyethylene, and/or copolymers and/or blends of any of these.

In some embodiments, the plastic is a thermoplastic and/or olefin material. The plastic may be oriented uniaxially or biaxially to impart high-strength thereto. A biaxial orientation may be preferred for greatest strength. One or more of the surfaces of the plastic layer may be corona discharge treated to render one or more of them receptive to inks and printing. Further, if a decorative package is desired, the plastic may be metallized as by vacuum deposition.

In some embodiments, the outer layer is a multilayer plastic film. In some embodiments, the multilayer film includes one to seven layers. In some embodiments, the multilayer film includes more than seven layers. In some embodiments, the multilayer assembly includes at least one of polypropylene, polyethylene, cyclic olefin copolymers, polyurethane, polyester, polyamide, and/or a copolymer of any of these. In some embodiments, at least the layer of shell layer 20 that provides the inward major surface 24 of shell layer 20 may contain a polymer that enables melt-bonding to the material of cushioning layer 10. Some exemplary layers capable of providing melt-bonding include, for example, those comprising low density polyethylene, linear low density polyethylene, metallocene linear low density polyethylene, polypropylene, olefinic block copolymers, and/or copolymers and/or blends of any of these. One or more of the layers of a multilayer outer layer may impart to the overall outer layer assembly a low gas permeability that enables air retention in the cushioning layer (e.g., bubble wrap). One or more of the layers in the multilayer assembly may provide tear resistance properties. Some exemplary layers capable of providing tear resistance include, for example, those comprising low density polyethylene, linear low density polyethylene, metallocene linear low density polyethylene, polypropylene, olefinic block copolymers, polyamide, polyester, polyurethane, and/or copolymers and/or blends of any of these.

In some embodiments, the outer layer is a two-ply or two-layer assembly or laminate. In some embodiments, the two-ply or two-layer assembly or laminate is a paper/plastic assembly or laminate. In some such embodiments, a paper layer is laminated to a plastic film layer. Another exemplary two-ply or two-layer outer layer or assembly is a laminate that includes a water impermeable plastic film having a first corona discharge treated surface that is adhesively cold laminated to the paper layer.

In some embodiments, the outer layer is three-ply. In some embodiments, the two-ply material(s) described above may further include an additional paper layer to form a paper-plastic-paper, three-ply laminate sheeting. The extra paper layer may be desirable for packaging objects with pointed edges or simply when a packaging material with more strength is desired. As the paper layers form the inner and outer sides of the packaging material, they can easily be printed with graphics or other indicia prior to application of the cushioning and/or cohesive material(s). This enables the packaging material to have one appearance on the outside of the package and another, different appearance on the side of the material that faces the item being shipped. Another exemplary outer layer is a three-ply laminate that includes a water impermeable plastic film, e.g., having first and second corona discharge treated surfaces that are adhesively cold laminated to first and second paper layers. In some embodiments, the outer layer is more than three layers.

It may also be desirable that outer shell layer 20 may have an outer major surface 23 (or a portion thereof) that is a printable major surface so that logos, messages, advertisements, emblems, trademarks or addressee information (or a location, e.g., rectangular box, that is designated for putting address information thereinto) etc., may be printed, e.g., on outward surface 23 of outer shell layer 20. In some embodiments, the outer layer may include one or more corona discharge treated surface to render it receptive to inks.

Thus in at least some embodiments, the outer surface 23 of shell layer 20 should be able to be provided with indicia or other printed information. If the material itself is not inherently receptive to such printed information, it can be treated to be receptive. For example, a plastic film of polyethylene that has the outer surface treated by a corona discharge can then be printed or provided with printed indicia. It is also possible, although less preferred, that the indicia be applied to the packaging material by an adhesive-backed sticker, label or the like.

In some embodiments, the outer shell layer 20 has a thickness of greater than about 0.5 mils, or greater than 0.75 mils, or greater than 1 mil, or greater than 1.25 mils, or greater than 1.5 mils, or greater than 1.75 mils, or greater than 2 mils. In some embodiments, the outer layer has a thickness of less than 5 mils, or less than 4.5 mils, or less than 4.0 mils, or less than 3.5 mils, or less than 3 mils. In some embodiments, the outer layer has a thickness of between about 0.5 mils and about 5 mils, or between about 1 mil and about 4 mils, or between about 2 mils and about 3 mils. In some embodiments where the outer layer is paper, the outer layer has a thickness of greater than about 3 mils.

In some embodiments, at least a portion, and in some instances, substantially the entire, outer major surface 23 of outer layer 20 is writable (e.g., can be written on with conventional writing instruments such as pens, pencils, and/or markers). In some embodiments, this can be achieved by selecting materials for the outer layer that inherently provide that characteristic. In some embodiments, this can be achieved by treating at least a portion of the surface of the selected outer layer to impart desired writability and/or adhesion (e.g., applying an adhesive-backed paper sheet or label). In some embodiments, one or more varnishes are applied to or included in the outer layer construction. Applying or including a varnish layer to a treated surface may impart writability by, for example, changing surface roughness and, thus, the surface coefficient of friction. In some embodiments, the varnish chemistry may be tailored to achieve compatibility with an ink and/or cohesive formulation. In addition, if desired a decorative package is provided in an embodiment wherein the exterior surface of the outer layer is metallized or aluminized. If a silver finish is desired, an aluminized surface may be preferred. Other metallizing treatments, e.g., with copper, iron, or alloys, can be used when other colors are desired.

In some embodiments, the outer shell layer 20 is water impermeable. In some embodiments, the outer layer is sufficiently tear and scuff resistant such that a wrapped item remains secure and protected during shipping and handling. In some embodiments, the outer layer includes one or more materials providing at least one of insulation from thermal or acoustic shock and/or radiation protection.

It is desired that the packaging assembly 1 should provide some degree of shock and/or impact resistance to prevent damage to an item being shipped. The herein-described inner cushioning layer 10 can be any suitable layer that provides cushioning of an item 100 that is packaged in (e.g., wrapped in) a packaging assembly 1. In some embodiments, it is desired that the cushioning layer have a relatively low profile to avoid undesirable bulk which could make packaging more complicated and/or storage more challenging. In some embodiments, the cushioning layer has a thickness of between about 1/32 inch and about 2 inches. In some embodiments, the cushioning portion has a thickness of greater than about 1/32, or about 7/64 inch, or about ¼ inch, or about ½ inch, or about ¾ inch, or about 1 inch. In some embodiments, the cushioning portion has a thickness of less than about 2 inches, or less than about 1 inch, or less than about ¾ inch, or less than about ½ inch.

In some embodiments, the inner cushioning layer 10 is a single layer. In some embodiments, the cushioning layer or portion includes multiple layers. In some embodiments, the cushioning layer 10 includes bubble wrap. As used herein, the term “bubble wrap” is meant to include all pliable, polymeric materials that include spaced, protruding air or gas-filled bubbles that are capable of providing cushioning. The term is meant to include those items referred to as bubble wrap, bubble pack, bubble paper, bubble film, air or gas bubble packing, bubble wrapping, and aeroplast. Some embodiments of bubble wrap include a first thin flexible layer 15 of plastic or polymeric material having a plurality of spaced apart recesses in one surface (so that layer 15 is significantly non-planar) and a second thin flexible, relatively flat “film” layer 16 of plastic material. The second “film” layer 16 is bonded to the one surface of the first layer 15 to seal air or gas into the recesses to form “bubbles”, as shown in detail in FIG. 3 and as will be readily understood by artisans in the field. The bubble wrap can include, for example, polyethylene as the plastic material for example, a linear low density polyethylene, a low density polyethylene and/or a high density polyethylene. However, other suitable plastics or polymers may also be used, such as, for example, polypropylene. Some commercially available bubble wraps include, for example, Scotch™ Cushion Wrap. Bubble wraps that may be particularly suitable are described in U.S. Provisional Patent Application No. 62/786,592, which is incorporated herein in its entirety. As noted above, in some embodiments, an inner cushioning layer 10 can include a bubble portion 15 and a film portion 16 that combine to form a bubble wrap. In some embodiments, the bubble wrap has a thickness of between about 1/32 inch and about ½ inch. In some embodiments, the bubble wrap has a thickness of greater than about 1/32, or about 7/64 inch, or about ¼ inch. In some embodiments, the bubble wrap has a thickness of less than about ½ inch, or less than about ¼ inch, or less than about ⅓ inch.

Further details of materials (e.g., bubble wraps) that can be used as an inner cushioning layer, and of materials that can be used as an outer shell layer, are described in U.S. Provisional Patent Applications Nos. 62/620,031 and 62/794,617 and in the resulting International (PCT) Patent Application Publication No. WO 2019/142172, all of which are incorporated by reference herein in their entirety.

In some embodiments, the inner cushioning layer 10 may include at least one layer of flexible foam. Exemplary flexible foams can include, for example, polyethylene, polyester, acrylic, polyurethane, or polypropylene. Regardless of the specific composition and/or geometric format (e.g., whether comprising bubble wrap, flexible foam, or both), an inner cushioning layer 10 as described herein will be distinguished from a so-called “cohesive” layer that is purposefully configured to adhere to itself in the manner described, e.g., in U.S. Provisional Patent Applications Nos. 62/620,031 and 62/794,617 and in the resulting International (PCT) Patent Application Publication No. WO 2019/142172. In particular, inner major surface 13 of inner cushioning layer 10 as disclosed herein, will not exhibit any property of being “cohesive”, self-adhering, self-bonding, or any like term or property.

It will be apparent to those skilled in the art that the specific exemplary elements, structures, features, details, configurations, etc., that are disclosed herein can be modified and/or combined in numerous embodiments. All such variations and combinations are contemplated by the inventor as being within the bounds of the conceived invention, not merely those representative designs that were chosen to serve as exemplary illustrations. Thus, the scope of the present invention should not be limited to the specific illustrative structures described herein, but rather extends at least to the structures described by the language of the claims, and the equivalents of those structures. Any of the elements that are positively recited in this specification as alternatives may be explicitly included in the claims or excluded from the claims, in any combination as desired. Any of the elements or combinations of elements that are recited in this specification in open-ended language (e.g., comprise and derivatives thereof), are considered to additionally be recited in closed-ended language (e.g., consist and derivatives thereof) and in partially closed-ended language (e.g., consist essentially, and derivatives thereof). To the extent that there is any conflict or discrepancy between this specification as written and the disclosure in any document that is incorporated by reference herein but to which no priority is claimed, this specification as written will control.

Claims

1. A packaging assembly comprising a flexible outer shell layer and a flexible inner cushioning layer in overlapping relation with each other and comprising at least one interior bond that bonds an interior area of the outer shell layer to an interior area of the inner cushioning layer.

2. The packaging assembly of claim 1, wherein the inner cushioning layer comprises bubble wrap that includes a film portion and a bubble portion that includes air or gas-filled bubbles, wherein the film portion of the bubble wrap is adjacent to the outer shell layer, and wherein the interior bond bonds a discrete area of the film portion of the bubble warp to the discrete portion of the outer shell layer.

3. The packaging assembly of claim 1 wherein the at least one interior bond occupies less than 20% of the total area of the outer shell layer and less than 20% of the total area of the inner cushioning layer.

4. The packaging assembly of claim 1 wherein the inner cushioning layer has a thickness of between about 1/32 inch and about 1 inch.

5. The packaging assembly of claim 1 wherein the outer shell layer is a multilayer structure.

6. The packaging assembly of claim 1 wherein the outer shell layer comprises at least one of paper, plastic, a nonwoven, or combinations thereof.

7. The packaging assembly of claim 1 wherein the outer shell layer comprises at least one of polypropylene, polyethylene, polyurethane, polyester, and/or a copolymer of any of these.

8. The packaging assembly of claim 1 wherein the outer shell layer comprises an oriented or biaxially oriented organic polymeric material.

9. The packaging assembly of claim 1 wherein the outer shell layer comprises an outward major surface that is a writable surface.

10. The packaging assembly of claim 1 wherein the at least one interior bond between the outer shell layer and the inner cushioning layer is a melt bond.

11. The packaging assembly of claim 1 wherein the at least one interior bond between the outer shell layer and the inner cushioning layer is provided by at least one piece of double-faced pressure-sensitive adhesive.

12. The packaging assembly of claim 1 wherein the at least one interior bond between the outer shell layer and the inner cushioning layer is a single interior bond that overlaps with a geometric center of the outer shell layer and a geometric center of the inner cushioning layer.

13. The packaging assembly of claim 1 wherein the at least one interior bond between the outer shell layer and the inner cushioning layer occupies less than 10% of the total area of the outer shell layer and less than 10% of the total area of the inner cushioning layer.

14. The packaging assembly of claim 1 wherein the outer shell layer and the inner cushioning layer are at least substantially co-extensive.

15. The packaging assembly of claim 1 further comprising at least one area of pressure-sensitive adhesive that is provided on a major surface of the inner cushioning layer that faces away from the outer shell layer, and wherein the pressure-sensitive adhesive comprises a major adhesive surface that faces away from the outer shell layer.

16. The packaging assembly of claim 15 wherein the pressure-sensitive adhesive comprises a release liner that is releasably disposed on the entirety of the major adhesive surface of the pressure-sensitive adhesive.

17. The packaging assembly of claim 1 wherein the packaging assembly is provided as a roll good comprising the outer shell layer and the inner cushioning layer, co-rolled with each other.

18. A method of packaging an item using a packaging assembly comprising a flexible outer shell layer and a flexible inner cushioning layer in overlapping relation with each other and comprising at least one interior bond therebetween, the method comprising:

positioning the packaging assembly with the inner cushioning layer facing upward;

placing the item to be packaged on the inner cushioning layer so that the item overlaps a geometric center of the of the outer shell layer and the inner cushioning layer;

wrapping the inner cushioning layer around the item into a protective configuration while the outer shell layer remains unmoving;

optionally securing the inner cushioning layer in the protective configuration;

wrapping the outer shell layer around the inner cushioning layer that is in the protective configuration so that the outer shell layer is in an encapsulating configuration in which the outer shell layer completely envelopes the inner cushioning layer and in which the inner cushioning layer is retained in the protective configuration;

and,

securing the outer shell layer in the encapsulating configuration.