Cushioning element for cushioning and protecting a product to be packaged and method for manufacturing such a cushioning element

Abstract

The invention relates to a cushioning element (2) comprising a first cushioning layer (3) made of a cellulose-based material and comprising an inner honeycomb structure (4) and first and second outer cover layers (5, 6), said first cushioning layer (3) comprising at least one assembly recess (7) opening in an outer surface of said first outer cover layer (5); and a second cushioning layer (8) comprising at least one assembly tab (13) received in said at least one assembly recess (7) in order to assemble said first and second cushioning layers (3, 8) together.

Description

Technical Field

[0001] This invention relates to the field of cushioning elements configured to cushion and protect products to be packaged in packaging. Background Technology

[0002] To protect products during transport or storage, particularly from impacts, it is known to place the product in cardboard packaging and cushion it within the cardboard using one or more cushioning elements, for example, made of expanded polystyrene. This material allows for the easy and cost-effective manufacture of cushioning elements of various shapes and thicknesses.

[0003] However, due to regulatory reasons, expanded polystyrene is increasingly being banned from use in the manufacture of cushioning components.

[0004] To overcome this drawback, it is known to manufacture such cushioning components using cellulose-based materials, particularly honeycomb paperboard. However, to manufacture thicker cushioning components, several layers of honeycomb paperboard need to be stacked one on top of the other and glued together. This manufacturing method requires each manufactured cushioning component to remain stationary for a predetermined period of time to ensure the adhesive used cures, which increases the cost of manufacturing thicker cushioning components. Furthermore, the adhesive used is typically a hot melt adhesive, which generates waste in the paperboard recycling chain that forms such cushioning components. Summary of the Invention

[0005] The present invention aims to overcome these shortcomings.

[0006] The fundamental technical problem of this invention lies in providing a cushioning component that is simple in structure, economical, and has a very high recyclability.

[0007] Therefore, the object of the present invention is to provide a cushioning element configured to cushion and protect a product to be packaged in packaging, the cushioning element comprising at least:

[0008] A first buffer layer, at least partially made of a cellulose-based material, comprising an internal honeycomb structure and first and second outer covering layers disposed on both sides of the internal honeycomb structure. The first buffer layer includes at least one assembly recess, which opens in the outer surface of the first outer covering layer and includes at least a first recess portion defined by the first outer covering layer and a second recess portion defined by the internal honeycomb structure.

[0009] A second buffer layer, wherein the first and second buffer layers are stacked on top of each other, the second buffer layer including at least one assembly tab, the at least one assembly tab being received at least partially in a second recess portion of at least one assembly recess in order to assemble the first and second buffer layers together.

[0010] By using this configuration of the buffer component according to the invention, particularly by assembling the first and second buffer layers by at least one assembly tab and at least one assembly recess, multiple buffer layers can be easily assembled together, at least one of which is at least partially made of cellulose-based material, without the need for glue and / or additional assembly elements, and without the need for complex and expensive assembly equipment. This significantly reduces the manufacturing cost of such buffer component and makes it highly reusable.

[0011] Buffer elements may also have one or more of the following features, individually or in combination.

[0012] According to one embodiment of the present invention, the maximum lateral dimension of at least one assembly tab is greater than the maximum lateral dimension of at least one assembly recess.

[0013] According to one embodiment of the invention, the second buffer layer is at least partially made of a cellulose-based material.

[0014] According to one embodiment of the invention, at least one assembly recess has a central longitudinal axis. Advantageously, the central longitudinal axis extends substantially perpendicular to the first and second outer cover layers.

[0015] According to one embodiment of the present invention, at least one assembly recess has a polygonal cross-section with N sides, where N is an integer greater than or equal to 3. In this specification, the "cross-section" of the at least one assembly recess refers to a section perpendicular to the central longitudinal axis of the at least one assembly recess.

[0016] According to one embodiment of the invention, at least one assembly recess has a polygonal cross-section with four sides, i.e., a quadrilateral, such as a square or rectangle. These features ensure reliable assembly of the first and second buffer layers.

[0017] According to one embodiment of the invention, the ratio of the cross-section of at least one assembly recess to the cross-section of each compartment of the internal honeycomb structure is between 0.8 and 1.2, for example, between 0.9 and 1.1.

[0018] According to one embodiment of the invention, the maximum width of at least one assembly tab is greater than the width of the largest side of the cross-section of at least one assembly recess. In other words, the maximum width of at least one assembly tab is greater than the width of the widest inner surface of at least one assembly recess.

[0019] According to one embodiment of the invention, the width of at least one assembly tab varies, for example, increases, between the proximal edge of at least one assembly tab and the distal edge of at least one assembly tab, the proximal edge of which is connected to the main portion of the second buffer layer.

[0020] According to one embodiment of the invention, the depth of at least one assembly recess is greater than the width of the largest side of the cross-section of at least one assembly recess. In other words, the depth of at least one assembly recess is greater than the width of the widest inner surface of at least one assembly recess. These arrangements further improve the reliability of the assembly of the first and second buffer layers.

[0021] According to one embodiment of the invention, at least one assembly tab is polygonal, such as a quadrilateral or trapezoid.

[0022] According to one embodiment of the invention, at least one assembly tab includes a central portion connected to a main portion of the second buffer layer and two lateral assembly portions disposed on either side of the central portion. The two lateral assembly portions are configured to mate with the inner wall of an internal honeycomb structure, the inner wall of which at least partially defines at least one assembly recess. These arrangements further improve the reliability of the assembly of the first and second buffer layers.

[0023] According to one embodiment of the present invention, the second buffer layer includes an auxiliary internal honeycomb structure and first and second auxiliary outer covering layers disposed on both sides of the auxiliary internal honeycomb structure, wherein at least one assembly tab is obtained by cutting the first auxiliary outer covering layer of the second buffer layer. These arrangements enable the buffer element according to the present invention to have enhanced buffering and protective performance.

[0024] According to one embodiment of the invention, at least one assembly recess is not through, i.e., its depth is less than the thickness of the first buffer layer.

[0025] According to one embodiment of the invention, at least one assembly recess is through and also has an opening in the outer surface of the second outer cover layer.

[0026] According to one embodiment of the present invention, the second auxiliary outer cover layer of the second buffer layer includes at least one through-hole that opens in at least one compartment of the auxiliary internal honeycomb structure and positions at least partially facing at least one assembly tab.

[0027] According to one embodiment of the present invention, the internal honeycomb structure of the first buffer layer is honeycomb-shaped.

[0028] According to one embodiment of the present invention, the auxiliary internal honeycomb structure of the second buffer layer is honeycomb-shaped.

[0029] According to one embodiment of the present invention, the internal honeycomb structure of the first buffer layer and / or the first and second outer covering layers are formed of cardboard.

[0030] According to one embodiment of the present invention, the auxiliary internal honeycomb structure of the second buffer layer and / or the second outer covering layer are formed of cardboard.

[0031] According to one embodiment of the present invention, the first buffer layer is made of honeycomb paperboard.

[0032] According to one embodiment of the present invention, the second buffer layer is made of honeycomb paperboard.

[0033] According to one embodiment of the invention, each compartment of the internal honeycomb structure of the first buffer layer has a hexagonal shape.

[0034] According to one embodiment of the present invention, each compartment of the auxiliary internal honeycomb structure of the second buffer layer has a hexagonal shape.

[0035] According to one embodiment of the invention, the second cushioning layer is made of corrugated cardboard or obtained by molding or extruding cellulose fibers.

[0036] According to another embodiment of the invention, the second buffer layer is made of a plastic material, such as a biologically derived or recycled plastic material. Advantageously, the plastic material is biodegradable.

[0037] According to one embodiment of the invention, at least one of the first buffer layer and the second buffer layer includes a receiving recess configured to at least partially accommodate the product to be packaged.

[0038] According to one embodiment of the invention, the product to be packaged is a household appliance, such as an electric cooking appliance, a household cleaning appliance (such as a steam or vacuum type), a garment processing appliance (such as an ironing and / or steaming appliance), or a hair styling appliance. The product to be packaged can also be any type of fragile product, such as a computer or monitor.

[0039] According to one embodiment of the present invention, the first buffer layer includes a plurality of assembly recesses, for example, 2 to 20, each assembly recess opening in the outer surface of the first outer cover layer, and each assembly recess including at least a first recess portion defined by the first outer cover layer and a second recess portion defined by the internal honeycomb structure.

[0040] According to one embodiment of the invention, the second buffer layer includes a plurality of assembly tabs, for example, 2 to 20, each assembly tab having a maximum lateral dimension greater than the maximum lateral dimension of a corresponding assembly recess, each assembly tab being received at least partially in a second recess portion of the corresponding assembly recess in order to assemble the first and second buffer layers together.

[0041] According to one embodiment of the invention, the cushioning element further includes a protective layer fastened to the outer surface of the second cushioning layer opposite to the first cushioning layer. The protective layer may be made of, for example, a nonwoven material, such as felt. The presence of this protective layer prevents any risk of the second cushioning layer scratching the product to be packaged.

[0042] The present invention also relates to a method for manufacturing a cushioning element configured to cushion and protect a product to be packaged in packaging, the method comprising the following steps:

[0043] A first cushioning layer, at least partially made of a cellulose-based material, is provided, the first cushioning layer comprising an internal honeycomb structure and first and second outer covering layers disposed on both sides of the internal honeycomb structure.

[0044] A second buffer layer is provided, which is, for example, at least partially made of a cellulose-based material.

[0045] The first buffer layer is cut to form at least one assembly recess in the first buffer layer, the at least one assembly recess opening in the outer surface of the first outer cover layer and including at least a first recess portion defined by the first outer cover layer and a second recess portion defined by the internal honeycomb structure.

[0046] Cut the second buffer layer to form at least one assembly tab in the second buffer layer.

[0047] Stack the first and second buffer layers such that at least one assembly recess faces at least one assembly tab.

[0048] The first and second buffer layers are assembled by deforming at least one assembly tab and at least partially introducing it into a second recessed portion of at least one assembly recess.

[0049] According to one embodiment of the manufacturing method, the maximum lateral dimension of at least one assembled tab is greater than the maximum lateral dimension of at least one assembled recess.

[0050] According to one embodiment of the manufacturing method, an assembly step is performed using a stamping tool configured to deform at least one assembly tab and at least partially introduce it into a second recess portion of at least one assembly recess.

[0051] According to one embodiment of the manufacturing method, the assembly step includes displacing the stamping tool toward the first buffer layer and along a displacement direction substantially perpendicular to the extension planes of the first and second buffer layers.

[0052] According to one embodiment of the manufacturing method, the stamping tool used in the assembly step includes a stamping head, the stamping head including a circular free end.

[0053] According to one embodiment of the manufacturing method, the stamping head used in the assembly step includes an end chamfer configured to orient the deformation of at least one assembly tab according to a predetermined deformation orientation in the assembly step.

[0054] According to one embodiment of the manufacturing method, the stamping tool used in the assembly step includes a guide portion configured to engage with at least one assembly recess when at least one assembly tab is introduced into at least one assembly recess. Advantageously, the cross-section of the guide portion is substantially complementary to the cross-section of the at least one assembly recess.

[0055] According to one embodiment of the manufacturing method, the provided second buffer layer includes an auxiliary internal honeycomb structure and first and second auxiliary outer cover layers disposed on both sides of the auxiliary internal honeycomb structure, and at least one assembled tab is obtained by cutting the first auxiliary outer cover layer of the second buffer layer.

[0056] According to one embodiment of the manufacturing method, the manufacturing method includes the step of cutting a second auxiliary outer cover layer of the second buffer layer to form at least one through hole in the second auxiliary outer cover layer, the at least one through hole opening in at least one compartment of the auxiliary internal honeycomb structure and positioning at least partially facing at least one assembly tab.

[0057] According to one embodiment of the manufacturing method, prior to the step of deforming at least one assembly tab, the assembly step includes the step of displacing a stamping tool through at least one through-hole and a compartment, wherein the at least one through-hole opens in the compartment.

[0058] According to one embodiment of the manufacturing method, the assembly step includes the following steps: introducing a cut portion of the second auxiliary outer cover layer into at least one assembly recess; and retaining at least one assembly tab in the at least one assembly recess by the cut portion introduced into the at least one assembly recess. These steps of the manufacturing method according to the invention further improve the reliability of the assembly of the first and second buffer layers.

[0059] According to one embodiment of the manufacturing method, the shape of at least one orifice is substantially the same as the shape of at least one assembly tab. In other words, the cut portion of the second auxiliary outer cover layer has a shape substantially the same as that of at least one assembly tab. Attached Figure Description

[0060] Referring to the accompanying drawings, the objectives, aspects, and advantages of the present invention can be better understood through the following description of several specific embodiments, which are presented in a non-limiting manner, wherein:

[0061] Figure 1 This is a partial top perspective view of the buffer element according to the first embodiment of the present invention;

[0062] Figure 2 yes Figure 1 A top view of the first buffer layer of the buffer element;

[0063] Figure 3 yes Figure 1 A top view of the second buffer layer of the buffer element;

[0064] Figure 4 yes Figure 3 A top view of the second buffer layer;

[0065] Figure 5 yes Figure 1 A partial top view of the buffer element;

[0066] Figure 6 It is along Figure 5 A sectional view along line 6-6;

[0067] Figure 7 It is along Figure 5 A sectional view along line 7-7;

[0068] Figure 8 It is used for manufacturing Figure 1 A bottom-view perspective of the stamping tool for the buffer element;

[0069] Figure 9 This is a schematic cross-sectional view of a buffer element according to a second embodiment of the present invention;

[0070] Figure 10 This is a schematic cross-sectional view of a buffer element according to a third embodiment of the present invention;

[0071] Figure 11 This is a schematic cross-sectional view of a buffer element according to a fourth embodiment of the present invention;

[0072] Figure 12 This is a schematic cross-sectional view of a buffer element according to a fifth embodiment of the present invention. Detailed Implementation

[0073] The figures only show elements necessary for understanding the invention. For ease of reading, the same reference numerals are used to denote the same elements in different figures.

[0074] Figures 1 to 7 A cushioning element 2 is shown, configured to cushion and protect the product to be packaged within the packaging. The product to be packaged can be, for example, a household appliance, such as an electric cooking appliance, a household cleaning appliance (e.g., a steam or vacuum type), a garment processor (e.g., an ironing and / or steaming appliance), or a hair styling appliance. The product to be packaged can also be any type of fragile product, such as a computer or monitor.

[0075] like Figure 1 , Figure 2 and Figure 6As shown, the cushioning element 2 includes a first cushioning layer 3 made of honeycomb paperboard. More specifically, the first cushioning layer 3 includes a honeycomb-type internal honeycomb structure 4 and first and second outer covering layers 5, 6 disposed on both sides of the internal honeycomb structure 4. Advantageously, each compartment of the internal honeycomb structure 4 has a hexagonal shape.

[0076] The first buffer layer 3 also includes a plurality of assembly recesses 7, each assembly recess opening in the outer surface of the first outer cover layer 5. The number of assembly recesses 7 can be, for example, between 2 and 20. Figures 1 to 7 In the illustrated embodiment, the first buffer layer 3 includes four assembly recesses 7, each disposed next to a corresponding corner of the first outer cover layer 5. However, the assembly recesses 7 may be disposed at other locations on the first buffer layer 3.

[0077] Advantageously, each assembly recess 7 has a central longitudinal axis extending perpendicular to the first and second outer cover layers 5, 6. According to the embodiment shown in the figure, each assembly recess 7 includes a first recess portion 7.1 defined by the first outer cover layer 5 and a second recess portion 7.2 defined by the internal honeycomb structure 4.

[0078] Each assembled recess 7 has a polygonal cross-section with N sides, where N is an integer greater than or equal to 3. According to Figures 1 to 7 In the illustrated embodiment, each assembly recess 7 has a quadrilateral cross-section, more specifically a square or rectangular cross-section. Advantageously, the cross-section of each assembly recess 7 is square, and the length of each side of the cross-section of each assembly recess 7 is between 10 and 20 mm, for example, about 13 mm.

[0079] Advantageously, the depth of each assembly recess 7 is greater than the width of each side of the cross-section of the assembly recess 7, and therefore greater than the width of each inner surface of the assembly recess 7. For example, this depth can be approximately 15 mm. Figures 1 to 7 In the illustrated embodiment, each assembly recess 7 is not through, meaning its depth is less than the thickness of the first buffer layer 3. However, according to an alternative embodiment of the invention, each assembly recess 7 may be through, thus also having an opening in the outer surface of the second outer cover layer 6.

[0080] like Figure 1 , Figure 3 and Figure 6 As shown, the buffer element 2 also includes a second buffer layer 8 made of a cellulose-based material. Figure 1 and Figure 6 As shown, the first and second buffer layers 3 and 8 are stacked on top of each other and assembled together.

[0081] according to Figures 1 to 7In the illustrated embodiment, the second buffer layer 8 is made of honeycomb paperboard, and more specifically includes a honeycomb-shaped auxiliary internal honeycomb structure 9, and first and second auxiliary outer covering layers 11, 12 disposed on both sides of the auxiliary internal honeycomb structure 9. Advantageously, each compartment of the auxiliary internal honeycomb structure 9 is hexagonal.

[0082] The second buffer layer 8 also includes a plurality of assembly tabs 13, each assembly tab being obtained by cutting the first auxiliary outer cover layer 11 of the second buffer layer 8. The number of assembly tabs 13 is the same as the number of assembly recesses 7, and therefore, for example, between 2 and 20. Figures 1 to 7 In the embodiment shown, the second buffer layer 8 includes four assembled tabs 13, each assembled tab being disposed next to a corresponding corner of the first auxiliary outer cover layer 11.

[0083] Each assembly tab 13 has a maximum lateral dimension greater than the maximum lateral dimension of the corresponding assembly recess 7, and is configured to be at least partially received in the second recess portion 7.2 of the corresponding assembly recess 7 in order to assemble the first and second buffer layers 3, 8 together. Figures 1 to 7 In the embodiment shown, more specifically, the maximum width of each assembly tab 13 is greater than the width of each side of the cross-section of the corresponding assembly recess 7, and therefore greater than the width of each inner surface of the corresponding assembly recess 7.

[0084] according to Figures 1 to 7 In the illustrated embodiment, each assembled tab 13 is quadrilateral, more specifically trapezoidal. However, each assembled tab 13 can have any other shape, such as circular, rectangular, hexagonal, or kite-shaped. Each assembled tab 13 may, for example, have a proximal edge connected to the main portion of the second buffer layer 8 and having a first width, and a distal edge having a second width greater than the first width. The first width may, for example, be approximately 13 mm, and the second width may, for example, be approximately 21 mm.

[0085] Advantageously, each assembly tab 13 includes a central portion connected to a main portion of the second buffer layer 8 (more specifically, the first auxiliary outer cover layer 11), and two lateral assembly portions located on either side of the central portion. The two lateral assembly portions are configured to mate with the inner wall of the internal honeycomb structure 4, which at least partially defines a corresponding assembly recess 7. Advantageously, each lateral assembly portion has a generally triangular shape.

[0086] according to Figures 1 to 7In the illustrated embodiment, the second auxiliary outer cover layer 12 of the second buffer layer 8 includes a plurality of through-holes 14, each through-hole opening in at least one corresponding compartment of the auxiliary internal honeycomb structure 9, and each through-hole being positioned at least partially facing a corresponding assembly tab 13. Advantageously, the shape of each through-hole 14 is substantially the same as the shape of the corresponding assembly tab 13.

[0087] like Figure 1 As shown, the first and second buffer layers 3 and 8 also define a receiving recess 15, which is configured to at least partially accommodate the product to be packaged.

[0088] The manufacturing method for producing the buffer element 2 according to the present invention is described below. This manufacturing method includes the following steps:

[0089] Provide the first buffer layer 3,

[0090] Provide a second buffer layer 8,

[0091] Cut the first buffer layer 3 to form the assembly recess 7 in the first buffer layer 3.

[0092] Cut the second buffer layer 8 to form the assembly tab 13 in the second buffer layer 8.

[0093] Stack the first and second buffer layers 3 and 8 such that each assembly recess 7 faces the corresponding assembly tab 13, and

[0094] The first and second buffer layers 3, 8 are assembled by deforming each assembly tab 13 and at least partially introducing it into the second recess portion 7.2 of the corresponding assembly recess 7.

[0095] According to one embodiment of the manufacturing method, the assembly step is performed using a stamping tool 16, which is configured to deform each assembly tab 13 and at least partially introduce it into the second recess portion 7.2 of the corresponding assembly recess 7.

[0096] Advantageously, the stamping tool 16 includes a stamping head 17, which includes:

[0097] The circular free end 17.1 is configured to allow the lateral assembly portion of each assembly tab 13 to deform when each assembly tab 13 is introduced into the corresponding assembly recess 7, and to re-center them when the first and second buffer layers 3, 8 are assembled.

[0098] The end chamfer 17.2 is configured to orient the deformation of each assembly tab 13 according to a predetermined deformation orientation when the assembly tab 13 is introduced into the corresponding assembly recess 7.

[0099] The guide portion 17.3 is configured to engage with each assembly recess 7 when the corresponding assembly tab 13 is introduced into the assembly recess 7, and the guide portion 17.1 advantageously has a cross section substantially complementary to the cross section of each assembly recess 7.

[0100] According to one embodiment of the manufacturing method, the assembly step includes the following steps:

[0101] a) Position the stamping tool 16 so that it faces the through hole 14 provided in the second buffer layer 8.

[0102] b) Displace the stamping tool 16 toward the second buffer layer 8 and through the orifice 14 and the auxiliary internal honeycomb structure 9 in a vertical displacement direction that is perpendicular to the extension plane of the first and second buffer layers 3 and 8.

[0103] c) The corresponding assembly tab 13 is deformed and at least partially introduced into the second recessed portion 7.2 of the corresponding assembly recess 7.

[0104] d) Introduce the cut portion 18 of the second auxiliary outer cover layer 12 (obtained when the second auxiliary outer cover layer 12 is cut to form the corresponding through-hole 14) into the corresponding assembly recess 7, and

[0105] e) The assembly tab 13 is held in the corresponding assembly recess 7 by means of the cutting portion 18 introduced into the assembly recess 7, and

[0106] f) Repeat steps a) through e) for each other through orifice 14.

[0107] Figure 9 A buffer element 2 according to a second embodiment is shown, which differs from the first embodiment mainly in that the buffer element 2 includes at least one third buffer layer 19 stacked on the second buffer layer 8, and further includes one or more additional assembly tabs 21 configured to engage with one or more additional assembly recesses 22 disposed on the second buffer layer 8. According to this embodiment of the invention, the size of the one or more additional assembly tabs 21 disposed on the third buffer layer 19 may be larger than the one or more assembly tabs 13 disposed on the second buffer layer 8.

[0108] Figure 10 A buffer element 2 according to a third embodiment is shown, the main difference from the second embodiment being that one or more additional assembly tabs 21 disposed on the third buffer layer 19 are laterally offset relative to one or more assembly tabs 13 disposed on the second buffer layer 8.

[0109] Figure 11The buffer element 2 according to the fourth embodiment is shown. Its main difference from the first embodiment is that the first and second buffer layers 3 and 8 are obtained by partially cutting a buffer board made of honeycomb paperboard, and the stacking of the first and second buffer layers 3 and 8 is achieved by folding the buffer board itself.

[0110] Figure 12 The buffer element 2 according to the fifth embodiment is shown. Its main difference from the fourth embodiment is that the buffer element 2 is obtained by repeatedly cutting the buffer board made of honeycomb paperboard and folding the buffer board into a "snail" shape, thereby forming a stack of different buffer layers, such as three or more layers.

[0111] According to one embodiment of the invention not shown in the figure, the second buffer layer 8 may be made of corrugated cardboard or obtained by molding or extruding cellulose fibers, rather than being made of honeycomb cardboard.

[0112] Of course, the present invention is by no means limited to the embodiments described and shown, which are given by way of example only. Modifications may be made, particularly in the configuration of various elements or through the substitution of equivalent techniques, without departing from the scope of protection of the present invention.

Claims

1. A cushioning element (2) configured to cushion and protect a product to be packaged in a package, said cushioning element (2) comprising at least: A first buffer layer (3) at least partially made of cellulose-based material, the first buffer layer (3) comprising an internal honeycomb structure (4) and a first outer cover layer (5) and a second outer cover layer (5, 6) disposed on both sides of the internal honeycomb structure (4), the first buffer layer (3) comprising at least one assembly recess (7), the at least one assembly recess (7) opening in the outer surface of the first outer cover layer (5) and comprising at least a first recess portion (7.1) defined by the first outer cover layer (5) and a second recess portion (7.2) defined by the internal honeycomb structure (4), and The second buffer layer (8) is stacked on top of the first buffer layer (3) and the second buffer layer (8), and the second buffer layer (8) includes at least one assembly tab (13), which is at least partially received in the second recess portion (7.2) of the at least one assembly recess (7) to assemble the first buffer layer (3) and the second buffer layer (8) together.

2. The buffer element (2) according to claim 1, wherein, The maximum lateral dimension of the at least one assembly tab (13) is greater than the maximum lateral dimension of the at least one assembly recess (7).

3. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly recess (7) has a polygonal cross-section with N sides, where N is an integer greater than or equal to 3.

4. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly recess (7) has a quadrilateral cross-section.

5. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly recess (7) has a square cross-section.

6. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly recess (7) has a rectangular cross-section.

7. The buffer element (2) according to claim 3, wherein, The maximum width of the at least one assembly tab (13) is greater than the width of the maximum side of the cross-section of the at least one assembly recess (7).

8. The buffer element (2) according to claim 3, wherein, The depth of the at least one assembly recess (7) is greater than the width of the largest side of the cross-section of the at least one assembly recess (7).

9. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly tab (13) has a polygonal shape.

10. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly tab (13) has a quadrilateral shape.

11. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly tab (13) has a trapezoidal shape.

12. The buffer element (2) according to claim 1 or 2, wherein, The at least one assembly tab (13) includes a central portion connected to a main portion of the second buffer layer (8), and two lateral assembly portions disposed on both sides of the central portion, the two lateral assembly portions being configured to engage with the inner wall of the internal honeycomb structure (4), the inner wall at least partially defining the at least one assembly recess (7).

13. The buffer element (2) according to claim 1 or 2, wherein, The second buffer layer (8) is at least partially made of cellulose-based material.

14. The buffer element (2) according to claim 1 or 2, wherein, The second buffer layer (8) includes an auxiliary internal honeycomb structure (9) and a first auxiliary outer cover layer (11) and a second auxiliary outer cover layer (12) disposed on both sides of the auxiliary internal honeycomb structure (9). The at least one assembly tab (13) is obtained by cutting the first auxiliary outer cover layer (11) of the second buffer layer (8).

15. The buffer element (2) according to claim 14, wherein, The second auxiliary outer cover layer (12) of the second buffer layer (8) includes at least one through hole (14) that opens in at least one compartment of the auxiliary internal honeycomb structure (9) and is positioned at least partially facing the at least one assembly tab (13).

16. The buffer element (2) according to claim 1 or 2, wherein, The second cushioning layer (8) is made of corrugated cardboard or obtained by molding or extruding cellulose fibers.

17. A method for manufacturing a cushioning element (2), the cushioning element being configured to cushion and protect a product to be packaged in a package, the method comprising the steps of: A first buffer layer (3) is provided, which is at least partially made of cellulose-based material. The first buffer layer (3) includes an internal honeycomb structure (4) and a first outer cover layer (5) and a second outer cover layer (6) disposed on both sides of the internal honeycomb structure (4). Provide a second buffer layer (8). The first buffer layer (3) is cut to form at least one assembly recess (7) in the first buffer layer (3), the at least one assembly recess (7) opening in the outer surface of the first outer cover layer (5) and including at least a first recess portion (7.1) defined by the first outer cover layer (5) and a second recess portion (7.2) defined by the inner honeycomb structure (4). Cut the second buffer layer (8) to form at least one assembly tab (13) in the second buffer layer (8). Stack the first buffer layer (3) and the second buffer layer (8) such that the at least one assembly recess (7) is positioned facing the at least one assembly tab (13), and The first buffer layer (3) and the second buffer layer (8) are assembled by deforming the at least one assembly tab (13) and at least partially introducing it into the second recess portion (7.2) of the at least one assembly recess (7).

18. The manufacturing method according to claim 17, wherein, The assembly step is performed using a stamping tool (16) configured to deform the at least one assembly tab (13) and at least partially introduce it into the second recess portion (7.2) of the at least one assembly recess (7).

19. The manufacturing method according to claim 18, wherein, The stamping tool (16) used in the assembly step includes a stamping head (17) with a round free end (17.1).

20. The manufacturing method according to any one of claims 17 to 19, wherein, The provided second buffer layer (8) includes an auxiliary internal honeycomb structure (9) and a first auxiliary outer cover layer (11) and a second auxiliary outer cover layer (12) disposed on both sides of the auxiliary internal honeycomb structure (9). The at least one assembled tab (13) formed is obtained by cutting the first auxiliary outer cover layer (11) of the second buffer layer (8).

21. The manufacturing method according to claim 20, comprising the step of cutting a second auxiliary outer cover layer (12) of the second buffer layer (8) to form at least one through hole (14) in the second auxiliary outer cover layer (12), the at least one through hole (14) opening in at least one compartment of the auxiliary internal honeycomb structure (9) and positioning at least partially facing the at least one assembly tab (13).

22. The manufacturing method according to claim 18, wherein, The provided second buffer layer (8) includes an auxiliary internal honeycomb structure (9) and a first auxiliary outer cover layer (11) and a second auxiliary outer cover layer (12) disposed on both sides of the auxiliary internal honeycomb structure (9). The at least one assembled tab (13) formed is obtained by cutting the first auxiliary outer cover layer (11) of the second buffer layer (8). The manufacturing method includes the step of cutting the second auxiliary outer cover layer (12) of the second buffer layer (8) to form at least one through hole (14) in the second auxiliary outer cover layer (12). The at least one through hole (14) opens in at least one compartment of the auxiliary internal honeycomb structure (9) and is positioned at least partially facing the at least one assembled tab (13). The assembly step includes the step of displacing the stamping tool (16) through the at least one through hole (14) and the compartment in which the at least one through hole (14) opens before the step of deforming the at least one assembled tab (13).

23. The manufacturing method according to claim 21 or 22, wherein, The assembly step includes the following steps: The cut portion of the second auxiliary outer cover layer (12) is introduced into the at least one assembly recess (7), and The at least one assembly tab (13) is held in the at least one assembly recess (7) by means of the cut portion introduced into the at least one assembly recess (7).

Images