Cushioning Assembly

BACKGROUND

Various types of mailers (i.e., protective envelopes or containers for mailing papers, books, merchandise, etc.) are known in the art. However, many of these comprise non-biodegradable and/or non-repulpable materials such as plastics, in particular as the cushioning elements of the mailer.

SUMMARY

One or more embodiments of the presently disclosed subject matter may address one or more of the aforementioned problems.

A cushioning assembly comprises a first sheet and a second sheet opposing the first sheet. The first sheet has an interior surface and the second sheet has an interior surface facing the first sheet interior surface. A plurality of foam elements are between the first and second sheets and adjacent both the first sheet interior surface and the second sheet interior surface. The plurality of foam elements is adhered to at least one of the first sheet interior surface and the second sheet interior surface. The aspect ratio of the plurality of foam elements is at least 1.2.

The plurality of foam elements may comprise starch. The first and second sheets may comprise cellulosic material. The cushioning assembly having a plurality of foam elements with an aspect ration of greater than 1.2 may provide surprisingly improved cushioning protection relative a comparable cushioning assembly having a plurality of foam elements of a spherical shape.

These and other objects, advantages, and features will be more readily understood and appreciated by reference to the detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative perspective view of a mailer embodiment of the presently disclosed subject matter;

FIG. 2 is a representative perspective cutaway view of the mailer of FIG. 1;

FIG. 3 is a representative sectional view taken along line 3-3 of FIG. 1;

FIG. 3A is a partial view taken of the area 3A of FIG. 3;

FIG. 4 is a representative sectional view taken along line 4-4 of FIG. 1, but having the flap 52 in the closed configuration;

FIG. 5 is a representative plan view of the components of a first sheet with an adhesive;

FIG. 6 is a representative plan view of the components of FIG. 5 further including foam elements;

FIG. 7 is a representative plan view of the components of a second sheet with an adhesive;

FIG. 8 is a representative plan view of the components of a second sheet with an alternative adhesive configuration;

FIG. 9 is a representative exploded view of the cushioning assembly embodiment of FIG. 10;

FIG. 10 is a representative plan view of a cushioning assembly embodiment of the presently disclosed subject matter;

FIG. 11 is a representative sectional view taken along line 11-11 of FIG. 10;

FIG. 12 is a representative perspective reverse view of the cushioning assembly embodiment of FIG. 10;

FIG. 13 is a representative perspective view of the cushioning assembly embodiment of FIG. 12 in a partially folded over configuration in the course of making the mailer assembly of FIG. 1;

FIG. 14 is a representative perspective view of a foam element;

FIG. 15 is the representative sectional view taken along line 15-15 of FIG. 14;

FIG. 16 is a representative perspective view of a foam element similar to that of FIG. 14, but having a curved configuration;

FIG. 17 is a representative perspective view of an alternative foam element configuration;

FIG. 18 is a representative sectional view taken along the line 18-18 of FIG. 17;

FIG. 19 is a representative cross-sectional view of an alternative foam element configuration;

FIG. 20 is a representative cross-sectional view of an alternative foam element configuration; and

FIG. 21 is a representative cross-sectional view of an alternative foam element configuration.

Various aspects of the subject matter disclosed herein are described with reference to the drawings. For purposes of simplicity, like numerals may be used to refer to like, similar, or corresponding elements of the various drawings. The drawings and detailed description are not intended to limit the claimed subject matter to the particular form disclosed. Rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.

DETAILED DESCRIPTION

Various embodiments of the presently disclosed subject matter are directed to a cushioning assembly having first and second sheets and a plurality of foam elements between the first and second sheet and adjacent the interior surfaces of both sheets. In an embodiment, cushion assembly 10 includes first sheet 12 and opposing second sheet 14. (FIGS. 10-12.) A plurality 16 of foam elements 18 is adhered between the first and second sheets to at least one of the first sheet interior surface 34 and the second sheet interior surface 36. In another aspect of the presently disclosed subject matter, mailer 100 comprises the cushioning assembly 10. (FIGS. 1-4.)

Sheets

In the embodiment of FIGS. 10-12, the cushioning assembly 10 comprises first sheet 12 and second sheet 14. The first sheet 12 has an interior surface 34 and second sheet 14 has interior surface 36 facing the interior surface 34 of the first sheet 12.

The first and second sheets may each independently comprise cellulosic material (i.e., cellulose-based material) and/or thermoplastic polymeric material. Exemplary cellulosic materials include paper (such as kraft paper), paperboard, corrugated, and bond paper. Exemplary thermoplastic polymeric materials include polypropylene, polyethylene, and polyester. Exemplary sheet comprising thermoplastic polymeric materials includes nonwoven spunbond polyethylene fiber such as Tyvek® by DuPont. Sheet comprising thermoplastic polymeric material may be oriented in one or more directions (e.g., biaxially oriented) to enhance the strength or other attributes of the sheet. A first and/or second sheet comprising thermoplastic polymeric material may be any of biodegradable and oxo-degradable.

Any of the first and second sheets (e.g., comprising cellulosic material) may further comprise any of one or more of a coating or sizing (e.g., to enhance the water resistance of the sheet), insect repellent, rodent repellent, and flame retardant.

The first and second sheets have a thickness suitable to provide acceptable performance for the desired end use. For example, the first and second sheets may independently have a thickness of at least any of 0.5, 1, 2, 3, and 5 mils, and/or at most any of 15 and 6 mils.

The first and second sheets may be discrete from each other as illustrated, for example, in FIGS. 9, 11-12. However, the first and second sheets do not have to be discrete from each other, which is to say that a single web may be folded over to define the first sheet and the opposing second sheet that are attached along a fold delineating between the first and second sheets (not illustrated).

Foam Elements

The cushioning assembly comprises a plurality of foam elements, which are between the first and second sheets and adjacent both the first sheet interior surface and the second sheet interior surface. A foam element is a discrete portion comprising foam. The plurality of foam elements may comprise, for example, any of at least 10, 20, 30, and 40 foam elements; and/or at most any of 100, 90, 80, 70, 60, 50, and 40 foam elements.

The “aspect ratio” of a plurality of foam elements is the average for a representative sample of the plurality of foam elements of the longest dimension of the foam element (i.e., length) divided by the shortest dimension of the foam element that is orthogonal to the longest dimension (e.g., width or diameter). The plurality of foam elements may have an aspect ratio of at least any of 1.2, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, and 6.0; and/or at most any of 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 6.0, 8.0, and 10.0.

The foam elements of the plurality of foam elements may have a cross-section profile generally conforming to any one or more of a circular shape (e.g., foam elements 18 and 22, FIGS. 14-16) or a non-circular shape (e.g., foam elements 24, 26, 28, and 30, FIGS. 17-21), such as any of: a star shape, where the star shape may have, for example, any of 3, 4, 5, or 6 protrusions (e.g., foam element 24 having protrusions 20, FIG. 18), a rectangular shape (e.g., foam element 26, FIG. 19), a “C” shape (e.g., foam element 28, FIG. 20), an “X” shape or a cross shape (e.g., foam element 30, FIG. 21), a triangular shape, an ellipse shape, a “peanut” shape, an “I” shape, an “S” shape, and a “T” shape (not illustrated).

The foam elements of the plurality of foam elements may be essentially straight, such that the longitudinal extent is an axis (e.g., foam element 22, FIG. 14; foam element 24, FIG. 17); alternatively, the foam elements of the plurality of foam elements may be curved (e.g., curled), such that the longitudinal extent is non-linear (e.g., foam element 18, FIG. 16). If the longitudinal extent of a foam element is non-linear (i.e., curved), then the “length” of the foam element is taken along the curvature of the longitudinal extent of the element so that the measurement accounts for the entire length of the element as if it were straightened.

The plurality of foam elements may have an average length (i.e., the longest dimension of the element), for example, that is at least any of 5, 10, 15, 20, and 25 mm, and/or at most any of 20, 30, 40, 50, 70, and 100 mm. The plurality of foam elements may have an average dimension in the shortest dimension of the foam element that is orthogonal to the longest dimension (e.g., width or diameter) that is, for example, at least any of 2, 3, 4, 5, 7, and 10 mm, and/or at most any of 5, 7, 10, 15, and 20 mm.

The foam elements of the plurality of foam elements may comprise thermoplastic polymeric material such as any one or more of polyolefin (e.g., polyethylene or polypropylene) and polystyrene. The foam elements may comprise a thermoset polymeric material such as polyurethane.

The foam elements of the plurality of foam elements may comprise starch. Starch in its various forms is well known in the art, comprising various amounts of amylose and/or amylopectin forms of starch. Useful natural starch can be obtained from one or more cereals or grains (e.g., corn, wheat, rice, and sorghum), roots (e.g., cassava), legumes (e.g., peas), and tubers (e.g., potato and canna). Useful starch includes corn starch (i.e., starch derived from corn), potato starch, wheat starch, soybean starch, rice starch, sorghum starch, and tapioca starch.

Useful starch may comprise chemically modified starch, such as oxidized starch, etherificated starch, esterified starch, crosslinked starch, or starch having such chemical modifications combined. Chemically modified starch typically has hydroxyl groups reacted with one or more reagents. The degree of substitution associated with the reaction ranges from 0 (for native starch) up to 3 (fully substituted chemically modified starch). Useful etherificated starches include those having hydroxyl groups substituted with ethyl and/or propyl groups. Useful esterified starches include those having hydroxyl groups substituted with acetyl, propanoyl, and/or butanoyl groups. For example, the starch may comprise starch acetate having a degree of substitution (DS) of at least 0.1.

The plurality of foam elements may be biodegradable. Exemplary foam elements comprising starch, and that are biodegradable, are available from Sealed Air Corporation under the PakNatural® trademark for biodegradable starch-based foam loose fill.

The plurality of foam elements may comprise any of starch, thermoplastic polymeric material, or thermoset polymeric material in an amount of at least any of the following: 50, 60, 70, and 75% and/or at most any of the following: 99, 95, 90, and 85% by weight of the plurality of foam elements.

The plurality of foam elements may have a bulk density of at least any of the following: 0.25, 0.3, 0.4, and 0.5 lbs/ft3; and/or at most any of the following 0.9, 0.8, 0.6, and 0.5 lbs/ft3. Density of the foam is measured according to ASTM D3575.

Foam elements and various methods of manufacture for foam elements are known in the art; see for example, U.S. Pat. No. 3,188,264 to Holden, U.S. Pat. No. 3,961,000 to Ropiequet,_U.S. Pat. No. 4,073,842 to Smith, U.S. Pat. No. 4,169,179 to Bussey, U.S. Pat. No. 4,790,967 to Anderlind et al; U.S. Pat. No. 5,028,470 to Reichenecker, U.S. Pat. No. 5,095,054 to Lay et al; U.S. Pat. No. 5,185,382 to Neumann et al; U.S. Pat. No. 5,186,990 to Starcevich; U.S. Pat. No. 5,413,855 to Kolaska et al; U.S. Pat. No. 5,713,526 to Martin et al; U.S. Pat. No. 5,736,586 to Bastioli et al; U.S. Pat. No. 6,894,136 to Markham et al; and U.S. patent application Ser. No. 13/338,993 entitled “Foam and Methods of Making the Same” by Kannankeril et al filed Dec. 28, 2011, each of which is incorporated herein in its entirety by reference.

For example, a conventional type of extruder may be used (e.g., single screw, double screw, and/or tandem extruder) to extrude the foam elements. Various configurations for the cross-sectional profile of the foam elements (e.g., FIGS. 15, 18-21) may be made, for example, by utilizing an extrusion die having the desired cross-sectional configuration for the foam element. The die may be configured to produce the desired shape and size of the extruded foam elements.

The foam elements may comprise a coating and/or one or more additives to provide a hydrophobic attribute. For example, the foam elements may comprise a coating applied to the outside of the foam elements wherein the coating comprises one or more of styrene-acrylate latex and clay-based binders.

The foam elements may comprise one or more hydrophobic additives in the composition of the foam elements. For example, the foam elements may comprise one or more of cooked, cross-linked starch and low molecular weight paraffin wax. The foam elements may comprise one or more hydrophilic additives in the composition of the foam elements.

Foam elements comprising hydrophobic coating or additives may be advantageous if the adhesives used to adhere the foam elements to the first or second sheets comprise water-based adhesives.

Adhesives

The plurality of foam elements is adhered to at least one of the first sheet interior surface and the second sheet interior surface. The plurality of foam elements may be adhered to only one of the first sheet interior surface and the second sheet interior surface. The plurality of foam elements may be adhered to both of the first sheet interior surface and the second sheet interior surface.

The plurality of foam elements may be adhered by one or more adhesives. In the embodiment cushioning assembly 10, the plurality 16 of cushioning elements 18 is adhered to the interior surface 34 of first sheet 12 by adhesive 32. (FIGS. 6, 11.) Adhesive 32 may be applied in an internal region 42 of the interior surface 32 of first sheet 12 leaving a peripheral border 44 without an applied adhesive. (FIG. 5.)

Useful adhesives include water-based adhesives (polymeric latexes, such as polyvinyl acetate or polyacrylic copolymer emulsions), solvent-based adhesives, hot melt adhesives (e.g., waxes or polymeric resins), 100% solids adhesives, pressure sensitive adhesives, moisture-activated adhesives, solvent-activated adhesives, and heat-activated adhesives.

The plurality of foam elements may be adhered to the sheet by moistening the foam elements with water and applying the moistened foam elements to the sheet (or by moistening the sheet with water and applying the foam elements to the moistened sheet), in particular where the plurality of foam elements comprises starch and the sheet comprises cellulosic material (e.g., paper).

The first sheet may be attached to the second sheet to encase the plurality of foam elements between the first and second sheets. For example, adhesive 38 may be applied in peripheral border 40 of sheet 14 to define an internal region 46 without an applied adhesive. (FIG. 7.) In the cushioning assembly 10, the peripheral border 44 of the first sheet 12 corresponds with the peripheral border 40 of the second sheet 14 so that the adhesive 38 may attach the first and second sheets together in the respective peripheral borders to encase the plurality 16 of foam elements 18. (FIGS. 9-11.)

In an alternative embodiment, the second sheet 14 may include an adhesive 48 in the internal region 46 of the interior surface either covering the entire region (not illustrated) or intermittently covering the interior surface (illustrated FIG. 8). This adhesive in the internal region 46 may serve to attach the second sheet to the plurality of foam elements.

The adhesive 38, which is adapted to adhere first and second sheets together, may be the same or may be a different adhesive type or class than adhesive 48 or adhesive 32, which may generally be adapted to adhere the plurality of foam elements to the first or second sheet.

If the first or second sheets comprise thermoplastic polymeric material, then the first sheet may be attached to the second sheet by heat sealing techniques known in the art.

Making the Cushioning Assembly

Cushioning assembly 10 may be made by applying adhesive 32 to first sheet 12. (FIG. 5.) The method of applying the adhesive will correspond with the type of adhesive used. For example, the adhesive may be applied in any of the following ways: spraying, printing, roll coat, and silk screen. As illustrated, adhesive 32 is applied to interior surface 34 in internal region 42 leaving peripheral border 44 without an applied adhesive. This selective application of adhesive may be accomplished, for example, by using a stencil or mask.

A plurality 16 of foam elements 18 may be applied to the adhesive 32. (FIG. 6.) This may be accomplished by dumping a large amount of foam elements 18 onto the interior surface 34 of the first sheet 12 so that a plurality 16 of the foam elements adhere to sheet 12 by adhesive 32. The excess amount of foam elements (i.e., those that are not adhered) may be removed for example, by gravity (e.g., tilting the first sheet so that the excess falls off), by blowing, or by suction. Alternatively, first sheet 12 having adhesive 32 applied to it may be lowered onto a large amount of foam elements to contact them so that a plurality 16 of the foam elements 18 adheres to the first sheet in internal region 42 as it is raised from the large amount of foam elements.

In any of these ways of adhering a plurality 16 of foam elements 18 to the first sheet, it can be seen that the plurality of foam elements may be randomly distributed onto the sheet.

Adhesive 38 is applied to the interior surface 36 of second sheet 14 along peripheral border 40 leaving interior region 46 relatively adhesive free. (FIG. 7.) Alternatively, the adhesive 38 may be further applied along band regions 50 within the interior region 46 (FIG. 8), or the interior region may be otherwise sporadically covered with adhesive, or the entire region 46 may be covered with adhesive (not illustrated). Methods of applying the adhesives are known in the art.

The second sheet 14 is juxtaposed over the first sheet 12 to contact and place the plurality 16 of foam elements 18 between the first and second sheets so that the plurality 16 is adjacent both the first sheet interior surface 34 and the second sheet interior surface 36. The peripheral border 40 of second sheet 14 having adhesive 38 contacts the peripheral border 44 of first sheet 12 so that the first and second sheets attach to each other to encase the plurality 16 of foam elements 16. (FIGS. 9-11.) Accordingly, the interior surfaces of the first and second sheets directly adhere to each other in selected regions (i.e., the peripheral borders), such that the selected regions may enclose the plurality of foam elements.

Although the embodiment of cushioning assembly 10 has been described above in the context of having adhesive applied in only certain regions of the first and second sheets, it is within the scope of this disclosure for the adhesive to be applied on the entire interior surface of one of the first or second sheets while the other does not have adhesive applied to it—or the adhesive may be applied to both of the entirety of the interior surfaces of the first and second sheets. Further, it is also within the scope of this disclosure that adhesive may be applied to or coated onto the plurality of foam elements directly, either before the plurality of foam elements contact the first or second sheets, or after the plurality of foam elements has contacted the first or second sheets.

The cushioning assemblies of the presently disclosed subject matter may comprise components of such nature that the resulting cushioning assembly is any of one or more of biodegradable, compostable, sustainable, and/or repulpable.

Mailer

The cushioning assemblies of the presently disclosed subject matter may be used in protective packaging applications such as dunnage, void fill, and overwrap. Also, mailers (e.g., protective envelops) may comprise the cushioning assembly of the presently disclosed subject matter. For example, mailer 100 comprises cushioning assembly 10. (FIGS. 1-4.)

If cushioning assembly 10 is to be used in constructing a mailer, then it may be advantageous to form the cushioning assembly to have flap portion 52 extending from main portion 54 of second sheet 14. (FIGS. 7-8, 12.) Although cushioning assembly 10 has flap portion 52 as part of second sheet 14, in other embodiments such a flap portion could extent as part of first sheet 12. Closure adhesive 56 may be applied to flap portion 52. Appropriate closure adhesives are known in the art, and include contact and releasably lined adhesives (not illustrated).

Mailer 100 may be formed by folding over cushioning assembly 10 lengthwise along transverse fold 58 (FIG. 13) so that top portion 60 aligns with and is coextensive with bottom portion 62, and so that flap portion 52 remains extending. Adhesive (not illustrated) appropriate to attach top portion 60 to bottom portion 62 may be applied along longitudinal border portions 66 which extend along the left and right longitudinal side borders of cushioning assembly 10. If the border portions comprise thermoplastic polymeric material, then top portion 60 may be attached to bottom portion 62 by heat sealing.

The transverse border portion 68 may be free of adhesive so that when top portion 60 is attached to bottom portion 62 along the left and right longitudinal border portions 66, mailer 100 is created having opening 64. (FIGS. 1-4.) In use, product 102 may be inserted into mailer 100 through opening 64. (FIG. 2.) The mailer 100 may be closed by attaching (e.g., adhering) flap portion 52 to top portion 60. (FIG. 4.)

Other embodiments of mailers comprising the cushioning assemblies of the presently disclosed subject matter may be formed by folding and adhering the cushioning assemblies in other configurations. Examples of these other configurations include adhering two distinct cushioning assemblies together such that there is no need for fold 58. A mailer may also be made from the cushioning assembly by folding it over with two longitudinal folds (i.e., a “C-fold”), adhering it along the central longitudinal seam, and adhering it transversely along a bottom seam. A mailer may also be made from the cushioning assembly by folding it over with one longitudinal folds (i.e., a “Mold”), adhering it along an edge longitudinal seam, and adhering it transversely along a bottom seam.

EXAMPLES

The following examples are presented for the purpose of further illustrating and explaining the present invention and are not to be taken as limiting in any regard. Unless otherwise indicated, all parts and percentages are by weight.

Example 1

A cushioning assembly was made as follows. Moisture was applied to loose fill foam elements (PakNatural® biodegradable starch-based foam loose fill from Sealed Air Corporation), which made them tacky. The foam elements had a curved cylinder configuration, having an average cross-section diameter of about 4 mm and an average length of about 12 mm. The moistened foam elements were randomly scattered onto one side of a first sheet of paper to a depth of about 1.5 times the average cross-section diameter. A second sheet of paper was applied to the top of the moistened foam elements so that the plurality of foam elements was sandwiched between and adhered to both the first and second sheets. The first and second sheets of paper were kraft paper 40 pound (basis weight). The foam elements bonded well to both the interior surfaces of the first and second sheets of paper. The entire resulting cushioning assembly was recyclable, repulpable, and biodegradable.

Example 2

Example 2 cushioning assembly having a mailer configuration was made as follows. A first adhesive, which was a pressure sensitive spray adhesive available from 3M Corporation, was sprayed onto one surface of a first sheet of uncoated kraft paper 40 pound (basis weight) to cover an interior area of the sheet but leaving a ½ inch border around the paper without applied adhesive. The first sheet was then turned adhesive side down and lowered onto a pile of loose fill foam elements (PakNatural® biodegradable starch-based foam loose fill from Sealed Air Corporation), hand-pressed down, and then raised away from the pile. A plurality of foam elements adhered to the interior area of the first sheet in a randomly distributed fashion where the adhesive had been applied. The foam elements had a curved cylinder configuration, having an average cross-section diameter of about 5 mm and an average length of about 20 mm, so that the aspect ratio was about 4.

A second adhesive, which was a polyvinyl acetate (PVA) water-based adhesive, was sprayed generally upon the ½-inch border previously lacking adhesive. A second sheet of coated kraft paper 47 pound (basis weight), having a PVA water-based type of coating, was placed over the top of the foam elements and adhered to the first sheet in the border area where the second adhesive had been applied, so that the plurality of foam elements was sandwiched between the first and second sheets.

A third adhesive was applied to a ½-inch border region running along the length of the left and right sides of one surface of the first sheet of the resulting cushioning assembly. This was folded over lengthwise (as in FIG. 13) to adhere the cushioning assembly in the mailer configuration illustrated in FIG. 1.

Example 3

Example 3 and Sample 1 cushioning assemblies were made as described above in Example 2, except that these did not have the third adhesive applied, nor were they folded over into the mailer configuration. There were also the following differences:

Sample 1 was formed using starch-based foam elements having an aspect ratio of about 1 (i.e., spherically-shaped beads). These foam elements had a diameter of about 3/16 inch (4.76 mm) and were made of the same starch-based foam material as the PakNatural® biodegradable starch-based foam loose fill. The Sample 1 cushioning assembly had one layer of the spherical foam elements between the first and second sheets. The overall thickness of the Sample 1 cushioning assembly was about 3/16 inch (4.76 mm).

Example 3 was formed using starch-based foam elements having an aspect ratio of about 3. The foam elements had a configuration of a curved cylinder, a cross-section diameter of about ⅛ inch (3.18 mm), and a length of from ¼ inch to ½ inch (6.35 mm to 12.7 mm). The overall thickness of the Example 3 cushioning assembly was about 3/16 inch (4.76 mm).

Three samples of each of the Sample 1 and the Example 3 cushioning assemblies were subjected to a shock absorption drop test using an accelerometer to measure the maximum amount of deceleration placed upon the dropped object that the cushioning assembly protected. Each sample to be tested was cut to 12-inch by 12-inch length and width dimensions, and placed in the bottom of a cardboard box of corresponding length and width dimensions. A plate having 12-inch by 12-inch by ¼-inch dimensions with an accelerometer attached to it was placed on top of the cushioning assembly. The box with the cushioning assembly and the accelerometer/plate on top of the cushioning assembly was dropped to the floor from a given, predetermined height. Various weights (loads) were placed on top of the plate to vary the load of the test. Each sample was dropped 5 times at each of the loads, beginning with the smaller load and working up to the larger load. The peak G-force value shown by the accelerometer for each drop was recorded. The averaged results are reported in Table 1.

TABLE 1

G-force units*

Load of test
(averaged for five drop of three samples)

(lb/in2)
Example 3
Sample 1

0.05
183
232

0.1
150
247

0.15
188
250

*1 g-force unit equals 9.807 m/s2 or 9.807 N/kg.

The G value corresponds to the impact force (i.e., the peak acceleration value) felt by the “protected” object (i.e., the plate/accelerometer) from the drop. A lower G-force unit value represents better protection because of delayed deceleration.

Although the overall thickness of the Example 3 and the Sample 1 cushioning assemblies were about the same and the material of the foam elements was the same, the Example 3 cushioning assembly surprisingly and unexpectedly provided greater protection to the dropped object. This is shown by the much lower g-force units that the dropped object experienced with the Example 3 cushioning assembly (having non-spherically shaped foam elements) compared to the Sample 1 cushioning assembly (having spherically shaped foam elements).

Various Embodiments

Various and additional embodiments of the disclosed subject matter are described and recited in the following sentences A through W.

A. A cushioning assembly comprising:

a first sheet and a second sheet opposing the first sheet, wherein the first sheet has an interior surface and the second sheet has an interior surface facing the first sheet interior surface;

a plurality of foam elements between the first and second sheets and adjacent both the first sheet interior surface and the second sheet interior surface, wherein:

the plurality of foam elements is adhered to at least one of the first sheet interior surface and the second sheet interior surface; and

the aspect ratio of the plurality of foam elements is at least 1.2.

B. The cushioning assembly of sentence A wherein the plurality of foam elements comprises any of at least 10, 20, 30, and 40 foam elements; and/or at most any of 100, 90, 80, 70, 60, 50, and 40 foam elements.
C. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements has an aspect ratio of at least any of 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, and 6.0; and/or at most any of 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 6.0, 8.0, and 10.0
D. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements has an average length of at least 5, 10, 15, 20, and 25 mm and/or at most any of 20, 30, 40, 50, 70, and 100 mm.
E. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements has an average dimension in the shortest dimension of the foam element that is orthogonal to the longest dimension, wherein the average dimension in the shortest dimension is at least any of 2, 3, 4, 5, 7, and 10 mm, and/or at most any of 5, 7, 10, 15, and 20 mm.
F. The cushioning assembly of any one of the previous sentences wherein the first sheet is attached to the second sheet to encase the plurality of foam elements.
G. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements comprises starch.
H. The cushioning assembly of sentence G wherein the starch is derived from sorghum.
I. The cushioning assembly of any one of the previous sentences wherein the first and second sheets comprise cellulosic material.
J. The cushioning assembly of any one of the previous sentences further comprising a non-water based adhesive adhering the plurality of foam elements to at least one of the first sheet interior surface and the second sheet interior surface.
K. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements comprise a hydrophobic coating on or additive in the foam elements.
L. The cushioning assembly of any one of the previous sentences A through I and K further comprising a water-based adhesive adhering the plurality of foam elements to at least one of the first sheet interior surface and the second sheet interior surface.
M. The cushioning assembly of any one of the previous sentences wherein the interior surface of the first sheet is adhered directly to the interior surface of the second sheet in selected regions.
N. The cushioning assembly of sentence M wherein the selected regions enclose the plurality of foam elements.
O. The cushioning assembly of any one of the previous sentences wherein the foam elements of the plurality of foam elements have a curved longitudinal extent.
P. The cushioning assembly of any one of the previous sentences wherein the cross-section profile of the foam elements of the plurality of foam elements comprises one or more of the following shapes: circular shape, star shape, rectangular shape, “C” shape, cross shape, triangular shape, ellipse shape, peanut shape, “I” shape, “S” shape, and “T” shape.
Q. The cushioning assembly of any one of the previous sentences wherein the cushioning assembly is one or more of any of repulpable, biodegradable, and sustainable.
R. The cushioning assembly of any one of the previous sentences wherein the first and second sheets comprise thermoplastic polymeric material.
S. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements comprises starch in an amount of at least any of the following: 50, 60, 70, and 75% and/or at most any of the following: 99, 95, 90, and 85% by weight of the plurality of foam elements.
T. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements comprises thermoplastic polymeric material in an amount of at least any of the following: 50, 60, 70, and 75% and/or at most any of the following: 99, 95, 90, and 85% by weight of the plurality of foam elements.
U. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements comprises thermoset polymeric material in an amount of at least any of the following: 50, 60, 70, and 75% and/or at most any of the following: 99, 95, 90, and 85% by weight of the plurality of foam elements.
V. The cushioning assembly of any one of the previous sentences wherein the plurality of foam elements has a bulk density of at least any of the following: 0.25, 0.3, 0.4, and 0.5 lbs/ft3; and/or at most any of the following 0.9, 0.8, 0.6, and 0.5 lbs/ft3.
W. A mailer comprising the cushioning assembly of any one of the previous sentences.

Any numerical value ranges recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable (e.g., temperature, pressure, time) may range from any of 1 to 90, 20 to 80, or 30 to 70, or be any of at least 1, 20, or 30 and/or at most 90, 80, or 70, then it is intended that values such as 15 to 85, 22 to 68, 43 to 51, and 30 to 32, as well as at least 15, at least 22, and at most 32, are expressly enumerated in this specification. For values that are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

The above descriptions are those of preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. Except in the claims and the specific examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material, reaction conditions, use conditions, molecular weights, and/or number of carbon atoms, and the like, are to be understood as modified by the word “about” in describing the broadest scope of the invention. Any reference to an item in the disclosure or to an element in the claim in the singular using the articles “a,” “an,” “the,” or “said” is not to be construed as limiting the item or element to the singular unless expressly so stated. The definitions and disclosures set forth in the present Application control over any inconsistent definitions and disclosures that may exist in an incorporated reference. All references to ASTM tests are to the most recent, currently approved, and published version of the ASTM test identified, as of the priority filing date of this application. Each such published ASTM test method is incorporated herein in its entirety by this reference.

Cushioning Assembly

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