Multi-wall packaging

Abstract

An envelope for containing one or more items includes first and second flexible walls. The second wall overlies and is secured to the first flexible wall. The second flexible wall can include multiple overlapping paper layers attached to one another, at least two of the multiple overlapping paper layers defining an interlayer area where at least two of the multiple overlapping paper layers are not adhered to one another.

Description

[Technical Field]

[0001] The present disclosure relates generally to packaging for holding items, for example, during transport. More specifically, embodiments of the present disclosure relate to packaging materials that include one or more multi-layer or multi-layer walls. [Background technology]

[0002] Paper is increasingly being used for mailing envelopes and other envelopes for shipping small to medium-sized items due to its various advantages in such applications. For example, unlike plastic film, most types of paper are easily recyclable. However, in some applications, paper may be less tear-resistant than plastic film, which can adversely affect the ability of a paper envelope to remain intact and properly hold its contents if dropped or otherwise mishandled during transport. Summary of the Invention [Means for solving the problem]

[0003] In one aspect of the disclosed technology, an envelope for containing an item includes a first flexible wall and a second flexible wall overlying the first flexible wall and secured to the first flexible wall around a containment boundary that encloses multiple sides of a containment area defined by the first and second flexible walls. The containment area is configured to contain an item. The second flexible wall includes at least two overlapping paper layers secured to each other around an inter-layer boundary that encloses multiple sides of an inter-layer area defined by the overlapping paper layers. The at least two overlapping paper layers are not adhered to each other in at least a portion of the inter-layer area, and the inter-layer area is empty, so that the at least two overlapping paper layers abut each other across a majority of the inter-layer area.

[0004] In another aspect of the disclosed technology, the interlayer region overlaps more than about half of the receiving region.

[0005] In other aspects of the disclosed technology, the interlayer region overlaps greater than about 75 percent of the receiving region.

[0006] In another aspect of the disclosed technology, the interlayer region overlies substantially the entire receiving region.

[0007] In another aspect of the disclosed technology, at least two overlapping layers of paper are slidable relative to one another over a majority of the interlayer area.

[0008] In other aspects of the disclosed technology, the storage area is accessible through an opening defined by first and second flexible walls, and the envelope further includes a coupling element disposed on at least one of the first and second flexible walls and configured to secure the first flexible wall to the second flexible wall to close the opening.

[0009] In another aspect of the disclosed technology, the opening is defined by a slit formed in a plurality of overlapping paper layers of the second flexible wall.

[0010] In another aspect of the disclosed technology, the slit is directly adjacent to the coupling element.

[0011] In another aspect of the disclosed technology, the bonding element is a heat seal material.

[0012] In another aspect of the disclosed technology, the bonding element is an adhesive material.

[0013] In another aspect of the disclosed technology, the slit is a first slit and the opening is further defined by a second slit formed in the first flexible wall.

[0014] In another aspect of the disclosed technology, the first flexible wall includes at least two overlapping paper layers secured to one another around an inter-layer boundary that surrounds multiple sides of an inter-layer area defined by the at least two overlapping paper layers of the first flexible wall.

[0015] In another aspect of the disclosed technology, the first flexible wall includes at least one interlayer seal configured to secure at least two overlapping layers of paper attached to one another, the at least one interlayer seal defining at least a portion of an interlayer boundary.

[0016] In another aspect of the disclosed technology, the envelope further includes at least one inter-wall seal configured to secure the first and second flexible walls to one another, the at least one inter-wall seal defining at least a portion of the containment boundary.

[0017] In another aspect of the disclosed technology, at least one interlayer seal overlies at least one interwall seal.

[0018] In another aspect of the disclosed technology, the at least one inter-wall seal is a first inter-wall seal, and the envelope further includes a second inter-wall seal, the first inter-wall seal extending along a first side of each of the first and second flexible walls, the second inter-wall seal extending along a second side of each of the first and second flexible walls, and the storage area is accessible through an opening defined by the first and second flexible walls, the opening extending between the first and second inter-wall seals.

[0019] In another aspect of the disclosed technology, the second flexible wall includes a first portion adjacent to the first flexible wall along the first fold line.

[0020] In other aspects of the disclosed technology, the second flexible wall further includes a second portion adjacent to the first flexible wall along the second fold line, an end of the second portion overlapping and attached to an end of the first portion.

[0021] In other aspects of the disclosed technology, the second flexible wall includes at least first, second, and third overlapping layers of paper, the interlayer region being disposed between the first and second layers, and the envelope further including an expandable material disposed between the second and third layers.

[0022] In another aspect of the disclosed technology, the envelope further includes a gusset adjacent the first and second flexible walls.

[0023] In another aspect of the disclosed technology, the web stock includes a plurality of envelopes as described above, each envelope being adjacent to one of the adjacent envelopes.

[0024] In another aspect of the disclosed technology, each envelope is adjacent to an adjacent envelope along an area of ​​weakness between the adjacent envelopes.

[0025] The following drawings illustrate certain embodiments of the present disclosure and therefore do not limit the scope of the disclosure. The drawings are not to scale and are intended to be used in conjunction with the following detailed description. Embodiments of the present disclosure are described below in conjunction with the accompanying drawings, in which like numbers refer to like elements. [Brief explanation of the drawings]

[0026] [Figure 1] FIG. 1 is a top perspective view of an envelope having a multi-layer wall. [Figure 2] FIG. 2 shows how the continuous wall web used to form the envelope shown in FIG. 1 is formed. [Figure 3] FIG. 3 shows how the wall web shown in FIG. 2 is formed into the continuous web stock of the envelope shown in FIG. [Figure 4] FIG. 4 is an enlarged cross-sectional view taken along plane "IV-IV" of FIG. [Figure 4A] 4A is a perspective view of a bagger configured for use with the envelopes shown in FIG. 1. FIG. [Figure 5] FIG. 5 shows a continuous web stock for another embodiment of the envelope shown in FIG. [Figure 6] FIG. 6 is a cross-sectional view taken along the plane "VI-VI" of FIG. [Figure 7] FIG. 7 is an enlarged cross-sectional view taken along plane "VII-VII" of FIG. [Figure 8]FIG. 8 shows a continuous web stock for another embodiment of the envelope shown in FIG. [Figure 9] FIG. 9 is an enlarged cross-sectional view taken along plane "IX-IX" of FIG. [Figure 10] FIG. 10 shows a continuous web stock for another embodiment of an envelope. [Figure 11] FIG. 11 is a plan view of one of the envelopes shown in FIG. [Figure 12] FIG. 12 shows the continuous wall web in an unfolded state used to form the container webstock shown in FIG. [Figure 13] FIG. 13 shows a continuous web stock for another embodiment of an envelope. [Figure 14] FIG. 14 is a perspective view of another embodiment of an envelope having gusseted sides. [Figure 15] FIG. 15 is a top view of the envelope shown in FIG. [Figure 16] FIG. 16 is a cross-sectional view of another embodiment of an envelope. [Figure 17] FIG. 17 is a perspective view of a bag formed for another embodiment of an envelope. [Figure 18] FIG. 18 is a perspective view of a web stock used in the bag making machine shown in FIG. [Figure 19] FIG. 19 is a perspective view of a side-loading envelope web stock. DETAILED DESCRIPTION OF THE INVENTION

[0027] The inventive concepts are described with reference to the accompanying drawings, in which like reference numerals represent like parts and assemblies throughout the several views. The drawings are not drawn to scale and are provided solely for the purpose of illustrating the inventive concepts. The drawings do not limit the scope of the present disclosure or the appended claims. Several aspects of the inventive concepts are described below with reference to exemplary applications. It should be understood that numerous specific details, relationships, and methods are set forth to provide a thorough understanding of the inventive concepts. However, one of ordinary skill in the relevant art will readily appreciate that the inventive concepts can be practiced without one or more of the specific details, or using other methods. In other instances, well-known structures or operations have not been shown in detail to avoid obscuring the inventive concepts.

[0028] 1-4 illustrate an embodiment of an envelope 10. The envelope 10 is configured to contain and hold an item, typically enclosing the item while it is being mailed or shipped, or while it needs to be packaged in a sealed container. As used herein, the term "envelope" includes, but is not limited to, a flat shipping container (including a mailing envelope) that is flexible enough to expand and bend around an item when the item is inserted into a pocket within the envelope, and in which the sidewalls or thickness of the container are significantly smaller (e.g., less than one-tenth) than the width and / or height of the container.

[0029] 1 and 4, envelope 10 comprises two flexible walls 11 joined in a manner described below. Walls 11 define a storage area in the form of envelope pockets 12. Envelope pockets 12 are configured to receive and hold items (not shown). Each wall 11 includes two layers, each formed by a layer 13 of a suitable material, such as paper. In alternative embodiments, one of walls 11 can be a single-ply wall formed from a single layer 13, and the other wall 11 can be a two-ply wall formed from two of the layers 13. In other alternative embodiments, one or both of layers 13 can be formed from a plastic film.

[0030] Referring to Figure 1, the layers 13 of each wall 11 are secured together by two longitudinal interlayer seals 18 and two transverse interlayer seals 20. The longitudinal and transverse interlayer seals 18, 20 are formed from a bonding element in the form of an adhesive material 24, shown in Figure 2. The longitudinal and transverse directions are indicated by arrows "L" and "T," respectively, in Figures 1-3.

[0031] The adhesive material 24 may be a cold glue. Other types of adhesive materials and other types of joining elements may be used instead of cold glue. For example, in alternative embodiments, adhesive elements may be made of adhesive materials and heat seal materials.

[0032] Each longitudinal interlayer seal 18 is disposed along a corresponding longitudinal edge of wall 11 and extends generally longitudinally of wall 11. In alternative embodiments, each longitudinal interlayer seal 18 may be offset from the corresponding edge of wall 11. The longitudinal interlayer seals 18 are continuous. In alternative embodiments, the longitudinal interlayer seals 18 may be discontinuous.

[0033] The horizontal interlayer seals 20 are disposed along the bottom and top edges of the wall 11 and extend generally laterally of the wall 11 between the vertical interlayer seals 18. The horizontal interlayer seals 20 may be offset from the bottom and top edges of the wall 11 in alternative embodiments. The horizontal interlayer seals 20 are continuous. In alternative embodiments, the horizontal interlayer seals 20 may be discontinuous.

[0034] 2 illustrates the production of a web 15 that forms an envelope 10. The web 15 is comprised of a continuous series of walls 11, with each wall 11 interconnected with adjacent walls 11 within the web 15. As described below, two webs 15 are joined together to form a web stock 16 of interconnected envelopes 10. Individual envelopes 10 are then separated from the web stock 16 by manual or automated means.

[0035] 2 illustrates the use of automated equipment to form web 15. Web 15 is formed from two substantially identical pieces of paper 22a, 22b that are joined together in the following manner to form the two layers 13 of each wall 10.

[0036] Adhesive material 24 is applied to paper strip 22a at locations corresponding to the desired locations of the longitudinal and transverse interlayer seals 18, 20. Adhesive-free paper strip 22b is placed on top of and aligned with paper strip 22a.

[0037] Rollers 23 of the automated equipment then press the sheets 22a, 22b together, causing the adhesive 24 on the lower sheet 22a to contact the other sheet 22b and form interlayer seals 18, 20, securing the sheets 22a, 22b together to form a continuous web 16 of two-ply walls 11. In an alternative embodiment, adhesive 24 can be applied to corresponding locations on both sheets 22a, 22b before the sheets 22a, 22b are joined to form the web 16.

[0038] The above description of the formation of web 16 is presented for purposes of example only, and web 16 may be formed in other ways.

[0039] Examples of papers suitable for forming layer 13 include, but are not limited to, kraft paper, fiberboard, pulp-based paper, recycled paper, newsprint, paperboard, etc. For some applications, the paper may be a stretch paper configured to stretch or contract to a predetermined percentage of its original (unstretched) length without tearing. Parameters such as paper dimensions and weight can be varied depending on the intended application.

[0040] One or both of layers 13 may also have one or more functional layers disposed thereon, including, but not limited to, a waterproof layer configured to reduce water permeability, an airtight layer configured to reduce air permeability, other suitable material layers, and / or combinations thereof.

[0041] The longitudinal and transverse interlayer seals 18, 20 define and bound an interlayer region in the form of an interlayer space 30 located between the two layers 13 of each wall 10. The interlayer space 30 is shown in FIG. 4. One or both of the layers 13 may be air permeable, such that the interlayer space 30 is in fluid communication with the space outside the two layers 13. In such an embodiment, air or other fluids can pass in and out of the interlayer space 30 and are not trapped within the interlayer space 30. In an alternative embodiment, the layers 13 may be impermeable to air.

[0042] The two layers 13 of each wall 11 face each other across an interlayer space 30, but are not bonded to each other within the interlayer space 30. Additionally, the interlayer space 30 is sufficiently empty so that the layers 13 can abut or contact each other within the interlayer space 30 and slide relative to each other within the interlayer space 30. For example, the interlayer space 30 may be completely empty, i.e., no filler or other material may be present in the interlayer space 30.

[0043] In alternative embodiments, the interlayer space 30 may be partially filled with cushioning or padding, insulating materials, or other types of intumescent and non-intumescent materials. For example, in some alternative embodiments, up to about 10 percent of the interlayer space 30 may be filled with such materials. In other alternative embodiments, up to about 25 percent of the interlayer space 30 may be filled with such materials. In other alternative embodiments, up to about 50 percent of the interlayer space 30 may be filled with such materials. In other alternative embodiments, up to about 75 percent of the interlayer space 30 may be filled with such materials.

[0044] The multi-layered construction of wall 11 and the lack of fixed mechanical connections between layers 13 within interlayer space 30 improves envelope 10's resistance to tearing and punctures. Specifically, even if one layer 13 is torn or punctured, the presence of an intact or undamaged layer 13 will ensure that envelope pocket 12 underneath envelope 10 and the items within envelope pocket 12 remain enclosed.

[0045] Additionally, the tear or hole may propagate along the damaged layer 13, but not necessarily into the undamaged layer 13, because the vertical interlayer seal 18 and / or the horizontal interlayer seal 20 act as stoppers that prevent the tear or hole from propagating beyond the vertical interlayer seal 18 or the horizontal interlayer seal 20. Thus, even if the tear or hole propagates through most or all of the damaged layer 13, the envelope pocket 12 remains intact, and any items held therein may remain within the envelope pocket 12.

[0046] Additionally, the use of two plies 13 facilitates the use of lower basis weight paper, providing greater flexibility to wall 11 while maintaining the strength and tear resistance required for a particular application. For example, ply 13 can be formed of a relatively low basis weight paper, such as two plies of 30-45 lb. paper, instead of one ply of 90 lb. paper.

[0047] Each wall 11 defines one interlayer space 30. In other embodiments, one or both walls 11 may define more than one interlayer space 30. For example, another embodiment may have two interlayer spaces 30 defined by three longitudinal interlayer seals 18. Two of the longitudinal interlayer seals 18 may be located along the longitudinal edges of the wall, as in wall 11. The third longitudinal interlayer seal 18 may be located approximately in the center of the wall, i.e., approximately halfway between the longitudinal edges of the wall. This divides the space between layers 13 into two interlayer spaces 30.

[0048] In other alternative embodiments, wall 11 has three or more longitudinal interlayer seals 18, defining three or more interlayer spaces 30 within wall 11. In other alternative embodiments, there may be two or more horizontal interlayer seals 20, similarly dividing the space between layers 13 into one or more interlayer spaces 30. In other alternative embodiments, one or more interlayer seals may extend in a direction other than the longitudinal and horizontal directions. In other alternative embodiments, small bands or dots of adhesive located between layers 13 and inside the longitudinal, lower, and upper edges of wall 11 may be used to further bond layers 13 together while still allowing some relative movement between layers 13.

[0049] 1 and 4, the walls 11 of each envelope 10 are secured together by two longitudinal inter-wall seals 26 and one transverse inter-wall seal 28. The longitudinal and transverse inter-wall seals 26, 28 are formed from a bonding element in the form of an adhesive material 34, shown in FIG. 3. The adhesive material 34 may be cold glue. In alternative embodiments, other types of adhesive materials and other types of bonding elements may be used instead of cold glue.

[0050] Each longitudinal inter-wall seal 26 is disposed along a corresponding longitudinal edge of the envelope 10 and extends generally longitudinally of the envelope 10. In alternative embodiments, each longitudinal inter-wall seal 26 may be offset from the corresponding edge of the envelope 10. The longitudinal inter-wall seals 26 are continuous. In alternative embodiments, the longitudinal inter-wall seals 26 may be discontinuous.

[0051] The transverse inter-wall seal 28 is disposed along the lower or bottom edge of the envelope 10 and extends generally transversely of the envelope 10 between the longitudinal inter-wall seals 26. The transverse inter-wall seal 28 may be offset from the lower edge of the envelope 10 in alternative embodiments. The transverse inter-wall seal 28 is continuous. The transverse inter-wall seal 28 may be discontinuous in alternative embodiments.

[0052] Referring to Figures 1, 3, and 4, a band-shaped joining element, a heat seal material 31, is disposed on the inward-facing surface of each inner layer 13 of each wall 11, with the bands of heat seal material 31 facing each other. The heat seal material 31 is disposed along and extends from the top edge of each wall 11. In alternative embodiments, the heat seal material 31 may be offset from the top edge of the wall 11. The heat seal material 31 may be a continuous band extending between the longitudinal inter-wall seals 26. In alternative embodiments, the heat seal material 31 may be discontinuous. Also, in alternative embodiments, the heat seal material 31 may be disposed on only one of the walls 11. In other alternative embodiments, other types of joining elements may be used instead of the heat seal material 31. For example, an adhesive covered with a release strip or a hot melt adhesive may be used instead of the heat seal material 31.

[0053] Envelope pocket 12 is shown in Figures 1 and 4. Envelope pocket 12 is defined by the opposing inner surfaces of walls 11 and is bounded by longitudinal and lateral inter-wall seals 26, 28, which form containment boundaries for items packaged within envelope 10.

[0054] Alternate embodiments may include two or more longitudinal inter-wall seals 26 and / or two or more longitudinal inter-wall seals 28 that define multiple cavities 12 within the envelope 10 .

[0055] The interlayer space 30 covers substantially the entire envelope pocket 12. In another embodiment, the interlayer space 30 can cover approximately 75% or more of the envelope pocket 12. In another embodiment, the interlayer space 30 can cover approximately half or more of the envelope pocket 12.

[0056] The flexibility of paper walls 11 allows envelope 10 to be stored and shipped in a substantially flat, compact configuration with minimal or substantially no envelope pocket 12 volume. When a user wishes to fill envelope 10 with items, envelope pocket 12 can be expanded by separating or pulling apart walls 11 at or near the top of envelope pocket 12 and inserting the items to be packaged between walls 11. Once the items are placed in envelope 10, heat seal material 31 on walls 11 is activated, i.e., heated and pressed together, so that opposing strips of heat seal material 31 form a pocket closure upon cooling. The pocket closure closes and seals the open end of envelope pocket 12, thereby retaining the packaged items within envelope pocket 12.

[0057] In alternative embodiments, a single cold adhesive band covered with a release strip, two opposing cold adhesive bands each covered with a release strip, or other types of adhesive may be used instead of the heat seal material 31 to seal the opening of the envelope pocket 12.

[0058] Figure 3 shows two of the webs 15 of the two-ply wall 11 shown in Figure 2 being joined using another automated device to form the continuous web stock 16 of the envelope 10. For ease of illustration and description, the two webs 15 are referred to as webs 15a and 15b.

[0059] The longitudinal inter-wall seals 26 and the transverse inter-wall seals 28 can be formed from a sealing material, such as adhesive 34, applied to one side of web 15a. As shown in FIG. 3, adhesive 34 is applied to web 15a in locations corresponding to the desired locations of the longitudinal and transverse inter-wall seals 26, 28. Heat seal material 31 is also applied to web 15a. Web 15b, which is adhesive-free other than heat seal material 31, is placed on top of and aligned with web 15a. Rollers 36 of an automated device press webs 15a, 15b together, causing adhesive material 34 on web 15a to adhere to the opposite surface of web 15b, forming longitudinal and transverse inter-wall seals 26, 28 and securing webs 15a, 15b together. This results in a continuous web stock 16 for envelopes 10, as shown in FIG. 3.

[0060] In another embodiment, adhesive material 34 may be applied to opposing locations on both webs 15 a , 15 b before they are joined to form web stock 16 .

[0061] Individual envelopes 10 can be separated from webstock 16 by cutting, severing, or tearing envelope 10 from webstock 16, with separation occurring between heat seal material 31 and the transverse interwall seal 28 adjacent heat seal material 31. The line of separation between envelope 10 and the remainder of webstock 16 is shown in FIG. 3 by line "C."

[0062] A weakened feature is provided in the webstock 16 along the separation line C, facilitating separation of individual envelopes 10 from the webstock 16 without cutting or otherwise severing the envelopes 10. For example, a weakened area corresponding to the separation line C can be provided by perforations, scoring, or other suitable techniques to weaken the material along the separation line C. The weakened area can extend partially or entirely along the separation line C. Alternative embodiments can be configured without a weakened area. In such applications, the envelopes 10 can be separated from the webstock 16 by cutting or otherwise severing the envelopes 10 from the webstock 16 using an automatic or manual cutting means.

[0063] 4 shows an individual envelope 10 before it is separated from its webstock 16. As can be seen in this view, the transverse interlayer seal 20 is aligned with or overlaps the transverse interwall seal 28 and the heat seal material 31. In an alternative embodiment, the transverse interlayer seal 20 may be offset from the transverse interwall seal 28 and the heat seal material 31 in the machine direction of the webstock 16.

[0064] As described above, individual envelopes 10 are separated from the webstock 16 by cutting or otherwise severing the webstock 16 transversely along lines "C" shown in Figures 3 and 4. Separation line C extends between the heat seal material 31 and the adjacent transverse inter-wall seals 28. Separation line C also penetrates the transverse inter-layer seals 20 of each wall 11. Thus, once an envelope 10 is separated from the webstock 16, the heat seal material 31 and the overlapping portions of each wall 11, including the overlapping portions of the transverse inter-layer seals 20, form the top of the newly separated envelope 10. The transverse inter-wall seals 28, the remaining portions of the transverse inter-layer seals 20, and the overlapping portions of the walls 11 form the bottom of the adjacent envelope 10 that is still attached to the webstock 16.

[0065] Because the heat seal material 31 on the newly separated envelope 10 has not yet been activated, the opposing strips of heat seal material 31 and the overlapping portions of the walls 10 can be unfolded to open the envelope 10 and place an item within the envelope pocket 12. As previously described, once an item has been placed within the envelope pocket 12, the heat seal material 31 can be heated and pressed together to form a pocket closure and seal the item within the envelope pocket 12.

[0066] The envelopes 10 are loaded, sealed, and separated from the web stock 16 by a bagger 200, shown in Figure 4A. The bagger 200 is shown for illustrative purposes only. The envelopes 10 may be loaded, sealed, and separated from the web stock 16 manually, or alternatively, by other automated means.

[0067] The webstock 16 is fed to the bagger 200 in an unexpanded, high-density configuration. For example, as shown in Figure 4A, the webstock 16 is fed in a fanfold feed configuration and held on shelves 201 attached to the feed side of the bagger 200. The webstock 16 may also be fed in other suitable configurations, such as a roll.

[0068] The bagging machine 100 includes fingers 202 that open the envelopes 10 to provide access to the envelope pockets 12 and allow the envelopes 10 to be filled with items to be packaged. For purposes of illustration, the outer and inner facing walls 11 of the envelope 10 are designated 11a and 11a, respectively, in FIG. 4A. The fingers 202 are configured to grip and pinch the upper portion of the outer facing wall 11a. The fingers 202 are attached to articulating jaws 203 that can move outward and inward, i.e., away from and toward the web stock 16 from the perspective of FIG. 4A.

[0069] Fingers 202 initially grasp and pinch wall 11a, and the outward movement of articulated jaws 203 and attached fingers 202 pulls wall 11a away from wall 11b, creating an opening in the top of envelope 10. As shown in Figure 4A, the outward movement of wall 11a breaks a portion of the perforation along separation line C, accommodating the expansion of envelope 10.

[0070] The bagging machine 200 may include a blower 214 configured to blow pressurized air onto the top of the envelope 10 to help separate the walls 11 a, 11 b, as indicated by arrow 216. Once the opening of the envelope pocket 12 is formed, the items to be packaged can be loaded into the envelope pocket 12 manually or by an automated machine, as indicated by arrow 218.

[0071] The bagging machine also includes a heat sealer / cutter 206. After the envelope pocket 12 is loaded with an item, the articulating jaw 203 moves the outwardly facing wall 11a, which remains gripped and pinched by the fingers 202, towards the inner wall 11b.

[0072] The inward movement of articulating jaw 203 and wall 11a ultimately sandwiches walls 11a, 11b between articulating jaw 203 and heat sealer / cutter 206. Heat sealer / cutter 206 applies heat and pressure to heat seal material 31 on walls 11a, 11b, thereby sealing envelope pocket 12 and forming a pocket closure that prevents packaged items from exiting envelope pocket 12.

[0073] The bagging machine 200 may be equipped with a pad 208 attached to and moving with the articulating jaws 203. The pad 208 is configured to compress or squeeze the envelopes 10 as the articulating jaws 203 move inward, and helps to expel air from the envelope pockets 12 before they are sealed. The bagging machine 200 may also include a label printer 210 configured to print labels and apply the labels to the envelopes 10.

[0074] After the envelope 10 is loaded and sealed, the heat sealer / cutter 206 separates the envelope from the web stock 16 along separation line C. Separation can be achieved by any suitable means, such as cutting, applying focused heat along the separation line, or pulling the web stock 16 away from the envelope 10 while sandwiching the envelope 10 between the articulating jaws 203 and the heat sealer / cutter 206. After the loaded envelope 10 is separated from the web stock 16, the envelope 10 can fall onto a conveyor (not shown) or other means for transporting or holding the envelope 10.

[0075] As described above, adhesive materials 24, 34 are applied in a pattern to locations on paper strips 22a, 22b and web 15 corresponding to the respective locations of longitudinal interlayer seals 18, lateral interlayer seals 20, longitudinal interwall seals 26, and lateral interwall seals 28. Alternatively, one or both of adhesive materials 24, 34 can be applied to the respective paper sheets 22a, 22b and / or web 15 by flood coating, followed by activation, e.g., application of heat and / or pressure, at selected locations on paper strips 22a, 22b and / or web 15. In another alternative embodiment, envelope webstock can be formed by C-folding a single web 15.

[0076] The adhesive elements, e.g., adhesive materials 24, 34, can be applied by any suitable known method directly to the exposed surface of the paper strips 22a, 22b or web 15. Alternatively, the adhesive elements can be applied on a tape, such as double-sided tape, or by any other suitable method.

[0077] The adhesive may include adhesive materials that adhere to other types of surfaces. The adhesive may adhere to opposing surfaces without relying on the presence of the same or complementary material on the opposing surface to form a connection between the two layer surfaces.

[0078] Examples of suitable adhesives include liquid adhesives and pressure-sensitive adhesives. Pressure-sensitive adhesives can be selected to bond with the initial application of slight external pressure. Examples of these include water-based acrylic pressure-sensitive adhesives similar to those used in packaging tape. These adhesives secure two surfaces with only surface contact, often with the initial application of slight external pressure. Other examples include dry adhesives. Dry adhesives typically do not require activation by water, solvents, or heat and will adhere well to many different surfaces.

[0079] Pressure-sensitive adhesives can be selected that are strongly and / or permanently tacky at room temperature. The application and use of pressure-sensitive adhesives can be automated. When used in assembly, pressure-sensitive adhesives that do not require setup or long cure times can save time compared to using typical liquid adhesives. Bonding is preferably instantaneous, allowing the manufacturing process to continue uninterrupted, saving significant time and labor. Examples of water-based acrylic pressure-sensitive adhesives include those known as RHOPLEX N-1031 Emulsion, RHOPLEX N-580 Emulsion, and RHOPLEX N-619 Emulsion. Other emulsion polymer or acrylic polymer blend adhesives are also known, and other suitable types of adhesives and / or contact adhesives can be used.

[0080] Adhesive materials include bonding materials that, upon contact with the same or a complementary adhesive, adhere one surface to the opposing surface, forming a bond between the two surfaces. Adhesives may not have sufficient adhesive strength to adhere to other materials, or the adhesion may be very weak compared to the bond formed when adhesives adhere to each other.

[0081] The adhesive may be a pressure-sensitive adhesive, in which case pressure is required to activate the bond. Examples of suitable adhesives include natural and synthetic latex-based adhesives. In some embodiments, the adhesive is applied as a liquid to the appropriate portions of the materials to be bonded, while in other embodiments, it is applied in other known forms. Some types of adhesives, such as those made with latex, are mixed with water without additional adhesive and adhere to the respective non-stick portions of the protective packaging material, remaining attached to the exposed surface material upon application upon drying. In some embodiments, the adhesive can be mixed with an adhesive that is often applied as a liquid onto the material. The adhesive can be selected so that after the adhesive-adhesive mixture is applied to the material, the adhesive evaporates, leaving the adhesive adhered to the non-stick material.

[0082] A heat seal is formed by sealing one thermoplastic to the same or a similar thermoplastic. For example, when sealing or fastening two plastic films together, heat and pressure are applied to the area of ​​the films that will form the seal, and the heat and pressure are sufficient to locally weld the films together in that area.

[0083] A heat seal can be formed between two paper substrates by applying a heat seal material to one of the substrates. When securing the substrates, sufficient heat and pressure are applied to the heat seal material, causing it to fuse to the substrates and secure them together.

[0084] Hot melt adhesives are thermoplastic polymers that are solid at room temperature; they melt when heated above their softening point, resolidify as heat is lost, and gain strength as they resolidify. Most hot melt adhesives do not undergo chemical reactions such as cross-linking or carrier removal (such as water evaporation) when melted to the molten state and resolidify. Therefore, hot melt adhesives can typically be reactivated, i.e., remelted and resolidified, after they are initially applied to a substrate.

[0085] Envelope 10 The above descriptions and features apply equally to the following embodiments unless otherwise specified.

[0086] 5-7 illustrate alternative embodiments in the form of envelopes 40. FIG. 5 illustrates web stock 42 of adjacent envelopes 40. Envelopes 40 are similar to envelope 10 and are formed in a similar manner to envelope 10, except that each envelope 40 includes a slit 44 extending across one wall 46 of the envelope 40 to provide access to an interior storage area in the form of an envelope pocket 47. More specifically, envelope 40 includes two walls 46. Each wall 46 is comprised of two layers 48 of paper material. Slits 44 are formed in both layers 48 of the associated wall 46, as shown in FIG. 7.

[0087] The layers 48 of each wall 46 are joined by longitudinal interlayer seals 50 located at or near the sides of the wall 46, as shown in FIG. 6, and transverse interlayer seals 52 located at the top and bottom of each wall 46, as shown in FIG. 7. The longitudinal interlayer seals 50 and transverse interlayer seals 52 may be formed in a manner similar to the longitudinal interlayer seals 18 and transverse interlayer seals 20 of the envelope 10. In an alternative embodiment, one of the walls 46 may be formed from a single layer 48. As shown in FIG. 7, the layers 48 of each wall 46 define an interlayer region therebetween in the form of an interlayer space 49.

[0088] The walls 46 are joined by longitudinal inter-wall seals 54 located on the sides of the envelope 40, as shown in Figure 6, and by transverse inter-wall seals 56 located at the top and bottom of each wall 46, as shown in Figure 7. The longitudinal inter-wall seals 54 and transverse inter-wall seals 56 may be formed in a manner similar to the longitudinal inter-wall seals 26 and transverse inter-wall seals 28 of the envelope 10.

[0089] Opposing walls 46 define an envelope pocket 47. As shown in FIG. 7 , a slit 44 is formed in one of the walls 46 to provide access to the envelope pocket 47. The slit 44 is positioned directly below the horizontal interlayer seal 54 of the associated wall 46. That is, the slit 44 is positioned immediately to the left of the horizontal interlayer seal 54 from the perspective of FIG. 7 . In alternative embodiments, the slit 44 may be offset longitudinally from the horizontal interlayer seal 54. The slit 44 may extend continuously across substantially the entire width of the wall 46 but stop short of the longitudinal interlayer seal 50 and the longitudinal interwall seal 54. In alternative embodiments, the slit 44 may be discontinuous and / or extend across less than substantially the entire associated wall 46.

[0090] The inwardly facing surface has a strip of heat-seal material 58 disposed thereon. The heat-seal material 58 is disposed on the wall 46 in which the slit 44 is formed, directly below the slit 44. The heat-seal material 48 is disposed on the other wall 46 such that the strips of heat-seal material 48 face each other, as shown in Figure 7. The heat-seal material 58 may be longitudinally offset from the slit 44 in alternative embodiments.

[0091] As previously described, the envelope pocket 47 can accommodate items to be packaged within the envelope 40. The flexibility of the paper wall 46 allows the envelope 40 to be stored and shipped in a substantially flat, compact configuration, with the envelope pocket 47 occupying minimal or substantially no volume. When a user wishes to fill the envelope 40 with items, the envelope pocket 47 can be expanded by separating or pulling apart the walls 46 at or near the top of the envelope pocket 47 and inserting the items to be packaged through the opening defined by the slits 44. Once the items are placed in the envelope 40, the heat seal material 58 on both opposing walls 46 can be heated and pressure can be applied to press the opposing strips of heat seal material 58 together, forming a pocket closure (not shown) that closes and seals the open end of the envelope pocket 47. In an alternative embodiment, the heat seal material 58 can be replaced by a single adhesive band covered with a release strip or a pair of opposing adhesive bands, each covered with a respective release strip, to seal the opening of the envelope pocket 47.

[0092] The envelopes 40 can be separated from the webstock 42 by cutting, severing, or tearing them along a separation line, shown as line "C1" in Figures 5 and 7. The separation line C1 passes through the wall 46, the lateral interlayer seal 52, and the lateral interwall seal 56. As can be seen in Figure 7, the separation line C1 is longitudinally offset from the slit 44. Perforations, cuts, or other means for weakening the separation line C1 may be provided by a separating device to facilitate separation of individual envelopes 40 from the webstock 42 without cutting or otherwise severing the envelopes 40.

[0093] After envelope 40 is separated from web 42, the portions of wall 46, lateral interlayer seal 52, and lateral interwall seal 56 below separation line C1, i.e., to the left of separation line C1 from the perspective of FIG. 7, form the top edge of envelope 40. The portions of wall 46, lateral interlayer seal 52, and lateral interwall seal 56 above separation line C1, i.e., to the right of separation line C1 from the perspective of FIG. 7, form the bottom edge of adjacent envelope 10 that is still attached to web stock 42.

[0094] 8 and 9 show another alternative embodiment in the form of envelope 60. Envelope 60 is shown as a portion of web stock 62 adjacent envelope 60. Envelope 60 is substantially identical to envelope 40, with the following exceptions: Components of envelope 60 that are substantially identical to envelope 40 are referenced using the same reference numerals.

[0095] Each envelope 60 has two slits 44, as opposed to the single slit 44 of envelope 40. Each slit 44 of envelope 60 extends across a respective one of the walls 46 of envelope 60, allowing access to interior envelope pocket 47 of envelope 40 from either side of envelope 40.

[0096] 10-12 illustrate an embodiment of an envelope 80. The envelope 80 is shown as part of the webstock 82 of the envelope 80. The webstock 82 is formed from a two-ply web 84, shown in FIG. 12. The web 84 is comprised of two layers of material joined by longitudinal and transverse interlayer seals (not shown) to form an unfilled interlayer area or space between the layers, as described above with respect to the web 15 of the envelope 10.

[0097] Web stock 82 is formed from web 84 by folding web 84 along fold lines 86a and 86b shown in Figure 12. Fold lines 86a and 86b define a first segment 92a of web 84 located to the left of fold line 86a, a second segment 92b located between fold lines 86a and 86b, and a third segment 92c located to the right of fold line 86b.

[0098] 12, adhesive 88a is disposed on the outer surface of webstock 82 along the longitudinally extending edge of third segment 92c. Additional adhesive 88b is disposed on the outer surface of webstock 82 between folds 86a, 86b. Adhesive 88b extends laterally and is disposed at multiple locations along the length of webstock 82.

[0099] A heat seal material 90 is disposed on the outer surface of the web 84. The heat seal material 90 extends laterally across the entire width of the web 84, with a portion of the heat seal material 90 located directly below the adhesive material 88b.

[0100] Web stock 82 of envelope 80 is formed by folding a first segment 92a of web 84 along crease 86a onto a second segment 92b. When first segment 92a is folded, it contacts adhesive 88b on second segment 92b, forming a lateral inter-wall seal 102 between first segment 92a and second segment 92b.

[0101] The third segment 92c is then folded about crease 86b. As the third segment 92c is folded, it contacts the adhesive 88b on the second segment 92b, forming a horizontal inter-wall seal 103 between the second segment 92b and the third segment 92c. As the third segment 92c is folded, the adhesive 88a on the third segment 92c contacts the longitudinally extending edge of the first segment 92a, forming a vertical inter-wall seal 104 between the first segment 92a and the third segment 92b.

[0102] Lateral and vertical inter-wall seals 102, 103, 104 secure the first, second, and third segments 92a, 92b, 92c together, so that each envelope 80 within the webstock 82 maintains the double-fold configuration shown in FIG. 10. When joined, the first and third segments 92a, 92c form a first wall 94 of the envelope 80. The second segment 92b forms an opposing second wall 96 of the envelope 80, as shown in FIG. 11. The first and second walls 94, 96 define an interior containment area or envelope pocket 98 for the envelope 80.

[0103] 10, the first wall 94 has a slit 100 formed therein. The slit 100 is located directly above the heat seal material 90, i.e., the slit 100 is located between the heat seal material 90 and adjacent lateral inter-wall seals 102, 103.

[0104] As described above with respect to envelope 10, individual envelopes 80 can be separated from their webstock 82 by cutting, severing, or tearing the envelope 80 from the webstock 82, the separation occurring between the heat seal material 90 and the lateral inter-wall seals 102, 103 adjacent the heat seal material 90. The separation line is indicated by line "C2" in FIG. 12. Means for weakening separation line C2 may be provided to facilitate separation of individual envelopes 80 from the webstock 82 without cutting or otherwise severing the envelope 80.

[0105] As described in connection with envelope 10, when a user wishes to stuff an item into envelope 80, the user can expand envelope pocket 98 by separating or pulling apart first wall 94 and second wall 96 at or near the top of envelope pocket 98 and inserting the item to be packaged between first wall 94 and second wall 96. Once the item is placed in envelope 80, heat seal material 90 on opposing first and second walls 94 and 96 can be activated, i.e., heated and pressed together, so that opposing strips of heat seal material 90 form a pocket closure (not shown) upon cooling. The pocket closure can close and seal the open end of envelope pocket 98.

[0106] An alternative embodiment of envelope 80 can be formed by folding web 84 along a single fold line that divides web 84 into two segments, such that the longitudinal edges of each of the two segments are joined by a longitudinal inter-wall seal, with one of the segments forming an entire first wall of the envelope and the second of the segment forming an entire second wall on the opposite side of the envelope.

[0107] 13 illustrates an envelope 110 including a laterally extending sealing strip 112 and an overlying release strip 114. The envelope 110 is shown as part of the webstock 111 of the adjacent envelope 110. The envelope 110 can be formed with any of the features of the envelopes described above, such as the multi-wall, interlayer seal, and interwall seal described above, with the following exceptions: the sealing strip 112 and release strip 114 are provided in place of the heat-activated pocket closures of the envelopes described above, and the envelope 110 has cut-out areas 116 formed therein in place of the slits that provide access to the envelope pockets of the envelopes described above.

[0108] Cutout area 116 is provided by removing an upper portion of wall 120 of envelope 110. Cutout area 116 defines an opening 122 that provides access to an interior storage area or envelope pocket of envelope 110. Cutout area 116 extends from opening 122 to cut line C3 where envelope 110 is separated from adjacent envelopes 110 in webstock 111.

[0109] Cutout area 116 exposes a portion of the inwardly facing surface of opposite wall 126 of envelope 110. Sealing strip 112 is disposed on the exposed portion of the surface of wall 126. Sealing strip 112 is shown as being longitudinally offset from opening 122. In an alternative embodiment, sealing strip 112 may be adjacent to opening 122.

[0110] The portion of wall 126 exposed by cutout area 116 forms flap 130. After an item is inserted into the envelope pocket of envelope 110 through opening 122, release strip 114 can be removed from sealing material 112 and flap 130 can be folded back onto wall 120. Sealing strip 112 includes an adhesive that adheres the exposed sealing strip 112 to wall 120, so that flap 130 covers opening 122. Sealing strip 112, alone or in combination with other sealing materials that may be disposed on wall 120, forms a seal that functions similarly to the pocket closure of the envelope described above, prohibiting access to the envelope pocket through opening 122.

[0111] 14 and 15 show an envelope 130 including a gusset 132 disposed between opposing walls 134 of the envelope 130. The walls 134 define an interior containment area or envelope pocket 135 configured to contain an item to be shipped or stored in the envelope 130. The envelope 130 and alternative embodiments thereof may also be formed with any of the features of the envelopes described above, such as the multi-layer walls, interlayer seals, and interwall seals described above. The gusset 132 is in a folded configuration that allows the envelope 130 to expand significantly, for example, when an item is inserted into the interior envelope pocket 135 of the envelope 130.

[0112] Each gusset 132 is integrally formed with one of the walls 134 of the envelope 130 and is joined to the other walls 134 by one or more inter-wall seals, as disclosed in connection with the previous embodiment. In other embodiments, the gussets 132 are formed separately from the walls 134 and are joined to each of the opposing walls 134 by inter-wall seals.

[0113] FIG. 16 illustrates an envelope 140 including a multi-layer wall 144 configured as follows. The envelope 140 may otherwise include one or more features of the envelopes described above. The wall 144 is comprised of a first layer 148, a second layer 150, and a third layer 152. The region between the first layer 148 and the second layer 150 is substantially empty except for an interlayer seal 153 that connects the first layer 148 to the second layer 150. Thus, the second layer can slide relative to the first layer 148. The region between the second layer 150 and the third layer 152 includes an inflating material 154 applied in an uninflated state to at least one of the second layer 150 and the third layer 152. The second and third layers 150, 152 and the inflating material 154 form another layer that can slide relative to the first layer 148.

[0114] In an alternative embodiment, the region between the first layer 148 and the second layer 150 can include an intumescent material 154 applied in an uninflated state to at least one of the first layer 148 and the second layer 150, and the region between the second layer 150 and the third layer 152 can be substantially empty except for the interlayer seal 153. In another alternative embodiment, the intumescent material 154 can be disposed in both the region between the first layer 148 and the second layer 150 and the region between the second layer 150 and the third layer 152.

[0115] Envelope 140 further includes a single-ply wall 156 opposite wall 144 and joined to wall 144 by an inter-wall seal 158. Walls 144, 156 define an interior containment area or envelope pocket 160 configured to contain items to be held within envelope 140. In an alternative embodiment, wall 156 may be a multi-layer wall and, like wall 144, may be constructed of intumescent material 154.

[0116] The expansion material 154 is configured to assume an expanded configuration when activated by an expansion initiator. The expansion initiator may be, for example, thermal, mechanical, and / or chemical, and / or may include other suitable initiation properties for activating the expansion material 154. Further description of expandable materials suitable for placement within the wall is provided in U.S. Patent Application No. 17 / 365,548, filed July 1, 2021, and entitled "Packaging Using Sealants Having Different Sealing Conditions," the contents of which are incorporated herein by reference in their entirety. In its expanded state, the expansion material provides cushioning for items within the envelope pocket 160.

[0117] FIG. 17 shows webstock 300 being formed into a C-folded envelope 304 by a bag-making machine 302. Webstock 300 is shown alone in FIG. 18 and has substantially the same two-layer construction as web 15, which forms envelope 10. As shown in FIG. 18, instead of the adhesive 34 and heat-seal material 31 that are placed on web 15 to produce webstock 16, which forms envelope 10, heat-seal material 306 is placed on one side of webstock 300. Heat-seal material 306 is applied to the outer surface of one of layers 307 of webstock 300. Heat-seal material 306 is placed in longitudinally extending strips along each side of webstock 300 and in transversely extending strips between the longitudinally extending strips.

[0118] The webstock 300 can be supplied as a roll attached to the supply side of a bag making machine 302, as shown in Figure 17. The webstock 300 can alternatively be supplied in other configurations, such as a fanfold supply configuration.

[0119] The webstock 300 is pulled through opposing guides or rollers 308 of the bag-making machine 302, causing the webstock 300 to fold along the longitudinally extending creases, resulting in a C-folded configuration of the webstock 300. As the webstock 300 is folded in this manner, the longitudinally extending strips of heat-seal material 306 on either side of the webstock 300 face each other, and the horizontally extending strips of heat-seal material 306 fold inward, as shown in FIG.

[0120] As the C-folded web stock 300 moves downward, as indicated by arrow 310, opposing fingers 309 in the loading area of ​​the bag-making machine 302 spread the side edges of the web stock 300 apart, allowing items to be packaged to be inserted into the partially formed envelope 304, as indicated by arrow 311. As described below, a laterally extending strip of heat seal material 306 at the bottom edge of the web stock 300 was activated during the formation of the previous envelope 304, creating a bottom transverse seal that prevents items from falling out after they have been loaded into the partially formed envelope 304.

[0121] The bag making machine 302 includes two opposing arms 310 that reciprocate between an inner position shown in FIG. 17 and an outer position (not shown). The arms 310 move between a lower position shown in FIG. 17 and an upper position (not shown). When in the inner and upper positions, the arms 310 can grasp the bottom edge of the web stock 300, which is aligned with the bottom edge of the partially formed envelope 304. Moving the arms 310 downward subsequently pulls the bottom edge of the web stock 300 and the partially formed envelope 304 downward to the position shown in FIG. 17. The movement of the bottom edge of the web stock 300 advances the web stock 300 through the bag making machine 302. The web stock 300 can be moved by other means in alternative embodiments.

[0122] The bag making machine 302 further includes a cutting and sealing unit 312 having two opposing arms 314 that reciprocate between an inner position shown in Figure 17 and an outer position (not shown). The cutting and sealing unit 312 also includes two L-shaped sealer cutters 316 mounted on each end of the arms 314.

[0123] As arm 310 pulls the bottom end of web stock 300 and partially formed envelope 304 downward to the position shown in FIG. 17, arm 314 of cut and seal unit 312 moves to an inward position and sealer cutter 316 contacts partially formed envelope 304.

[0124] The L-shaped configuration of the sealer cutter 316 aligns the sealer cutter 316 with the longitudinally extending strips of heat-seal material 306 that are opposed to each other by the C-fold configuration of the web stock 300. Similarly, the L-shaped configuration of the sealer cutter 316 aligns the sealer cutter 316 with the top strip of horizontally extending heat-seal material 306 that is folded inward by the C-fold configuration of the web stock 300. The sealer cutter 316 heats and compresses the opposing heat-seal material 306 to form a longitudinally extending seal along one side of the envelope 304 and a horizontally extending seal along the top of the newly formed envelope 304, the bottom of which was already formed during the production of the previous envelope 304.

[0125] Rollers may be included to help bring the longitudinally extending bands of heat seal material 306 into contact with one another.

[0126] Once the longitudinal and transverse seals are formed, the sealer cutter 316 can separate the newly formed envelope 304 from the webstock 300 by any suitable means, such as cutting, applying focused heat along the separation line, or pulling the envelope 304 away from the webstock 300. Because the separation line runs through the upper, transversely extending strip of heat seal material 306, the portion of this strip remaining on the webstock 300 after the cutting process forms the bottom transverse seal of the next envelope 304 formed from the webstock 300.

[0127] Once the newly formed and loaded envelope 304 is separated from the web stock 300, it may fall onto a conveyor (not shown) or other means for transporting or holding the envelope 304.

[0128] The above description of bag making machine 302 is presented for illustrative purposes only, and C-fold envelope 304 and its alternative embodiments may be formed using other types of bag making machines.

[0129] FIG. 19 shows web stock 330 for side-loading envelope 332. Web stock 330 is formed from two webs 334. Each web 334 is of substantially the same two-ply construction as web 15 forming envelope 10. Webs 334 are joined by one longitudinal inter-wall seal 336 that extends continuously along one side of web stock 330 and multiple transverse inter-wall seals 338 that extend across web stock 330 to form web sock 330. Individual envelopes 332 are separated from web stock 330 by separation lines that pass through each transverse inter-wall seal 338.

[0130] Each envelope 332 in the web stock 330 includes two opposing walls 340 that define an envelope pocket 342 in the envelope 332. The ends of the envelope pocket 342 on the unsealed side of the web stock 330 are open so that an item to be packaged can be inserted into the envelope pocket 342 manually or by an automated machine, as indicated by arrow 344. Once the item is inserted, a heat seal material 346 on the inward-facing surface of one or both walls 340 is activated to seal the envelope pocket 342 and prevent the packaged item from leaving the envelope pocket 342.

[0131] Once the envelope pocket 342 is sealed, the loaded envelope 332 can be separated from the web stock 330 by suitable means such as heating, application of concentrated heat, pulling, or the like.

[0132] While the present solution has been illustrated and described with respect to one or more embodiments, equivalent changes and modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. Moreover, while certain features of the present solution are disclosed only with respect to one of several embodiments, such features can be combined with one or more other features of other embodiments as desired and advantageous for any particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above-described embodiments. Rather, the scope of the present solution should be defined according to the following claims and their equivalents.

Claims

1. a first flexible wall; a second flexible wall overlying the first flexible wall and secured to the first flexible wall around a containment boundary that surrounds multiple sides of a containment area defined by the first and second flexible walls, the containment area being configured to contain items; the second flexible wall includes at least two overlapping paper layers secured to one another around an interlayer boundary surrounding multiple sides of an interlayer region defined by the at least two overlapping paper layers; the at least two overlapping paper layers are not bonded to one another in at least a portion of the interlayer region; An envelope for containing the item, wherein the interlayer area is substantially empty and the at least two overlapping paper layers abut each other over a majority of the interlayer area.

2. The envelope of claim 1 , wherein the interlayer area overlaps more than about half of the receiving area.

3. 3. The envelope of claim 2, wherein the interlayer area overlaps greater than about 75% of the receiving area.

4. 4. The envelope of claim 3, wherein the interlayer area overlies substantially the entire receiving area.

5. The envelope of claim 1 , wherein the at least two overlapping paper layers are slidable relative to one another over a majority of the interlayer area.

6. 10. The envelope of claim 1, wherein the receiving area is accessible through an opening defined by the first and second flexible walls, and the envelope further includes a joining element disposed on at least one of the first and second flexible walls and configured to secure the first flexible wall to the second flexible wall to close the opening.

7. 7. The envelope of claim 6, wherein the opening is defined by a slit formed in the plurality of overlapping paper layers of the second flexible wall.

8. 8. The envelope of claim 7, wherein the slit is immediately adjacent to the joining element.

9. 7. The envelope of claim 6, wherein the bonding element is a heat seal material.

10. The envelope of claim 6, wherein the bonding element is an adhesive material.

11. 8. The envelope of claim 7, wherein the slit is a first slit and the opening is further defined by a second slit formed in the first flexible wall.

12. 10. The envelope of claim 1, wherein the first flexible wall includes at least two overlapping paper layers secured to one another around an interlayer boundary surrounding multiple sides of an interlayer area defined by the at least two overlapping paper layers of the first flexible wall.

13. the first flexible wall includes at least one interlayer seal configured to secure the at least two overlapping paper layers together; The envelope of claim 12 , wherein the at least one interlayer seal defines at least a portion of the interlayer boundary.

14. 14. The envelope of claim 13, further comprising at least one inter-wall seal configured to secure the first and second walls together, the at least one inter-wall seal defining at least a portion of the containment boundary.

15. 15. The envelope of claim 14, wherein the at least one interlayer seal overlies the at least one interwall seal.

16. the at least one inter-wall seal is a first inter-wall seal; the envelope further includes a second inter-wall seal; the first inter-wall seal extends along a first side of each of the first and second flexible walls; the second inter-wall seal extends along a second side of each of the first and second flexible walls; the storage area is accessible through an opening defined by the first and second walls; 15. The envelope of claim 14, wherein the opening extends between the first and second inter-wall seals.

17. The envelope of claim 1 , wherein the second flexible wall includes a first portion adjacent the first flexible wall along a first fold line.

18. the second flexible wall further includes a second portion adjacent the first flexible wall along a second fold line; 18. The envelope of claim 17, wherein an end of the second portion overlaps and is attached to an end of the first portion.

19. 10. The envelope of claim 1, wherein the second flexible wall includes at least first, second, and third layers of paper, the interlayer area being disposed between the first layer and the second layer, and the envelope further including an expandable material disposed between the second layer and the third layer.

20. The envelope of claim 1 further comprising gussets adjacent the first and second flexible walls.

21. 10. A web stock comprising a plurality of envelopes according to claim 1, each envelope being adjacent to an adjacent envelope.

22. 22. The web stock of claim 21, wherein each envelope is adjacent to an adjacent envelope along an area of ​​weakness between the adjacent envelopes.

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