Patent Publication Number: US-2023150748-A1

Title: Cushioned mailer

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. Application No. 17/177,908, filed Feb. 17, 2021, which claims the benefit of U.S. Provisional Application No. 63/059,001, filed Jul. 30, 2020, each of which is hereby specifically incorporated by reference herein in its entirety. The present application further claims the benefit of U.S. Provisional Application No. 63/302,802, filed Jan. 25, 2022, which is hereby specifically incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to cushioning materials. More specifically, this disclosure relates to a sheet with cushioning inserts. 
     BACKGROUND 
     Cushioning sheets, such as wrapping paper and bubble wrap, are often used as cushioning for fragile objects during shipping. Wrapping paper typically comprises a single, thin sheet of paper that can be bunched up and packed around the object to limit movement of the object within a package and to provide cushioning from heavy impacts. However, wrapping paper easily crumples under force, and, once crumpled, can lose its volume and effectiveness. Bubble wrap typically comprises a plastic sheet defining air fill pockets. However, typical plastic bubble wrap is not recyclable. 
     SUMMARY 
     It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended neither to identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description. 
     Disclosed is a cushioned sheet comprising a first layer comprising a first base and a plurality of first sockets extending from the first base, each of the first sockets spaced apart from adjacent ones of the first sockets; a second layer coupled to the first layer by an adhesive, the second layer comprising a second base and a plurality of second sockets extending from the second base, each of the second sockets aligned with a corresponding one of the first sockets to define a void therebetween; and a plurality of cushioning inserts, each of the plurality cushioning inserts substantially spherical in shape and received in a corresponding one of the voids. 
     Also disclosed is a cushioned mailer comprising a first layer defining a plurality of first sockets; a second layer defining a plurality of second sockets, each of the first sockets aligned with a corresponding one of the second sockets to define a void therebetween; and a cushioning insert received within each of the voids; wherein the first layer is coupled to the second layer to define a cushioning sheet, the cushioning sheet defining an inner cavity configured to receive contents, the inner cavity at least partially surrounded by the first layer, the second layer facing away from the inner cavity. 
     Additionally, a method of forming a cushioning sheet is disclosed, the method comprising forming a plurality of first sockets in a first layer; forming a plurality of second sockets in a second layer, each of the second sockets corresponding to a one of the first sockets; positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets; and coupling the first layer to the second layer. 
     A cushioned mailer is disclosed, the cushioned mailer comprising a paper outer layer; a paper inner layer defining an inner cavity of the cushioned mailer, the inner cavity configured to receive contents therein, the inner cavity defining an opening at a top end of the cushioned mailer, the opening allowing access to the inner cavity; and an intermediate cushioning layer disposed between the paper outer layer and the paper inner layer, the intermediate cushioning layer comprising a plurality of cushioning inserts, each of the plurality of cushioning inserts being substantially uniform in size and shape. 
     Furthermore, disclosed is a cushioned mailer comprising a paper outer layer; a paper inner layer defining an inner cavity of the cushioned mailer, the inner cavity configured to receive contents therein, the inner cavity defining an opening at a top end of the cushioned mailer, the opening allowing access to the inner cavity; and an intermediate cushioning layer disposed between the paper outer layer and the paper inner layer, the intermediate cushioning layer comprising a textured paper sheet defining a plurality of cushioning sockets. 
     Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity. 
         FIG.  1    is a top perspective view of a first paper layer, in accordance with one aspect of the present disclosure. 
         FIG.  2    is a bottom perspective view of a second paper layer, in accordance with another aspect of the present disclosure. 
         FIG.  3    is a top perspective view of a layer rolling device or forming the first paper layer of  FIG.  1    and the second paper layer of  FIG.  2   . 
         FIG.  4    is a top view of a plurality of spherical cushioning inserts, in accordance with another example aspect of the present disclosure. 
         FIG.  5    is a top perspective view of the spherical cushioning inserts of  FIG.  4    applied to the first paper layer of  FIG.  1   . 
         FIG.  6    is a perspective view of a vacuum roller configured to deposit the spherical cushioning inserts of  FIG.  4    onto the first paper layer of  FIG.  1   . 
         FIG.  7    is a top perspective view of the second paper layer of  FIG.  2    laid over the first paper layer 1of  FIG.  1   , such that the spherical cushioning inserts of  FIG.  4    are received between the first and second paper layers. The first paper layer, second paper layer, and spherical cushioning inserts can together define a cushioning sheet, in accordance with another aspect of the present disclosure. 
         FIG.  8    is a detail cross-sectional view of the cushioning sheet of  FIG.  7    taken along line 8-8 in  FIG.  7   . 
         FIG.  9    is a perspective view of sheet rolling device configured to assist in adhering the first paper layer of  FIG.  1    to the second paper layer of  FIG.  2   , in accordance with another aspect of the present disclosure. 
         FIG.  10    is a top view of the cushioning sheet of  FIG.  7    after going through the sheet rolling device of  FIG.  9   . 
         FIG.  11    is a bottom view of the cushioning sheet of  FIG.  7    after going through the sheet rolling device of  FIG.  9   . 
         FIG.  12    is a top view of the spherical cushioning inserts, in accordance with another example aspect of the present disclosure. 
         FIG.  13    is a top perspective view of the spherical cushioning inserts of  FIG.  12    applied to the first paper layer, in accordance with another example aspect of the present disclosure. 
         FIG.  14    is rear perspective view of a rolling machine for forming the cushioning sheet of  FIG.  7   , in accordance with another example aspect of the present disclosure. 
         FIG.  15 A  is a front perspective view of the rolling machine of  FIG.  14   . 
         FIG.  15 B  is a cross-sectional view of the rolling machine of  FIG.  14    taken along line 15-15 in  FIG.  15 A . 
         FIG.  15 C  is a cross-sectional view of an adhesive applicator of the rolling machine of  FIG.  14   . 
         FIG.  16    is a detail perspective view of a roller assembly of the rolling machine of  FIG.  14   . 
         FIG.  17    is a front view of a cushioned mailer comprising the cushioning sheet of  FIG.  7   , in accordance with another example aspect of the present disclosure. 
         FIG.  18    is a front view of contents being inserted into an inner cavity of the cushioned mailer of  FIG.  17   . 
         FIG.  19    is a front view of the cushioned mailer of  FIG.  17    in an unfolded configuration. 
         FIG.  20    is a front perspective view of the cushioned mailer, in accordance with another aspect of the present disclosure, wherein the cushioned mailer is formed as a textured mailer. 
         FIG.  21    is a top plan view of an outer layer of the textured mailer of  FIG.  20   . 
         FIG.  22    is a top plan view of an inner layer of the textured mailer of  FIG.  20   . 
         FIG.  23 A  is a cross-section view of the textured mailer of  FIG.  20   , taken along line 23-23 in  FIG.  20   . 
         FIG.  23 B  is a cross-sectional view of the textured mailer in accordance with another aspect of the present disclosure. 
         FIG.  24    is a top perspective view of the textured mailer of  FIG.  20   . 
         FIG.  25    is a rear perspective view of the textured mailer of  FIG.  20   . 
         FIG.  26 A  is a detail view of the textured mailer of  FIG.  20   , showing example dimensions thereof. 
         FIG.  26 B  is another detail view of the textured mailer of  FIG.  20   , showing example dimensions thereof. 
         FIG.  27    is a top plan view of a first sheet comprising a plurality of the outer layers of  FIG.  21    and a second sheet comprising a plurality of the inner layers of  FIG.  22   , in accordance with an example aspect of the present disclosure. 
         FIG.  28    is a top perspective view of the first sheet of  FIG.  27   . 
         FIG.  29    is a top perspective view of the second sheet of  FIG.  27   . 
         FIG.  30    is a top plan view of the first sheet and the second sheet, in accordance with another example aspect of the present disclosure. 
         FIG.  31    is a front view of the cushioned mailer in accordance with another aspect of the present disclosure. 
         FIG.  32    is a close-up view of Detail A taken from  FIG.  31   . 
         FIG.  33    is a perspective view of a bottom end of the cushioned mailer of  FIG.  31   . 
         FIG.  34    is a cross sectional view of the cushioned mailer of  FIG.  31    taken along line 34-34 in  FIG.  31   . 
         FIG.  35    is a close-up view of Detail B taken from  FIG.  34   . 
         FIG.  36    is a cross-sectional view of the cushioned mailer in accordance with another example aspect of the present disclosure. 
         FIG.  37    is a perspective view of the rolling machine in accordance with another aspect of the present disclosure. 
         FIG.  38    is a front view of a schematic of the rolling machine of  FIG.  37   . 
         FIG.  39    is a perspective view of the vacuum roller in accordance with another aspect of the present disclosure. 
         FIG.  40    is a cross-sectional view of the vacuum roller of  FIG.  39    taken along line 40-40 in  FIG.  39   . 
         FIG.  41    is a cross-sectional view of the cushioning sheet in accordance with another example aspect of the present disclosure, taken along line 41-41 in  FIG.  37   . 
         FIG.  42    is a cross-sectional view of the cushioning sheet in accordance with another example aspect of the present disclosure. 
         FIG.  43    is a top view of a schematic of the rolling machine of  FIG.  37   . 
         FIG.  44    is a front perspective view of the cushioned mailer in accordance with another example aspect of the present disclosure, wherein the cushioned mailer is in an unsealed configuration. 
         FIG.  45    is another front perspective view of the cushioned mailer of  FIG.  44   , where a portion of an outer layer of the cushioned mailer is peeled back. 
         FIG.  46    is a top perspective view of the cushioned mailer of  FIG.  44   . 
         FIG.  47    is a front perspective of the cushioned mailer of  FIG.  44    in a sealed configuration. 
         FIG.  48    is a front view of a closure flap of the cushioned mailer in accordance with another example aspect of the disclosure. 
         FIG.  49    is a rear perspective view of the closure flap of  FIG.  48   . 
         FIG.  50    is a front perspective view of the closure flap of  FIG.  48   . 
         FIG.  51    is a from view of the cushioned mailer in accordance with another aspect of the present disclosure, where a portion of the outer layer is peeled back. 
         FIG.  52    is a close-up view of a textured sheet in accordance with another aspect of the present disclosure. 
         FIG.  53    is a top view of the outer layer of the cushioned mailer in a blank configuration, in accordance with another aspect of the present disclosure. 
         FIG.  54    is a front view of the cushioned mailer comprising the outer layer of  FIG.  53   . 
         FIG.  55    is a cross-sectional view of the cushioned mailer of  FIG.  54    taken along line 55-55 in  FIG.  54   . 
         FIG.  56    is a front view of the cushioned mailer comprising the outer layer of  FIG.  53    in accordance with another aspect of the disclosure. 
         FIG.  57    is a cross-sectional view of the cushioned mailer of  FIG.  56    taken along line 57-57 in  FIG.  56   . 
         FIG.  58    is a is a top view of the outer layer of the cushioned mailer in the blank configuration, in accordance with another aspect of the present disclosure. 
         FIG.  59    illustrates an exploded view of the cushioned mailer, in accordance with another aspect of the present disclosure. 
         FIG.  60    is a cross-sectional view of the cushioned mailer taken along line 60-60 in  FIG.  55   . 
         FIG.  61    is an exploded view of the textured sheet utilized in another packing application, in accordance with another aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. 
     The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof. 
     As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” can include two or more such elements unless the context indicates otherwise. 
     Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. 
     For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances. 
     As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. 
     The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect. 
     Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutations of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods. 
     Disclosed is a cushioning sheet and associated methods, systems, devices, and various apparatus. Example aspects of the cushioning sheet can comprise a first layer, a second layer, and a plurality of cushioning inserts received between the first layer and the second layer. In some aspects, the cushioning inserts can be substantially spherical in shape and can comprise a starch material. It would be understood by one of skill in the art that the cushioning sheet is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom. 
       FIG.  1    is a top perspective view of a first layer  100  of a cushioning sheet  700  (shown in  FIG.  7   ), in accordance with one aspect of the present disclosure. According to example aspects, the cushioning sheet  700  can be formed by a rolling machine  1400  (shown in  FIG.  14   ). In the present aspect, the first layer  100  can comprise a paper material and can therefore be a first paper layer  110 . In some aspects, the paper material can be a tissue-grade paper material, which may be covered with a coating to increase strength while maintaining flexibility. In other aspects, the first layer  100  can comprise any other suitable material known in the art. As shown, according to example aspects, the first paper layer  110  can comprise a substantially planar first base  120  defining a first upper surface  122  and a first lower surface  824  (shown in  FIG.  8   ). The first paper layer  110  can further define a plurality of first sockets  130  extending substantially downward from the first lower surface  824  of the planar first base  120 , relative to the orientation shown. In the present aspect, each of the first sockets  130  can be formed as a substantially semi-spherical dome and can define a substantially semi-spherical first recess  132 . As shown, each of the first sockets  130  are substantially uniform in size and shape, and each of the first recesses  132  are substantially uniform in size and shape. Each of the first sockets  130  can further define a substantially circular first opening  134  formed at the planar first base  120  that can allow access to the corresponding semi-spherical first recess  132 . In the present aspect, each of the first sockets  130  can be spaced apart from adjacent first sockets  130 , and the first sockets  130  can be oriented in a plurality of linear rows and columns; however, in other aspects, the first sockets  130  can be oriented in any other suitable arrangement or pattern. 
       FIG.  2    illustrates a second layer  200  of the cushioning sheet  700  (shown in  FIG.  7   ), in accordance with an aspect of the present disclosure. Like the first layer  100  (shown in  FIG.  1   ), the second layer  200  can comprise a paper material and can therefore be a second paper layer  210 . However, in other aspects, the second layer  200  can comprise any other suitable material known in the art, and may or may not comprise the same material as the first layer  100 . Example aspects of the second paper layer  210  can be substantially similar as the first paper layer  110  (shown in  FIG.  1   ), as described above. For example, the second paper layer  210  can comprise a substantially planar second base  220  defining a second upper surface  722  (shown in  FIG.  7   ) and a second lower surface  224 . The second paper layer  210  can further comprise a plurality of second sockets  230  extending from the planar second base  220 . However, unlike the first paper layer  110 , wherein the first sockets  130  (shown in  FIG.  1   ) can extend substantially downward from the first lower surface  824  (shown in  FIG.  1   ), the second sockets  230  can extend substantially upward from the second upper surface  722  of the second base  220 , relative to the orientation shown. In the present aspect, each of the second sockets  230  can be formed as a substantially semi-spherical dome and can define a substantially semi-spherical second recess  232 . As shown, each of the second sockets  230  are substantially uniform in size and shape, and each of the second recesses  232  are substantially uniform in size and shape. Each of the second sockets  230  can further define a substantially circular second opening  234  formed at the planar second base  220  that can allow access to the corresponding semi-spherical second recess  232 . In the present aspect, each of the second sockets  230  can be spaced apart from adjacent second sockets  230 , and the second sockets  230  can be oriented in a plurality of linear rows and columns; however, in other aspects, the second sockets  230  can be oriented in any other suitable arrangement or pattern. According to example aspects, the second sockets  230  and second recesses  232  of the second paper layer  210  can be substantially similar in size, shape, and arrangement to the first sockets  130  and first recesses  132  (shown in  FIG.  1   ) of the first paper layer  110 . 
     In some example aspects, as shown, an adhesive  240  may be applied to the second lower surface  224  of the planar second base  220 . The adhesive  240  can be configured to secure the second layer  200  to the first layer  100 , as described in further detail below. In other aspects, the adhesive  240  may instead be applied to the first upper surface  122  (shown in  FIG.  1   ) of the planar first base  120  (shown in  FIG.  1   ). In the present aspect, a thin film or layer of the adhesive  240  can be applied to the second lower surface  224 ; in other aspects, however, a substantially thick film or layer of the adhesive  240  may be applied. According to example aspects, the adhesive  240  can comprise a starch material, which can be repulpable in some aspects. For example, the adhesive  240  can be a thin film of a starch paste  242 . In other aspects, the adhesive  240  can be any other suitable adhesive, including but not limited to, plastic adhesives, tape, and the like. As shown, in the present aspect, the adhesive  240  is applied to the second lower surface  224  only though in other aspects, the adhesive  240  may also be applied within the second sockets  230 . Furthermore, while the adhesive  240  is depicted herein as covering only select portions of the second lower surface  224  of the planar second base  220 , in other aspects, the adhesive  240  may substantially or entirely cover the second lower surface  224 . 
       FIG.  3    illustrates a layer rolling device  300  for forming the first and second sockets  130 , 230  of the first and second layers  100 , 200  (shown in  FIGS.  1  and  2   , respectively). As shown, the layer rolling device  300  can comprise a first layer roller  310  and a second layer roller  320 . Each of the first and second layer rollers  310 , 320  can be substantially cylindrical in shape and can define a cylindrical outer surface  312 , 322 , respectively. The first layer roller  310  can define a plurality of semi-spherical socket indentations  314  formed in the corresponding cylindrical outer surface  312 , each of which can be substantially uniform in size and shape. The second layer roller  320  can define a plurality of semi-spherical socket projections  324  extending from the corresponding cylindrical outer surface  322 , each of which can be substantially uniform in size and shape, and which can be configured to fit within a corresponding one of the socket indentations  314 . According to example aspects, the first layer roller  310  and second layer roller  320  can be configured to rotate in unison, as each of the first layer  100  and second layer  200  are fed through the layer rolling device  300  between the first and second layer rollers  310 , 320 . Prior to passing through the layer rolling device  300 , each of the first and second layers  100 , 200  can be substantially planar. In some aspects, the first and second sockets  130 , 230  of the first and second layers  100 , 200  can be formed simultaneously by feeding the first and second layers  100 , 200  through the layer rolling device  300  at the same time, one on top of the other. However, in other aspects, such as the present aspect, the first layer  100  can be formed first, followed by the second layer  200 , or vice versa. 
     In example aspects, each of the socket indentations  314  of the first layer roller  310  can be configured to align with a corresponding one of the socket projections  324  of the second layer roller  320  as the first and second layer rollers  310 , 320  confront one another during rolling. Each of the socket projections  324  can be configured to push a corresponding portion of the first layer  100  and second layer  200  into the corresponding one of the socket indentations  314  to form the first sockets  130  and second sockets  230 , respectively. As such, each of the socket indentations  314  can be sized and shaped about equal to the first and second sockets  130 , 230 , and each of the socket projections  324  can be sized and shaped about equal to the first and second recesses  132 , 232  (shown in  FIGS.  1  and  2   , respectively). Furthermore, as the first and second layers  100 , 200  are fed through the layer rolling device  300 , the portions of the cylindrical outer surfaces  312 , 322  of the first and second layer rollers  310 , 320  extending between the socket indentations  314  can press the planar first base  120  and planar second base  220  (shown in  FIGS.  1  and  2   , respectively) therebetween to maintain the flat, planar shape thereof. 
       FIG.  4    illustrates a plurality of cushioning inserts  400  configured to be received between the first and second layers  100 , 200  (shown in  FIGS.  1  and  2   , respectively), as described in further detail below. In the present aspect, each of the cushioning inserts  400  can define a substantially spherical shape, as shown. Moreover, in the present aspect, each of the cushioning inserts  400  can comprise a starch material, such that the cushioning inserts  400  can be starch cushioning inserts  410 . For example, the starch material can comprise corn starch in some aspects. In other aspects, the cushioning inserts  400  may define any other suitable shape and/or may comprise any other suitable starch material or other material known in the art. The cushioning inserts  410  can further be repulpable in some aspects. According to example aspects, the cushioning inserts  400  can be formed by an extrusion process, followed by a chopping process. In some example aspects, in the extrusion process, the corn starch material can be extruded through a chamber with a small amount of moisture. The moisture can vaporize under heat during the extrusion, and an elongated, continuous tube of corn starch material can be formed. In the chopping process, a cutter can cut the tube of corn starch material into short segments, each of which can puff up and harden and cool into a substantially spherical shape. In the present aspect, each of the spherical cushioning inserts  400  can define a diameter Di of about .375 inches. However, in other aspects, the cushioning inserts  400  can define any other suitable size and shape and/or can be formed by any other suitable processes known in the art. 
       FIG.  5    illustrates a first step in assembling the cushioning sheet  700  of  FIG.  7   . As shown, each of the spherical cushioning inserts  400  can be placed into a corresponding one of the semi-spherical first sockets  130  of the first paper layer  110 , such that each of the spherical cushioning inserts  400  is partially received within a corresponding one of the semi-spherical first recesses  132  and can rest on a bottom  532  of the first socket  130 . For example, a lower portion  502  of each spherical cushioning insert  400  can be received within the corresponding first recess  132 , while an upper portion  504  of the spherical cushioning insert  400  can extend past the corresponding first opening  134  to be oriented outside of the first recess  132 . In the present aspect, the spherical cushioning inserts  400  can be sized such that a clearance is provided between the each of the spherical cushioning inserts  400  and corresponding sides  534  of the semi-spherical first socket  130 , as shown. As such, each of the spherical cushioning inserts  400  can be free to roll around within the corresponding semi-spherical first recess  132 . In some aspects, however, the clearance defined between the spherical cushioning inserts  400  and the sides  534  of the corresponding semi-spherical first sockets  130  may be reduced such that movement of the cushioning inserts  400  within the corresponding semi-spherical first recesses  132  may be limited or prohibited. Furthermore, in some aspects, the spherical cushioning inserts  400  may be secured to the first paper layer  110  within the corresponding first recesses  132  to limit or prohibit movement therein by a fastener, such as, for example, an adhesive, such as glue. For example, the glue can be PVA (polyvinyl acetate) glue in some aspects. 
     According to example aspects, as shown in  FIG.  6   , a vacuum roller  600  may be provided for picking up the spherical cushioning inserts  400  (shown in  FIG.  4   ) and depositing them onto the first paper layer  110  (shown in  FIG.  1   ). As shown, in the present aspect, the vacuum roller  600  can define a substantially cylindrical outer surface  602  and a plurality of insert indentations  604  formed therein, each of which can be configured to pick up and retain one of the spherical cushioning inserts  400  therein. For example, each of the insert indentations  604  may comprise a vacuum port  606  configured to draw a corresponding one of the cushioning inserts  400  into the insert indentation  604 . Each spherical cushioning insert  400  can then be released from the corresponding insert indention into a corresponding one of the first recesses  132  (shown in  FIG.  1   ) of the first paper layer  110 . In other aspects, the spherical cushioning inserts  400  can be deposited into the corresponding first recesses  132  by any other suitable method known in the art. In other aspects, the cushioning inserts  400  can be deposited by the vacuum roller  600  or any other suitable method into the second recesses  232  (shown in  FIG.  2   ) of the second paper layer  210  (shown in  FIG.  2   ), instead of the first paper layer  110 . 
       FIGS.  7  and  8    illustrate a second step in forming the cushioning sheet  700 , wherein the second layer  200  can be laid over the first layer  100  (shown in  FIG.  8   ), or vice versa, with the spherical cushioning inserts  400  (shown in  FIG.  8   ) received therebetween. As such, in the present aspect, the first layer  100  can be a lower layer and the second layer  200  can be an upper layer, relative to the orientations shown. Referring to  FIG.  8   , the first layer  100 , second layer  200 , and spherical cushioning inserts  400  can together define the cushioning sheet  700 . In the present aspect, the first layer  100  can be the first paper layer  110 , the second layer  200  can be the second paper layer  210 , and the cushioning sheet  700  can be wrapping paper  800  within which an object can be wrapped for cushioned protection. As shown, the second paper layer  210  can be positioned over the first paper layer  110  such that each of the second sockets  230  of the second paper layer  210  can be aligned with a corresponding one of the first sockets  130  of the first paper layer  110 . Each corresponding pair of first and second sockets  130 , 230  can together define a hollow, substantially spherical void  830  or bubble. 
     The spherical void  830  can comprise the corresponding semi-spherical first recess  132  and semi-spherical second recess  232 , and each of the cushioning inserts  400  can reside between a corresponding pair of first and second sockets  130 , 230  within the spherical void  830 . As shown, the lower portion  502  of the cushioning insert  400  can generally reside within the corresponding first recess  132  and the upper portion  504  of the cushioning insert  400  can generally reside within the corresponding second recess  232 . In the present aspect, a diameter of each void  830  can be larger than the diameter D 1  (shown in  FIG.  4   ) of the corresponding cushioning insert  400  and each of the cushioning inserts  400  can be received loosely within the void  830 , allowing the cushioning insert  400  to move around within the void  830 . In other aspects, the size of the voids  830  may be about equal to the size of the cushioning inserts  400  and/or the cushioning inserts  400  may be secured within the void  830  to limit or prohibit movement therein. Other aspects of the cushioning sheet  700  may not comprise the cushioning inserts  400 , and the voids  830  can be filled with any other suitable cushioning material. In other aspects, the voids  830  can be filled with air (or any other suitable gas), such that a plurality of cushioning air pockets can be formed between the first and second layers  100 , 200 . In such aspects, the first and second layers  100 , 200  may comprise a specific paper material that can be configured to limit or prevent the air from leaking out of the voids  830 . In some aspects, the first and second layers  100 , 200  can comprise a stretchy paper material. In some aspects, the first and second layers  100 , 200  can be coated in a material configured to limit or prevent the passage of air therethrough. Other aspects of the first and second layers  100  can comprise any suitable material, including paper and non-paper materials, configured to limit or prevent the passage of air therethrough. 
     As described above, example aspects of the second paper layer  210  can comprise an adhesive  240  (shown in  FIG.  2   ) applied to the second lower surface  224  thereof. The second lower surface  224  of the second paper layer  210  can engage the first upper surface  122  of the first paper layer  110 , and the adhesive  240  can join the second lower surface  224  to the first upper surface  122 , thereby securing the first and second paper layers  110 , 210  together. In some aspects, the second step of applying the second paper layer  210  over the first paper layer  110  can be the final step in forming the cushioning sheet  700 . However, in other aspects, a third step can comprise passing the cushioning sheet  700  through a sheet rolling device  900  (shown in  FIG.  9   ). As described above, the adhesive  240  can be repulpable in some aspects. In some example aspects, additional components of the cushioning sheet  700 , or the entire cushioning sheet  700 , can comprise repulpable materials. 
       FIG.  9    illustrates the sheet rolling device  900 , which can be provided for pressing the planar first base  120  of the first paper layer  110  (both  110  and  120  shown in  FIG.  1   ) against the planar second base  220  of the second paper layer  210  (both  210  and  220  shown in  FIG.  2   ) to ensure that the adhesive  240  (e.g., the starch paste  242 , both  240  and  242  shown in  FIG.  2   ) secures the first and second paper layers  110 , 210  to one another. As shown, the sheet rolling device  900  can define a first sheet roller  910  and a second sheet roller  920 . Each of the first and second sheet rollers  910 , 920  can define a cylindrical outer surface  912 , 922 , respectively and a plurality of semi-spherical indentations  914 , 924 , respectively, which can be sized about equal to or greater than each of the first and second sockets  130 , 230 . The first and second sheet rollers  910 , 920  can be configured to rotate in unison, as the cushioning sheet  700  (e.g., the wrapping paper  800 ), both shown in  FIG.  8   , is fed through the sheet rolling device  900  between the first and second sheet rollers  910 , 920 . According to example aspects, each of the indentations  914  of the first sheet roller  910  can be configured to align with a corresponding one of the indentations  924  of the second sheet roller  920  as the first and second sheet rollers  910 , 920  confront one another during rolling. As the cushioning sheet  700  is fed through the sheet rolling device  900 , each of the first sockets  130  (shown in  FIG.  1   ) of the first paper layer  110  can align with and extend into a corresponding one of the indentations  914  of the first sheet roller  910 , and similarly, each of the second sockets  230  (shown in  FIG.  2   ) of the second paper layer  210  can align with and extend into a corresponding one of the indentations  924  of the second sheet roller  920 . In this way, each of the semi-spherical first and second sockets  130 , 230 , as well as the spherical voids  830  (shown in  FIG.  8   ) formed by the first and second sockets  130 , 230 , can maintain their shapes as the cushioning sheet  700  is passed through the sheet rolling device  900 . 
     Furthermore, as the cushioning sheet  700  is fed through the sheet rolling device  900 , the portions of cylindrical outer surfaces  912 , 922  of the first and second sheet rollers  910 , 920  extending between the indentations  914 , 924  can be configured to contact the planar first and second bases  120 , 220  of the first and second paper layers  110 , 210 , respectively. The first and second sheet rollers  910 , 920  can press the first upper surface  122  (shown in  FIG.  1   ) of the first paper layer  110  against the second lower surface  224  (shown in  FIG.  2   ) of the second paper layer  210 , such that the adhesive  240  applied to the second lower surface  224  firmly engages the first upper surface  122 , thereby further securing the first and second paper layers  110 , 210  together. As described above, in some aspects, a substantially thin film or layer of the adhesive  240  can be applied to the second lower surface  224 . However, in some aspects, the film or layer of adhesive  240  can be thick enough such that some of the adhesive  240  may be pressed into some or all of the voids  830 , forming an adhesive ring around the corresponding cushioning insert  400  (shown in  FIG.  4   ) therein, which can aid in holding the cushioning insert  400  in place within the void  830  and/or which may increase the strength and/or cushioning ability of the cushioning sheet  700  in some aspects.  FIG.  10    illustrates a top view of the cushioning sheet  700  after being passed through the sheet rolling device  900  (shown in  FIG.  9   ) to ensure the first base  120  (shown in  FIG.  1   ) of the first paper layer  110  (shown in  FIG.  1   ) is adequately secured to the second base  120  of the second paper layer  210 , and  FIG.  11    illustrates a bottom view of the cushioning sheet  700  after passing through the sheet rolling device  900 . 
       FIG.  12    illustrates the cushioning inserts  400  according to another example aspect of the present disclosure, wherein the cushioning inserts  400  again define a substantially spherical shape. In the present aspect, the spherical shape of the cushioning inserts  400  is even more defined that the substantially spherical cushioning inserts shown in  FIG.  4   . Furthermore, in the present aspect, the cushioning inserts  400  can be the starch cushioning inserts  410 .  FIG.  13    illustrates each of the cushioning inserts  400  of  FIG.  12    placed into a corresponding one of the semi-spherical first sockets  130  of the first paper layer  110 . 
       FIGS.  14  and  15 A-B  illustrate the rolling machine  1400 , according to an example aspect of the present disclosure, for forming the cushioning sheet  700 .  FIG.  14    illustrates a rear perspective view of the rolling machine  1400 ,  FIG.  15 A  illustrates a front perspective view of the rolling machine  1400 , and  FIG.  15 B  illustrates a cross-sectional view of the rolling machine  1400  taken along line  15 - 15  in  FIG.  15 A . Example aspects of the rolling machine  1400  can comprise a roller assembly  1410 , which can comprise a plurality of rollers  1560  (shown in  FIG.  15 B ). In the present aspect, the roller assembly  1410  can comprise two of the layer rolling devices  300  (shown in  FIG.  15 B ) for simultaneously forming the first and second sockets  130 , 230  (shown in  FIGS.  1  and  2   , respectively) in the first and second layers  100 , 200 , respectively. Other aspects of the rolling machine  1400  can comprise only one of the layer rolling devices  300 , which can form the first and second sockets  130 ,  230  in the first and second layers 100 ,  200  either simultaneously or consecutively. The roller assembly  1410  of the rolling machine  1400  can further comprise the sheet rolling device  900  (shown in  FIG.  15 B ) for sealing the first layer  100  to the second layer  200  with the cushioning inserts  400  (shown in  FIG.  4   ) received therebetween. Referring to  FIG.  15 A , a drive system  1500  can be provided for driving the movement of the roller assembly  1410  during production of the cushioning sheet  700 . As shown, example aspects of the drive system  1500  can comprise one or more motors  1505  configured to impart rotational movement to the various rollers  1560  (shown in  FIG.  15 B ) of the roller assembly  1410 , as described in further detail below. 
     According to example aspects, each of the first and second layers  100 ,  200  can be formed as a roll of raw material  1510  (e.g., a roll of paper, as shown) prior to being passed through the rolling machine  1400 . Referring to  FIG.  15 B , the rolling machine  1400  can comprise the two layer rolling devices  300  - for example, a first layer rolling device  300   a  and a second layer rolling device  300   b . In some aspects, the rolling machine  1400  can comprise one or more steam units  1520  configured to steam the first and second layers 100 ,  200  prior to passage through the corresponding layer rolling devices  300 . Steaming the first and second layers  100 ,  200  can soften the paper material, which can allow the paper material to stretch without tearing during formation of the first and second sockets  130 ,  230  (shown in  FIGS.  1  and  2   , respectively). Example aspects of the steam unit  1520  can comprise a water tank  1522  (shown in  FIG.  15 A ), one or more steam pans  1524 , and one or more conduits  1526  (shown in  FIG.  15 A ) for transferring water from the water tank  1522  to the steam pans  1524 . The steam pans  1524  can be configured to heat the water received from the water tank  1522  to produce steam. In example aspects, as shown, each of the first and second layers  100 ,  200  can pass over a corresponding one of the steam pans  1524  before being fed into the corresponding layer rolling device  300 . The layer rolling devices  300  can then form the first and second sockets  130 ,  230  in the first and second layers  100 ,  200 , as described above. In some aspects, one or both the steam units  1520  can be turned off or left unused when it is desired to cold set the first and/or second layers  100 ,  200 . Other aspects of the rolling machine  1400  may not comprise the steam units  1520  or the steam units  1520  can be removed as desired. Furthermore, in example aspects, the layer rolling devices  300  can be used to form the first and second sockets  130 ,  230  in the corresponding first and second layers  100 ,  200 , and the first and second layers  100 ,  200  can then be removed from the rolling machine  1400  and used as textured sheets  51110  (shown in  FIG.  51   ) of material (e.g., a textured paper sheets). In some aspects, only one of the layer rolling devices  300  may be used or provided for forming a textured sheet  51110  from the first layer  100  and/or second layer  200 . 
     Once the first sockets  130  have been formed in the first layer  100  by the corresponding first layer rolling device  300   a , the cushioning inserts  400  (shown in  FIG.  4   ) can be positioned within the first sockets  130 . Example aspects of the rolling machine  1400  can comprise the vacuum roller  600  for picking up the cushioning inserts  400  from a hopper  1530  or other repository and depositing them onto the first upper surface  122  (shown in  FIG.  1   ) of the first layer  100 . Some aspects of the rolling machine  1400  can also comprise a vibration mechanism  1540  configured to vibrate each of cushioning inserts  400  into a corresponding one of the insert indentations  604  (shown in  FIG.  6   ) of the vacuum roller  600 . For example, in the present aspect, the vibration mechanism  1540  can comprise a vibrating conveyor belt  1542 . The cushioning inserts  400  can be fed from the hopper  1530  onto the vibrating conveyor belt  1542 , which can agitate the cushioning inserts  400  thereon. The agitated cushioning inserts  400  can be transported along the conveyor belt  1542  and can be deposited onto the vacuum roller  600 . The movement of the cushioning inserts  400  caused by the vibrating conveyor belt  1542  can aid in locating the cushioning inserts  400  within the insert indentations  604 . For example, the agitated cushioning inserts  400  can slide, roll, or otherwise move across the cylindrical outer surface  602  (shown in  FIG.  6   ) of the vacuum roller  600  until dropping into a corresponding one of the insert indentations  604 . The cushioning inserts  400  can be retained within the corresponding insert indentations  604  of the vacuum roller  600  by suction provided through the corresponding vacuum port  606  (shown in  FIG.  6   ). 
     Additionally, once the second sockets  230  have been formed in the second layer  200  by the corresponding second layer rolling device  300   b , the adhesive  240  (shown in  FIG.  2   ) can be applied to the second lower surface  224  (shown in  FIG.  2   ) of the second layer  200 . According to example aspects, the rolling machine  1400  can comprise an adhesive applicator  1550  configured to apply the adhesive  240  to the second lower surface  224 . In the present aspect, the adhesive applicator  1550  can comprise an adhesive pan  1552  and an adhesive roller  1554 . A pool of the adhesive  240  can be received in the adhesive pan  1552 , and the adhesive roller  1554  can be continuously dipped into the pool of the adhesive  240  as the adhesive roller  1554  rotates, thereby continuously applying the adhesive  240  to the adhesive roller  1554 . After dipping into the pool of the adhesive  240 , the adhesive roller  1554  can rotate into contact with the second layer  200  to continuously apply the adhesive  240  to the second lower surface  224  thereof. An example aspect of the adhesive applicator  1550  is shown and described in further detail below with respect to  FIG.  15 C . 
     Once the cushioning inserts  400  have been deposited on the first layer  100  and the adhesive  240  has been applied to the second layer  200 , each of the first and second layers  100 , 200  can be simultaneously passed through the sheet rolling device  900  in facing contact with one another. As described above, when passing the first and second layers  100 ,  200  through the sheet rolling device  900 , each of the first sockets  130  of the first layer  100  can be aligned with a corresponding one of the second sockets  230  of the second layer  200  to define the substantially spherical void  830  (shown in  FIG.  8   ) therebetween. Each of the cushioning inserts  400  can be positioned within a corresponding one of the voids  830 , and the sheet rolling device  900  can adhere the first layer  100  to the second layer  200  to retain the cushioning inserts  400  within the corresponding voids  830 . The cushioning sheet  700  can then exit the sheet rolling device  900 , and in the present aspect, the cushioning sheet  700  can be wrapped around itself to define a finished roll  1515  of the cushioning sheet  700 . 
       FIG.  15 C  illustrates a cross-sectional view of the adhesive applicator  1550 . As shown, the adhesive applicator  1550  can comprise the adhesive pan  1552  within which a pool of the adhesive  240  (shown in  FIG.  2   ) can be received. The adhesive roller  1554  can be configured to rotate about a roller axis  1555  (going into the page) proximate to the adhesive pan  1552 , such that an outer roller surface  1556  of the adhesive roller  1554  can be continuously rotated into the pool of glue. The adhesive roller  1554  can further be continuously rotated into contact with the second layer  200  (shown in  FIG.  14   ) to apply the adhesive  240  thereto. For example, as a first portion of the outer roller surface  1556  rotates out of the pool of the adhesive  240  with the adhesive  240  applied thereto, the first portion can rotate into contact with the second layer  200 . Specifically, the first portion of the adhesive roller  1554  can rotate into contact with the second lower surface  224  (shown in  FIG.  2   ) of the second layer  200  as the second layer  200  moves through the roller assembly  1410  (shown in  FIG.  14   ) towards the sheet rolling device  900  (shown in  FIG.  15 B ), depositing the adhesive  240  on the second lower surface  224 . Furthermore, in some aspects, the adhesive applicator  1550  can further comprise a doctor blade  1558  configured to remove any excess adhesive  240  from the adhesive roller  1554  after application of the adhesive  240  to the second layer  200 . For example, after the first portion of the adhesive roller  1554  has applied the adhesive to the second layer  200 , the first portion can be rotated into contact with the doctor blade  1558 , which can scrape the outer roller surface  1556  to remove any excess adhesive  240  thereon prior to re-dipping the first portion into the pool of adhesive  240 . 
       FIG.  16    illustrates a detail view of a roller assembly  1410  of the rolling machine  1400  (shown in  FIG.  14   ), in accordance with an example aspect of the present disclosure. The roller assembly  1410  can comprise the pair of the layer rolling devices  300  and the sheet rolling device  900 . The layer rolling devices  300  and the sheet rolling device  900  can be operably connected to one another by the drive system  1500 , such that the various rollers  1560  thereof can rotate in unison. As described above, the drive system  1500  can comprise the motor  1505  (shown in  FIG.  15 A ). Furthermore, in the present aspect, each of the rollers  1560  can comprise a rotating axle  1602 , and the motor  1505  can be configured to directly drive one of the rotating axles  1602 . For example, in the present aspect, the motor  1505  can directly drive the rotating axle  1602  of the first layer roller  310  of the first layer rolling device  300   a . Example aspects of the drive system  1500  can further comprise a wheel  1604  or sprocket mounted on each of the rotating axles  1602 , and the wheels  1604  or sprockets can be interconnected by one or more straps  1606  or chains to transmit rotational motion between the rollers  1560 . 
     According to example aspects, each of the layer rolling devices  300  can comprise one or more of the first layer rollers  310  defining the socket indentations  314 , which can be considered female rollers  1610 . Each of the layer rolling devices  300  can further comprise one or more of the second layer rollers  320  defining the socket projections  324 , which can be considered male rollers  1620 . For example, in the present aspect, each layer rolling device  300  can comprise three small male rollers  1620   a , b , c  ( 1620   c  shown in  FIG.  15 B ) oriented in series and configured to engage one large female roller  1610 . Other aspects of the layer rolling devices  300  can comprise more female rollers  1610  and/or more or fewer male rollers  1620 . The male rollers  1620  and female roller  1610  of each layer rolling device  300  can be interconnected by the drive system  1500  as described above and can rotate concurrently as the corresponding first and second layers  100 , 200  (shown in  FIG.  14   ) are fed therethrough. As described above, each of the socket projections  324  of the male rollers  1620  can be configured to align with a corresponding one of the socket indentations  314  of the corresponding female roller  1610  as the female and male rollers  1610 ,  1620  confront one another during rotation. Each of the socket projections  324  can be configured to push a portion of the corresponding first layer  100  or second layer  200  into the corresponding socket indentation  314  to form the first and second sockets  130 ,  230  (shown in  FIGS.  1  and  2   ), respectively. 
     In some aspects, some or all of the female and male rollers  1610 ,  1620  can be formed from a singular cylindrical structure  1630  extending from a first end  1625  of the corresponding roller  1560  to an opposite second end (not shown) of the corresponding roller  1560 . A length of the roller can be defined between the first end  1625  and the opposite second end. In some aspects, some or all of the female and male rollers  1610 ,  1620  can be formed from a plurality of cylindrical collars  1635  stacked laterally between the corresponding first end  1625  and the second end. Rollers  1560  comprising the collars  1635  can allow for selective adjustment of the length of the roller  1560  by adding or removing collars  1635 . Furthermore, according to example aspects, each of the collars  1635  can be either a smooth collar  1640  defining a substantially smooth outer collar surface  1642  or a socket collar  1650  defining a plurality of the socket projections  324  or the socket indentations  314 . For example, in the present aspect, each of the female rollers  1610  can define the singular cylindrical structure  1630 , while each of the male rollers  1620  can define a plurality of the collars  1635 . As shown, each of the male rollers  1620   a , b  can comprise one or more first smooth collars  1640   a  proximate to the corresponding first end  1625  and one or more second smooth collars  1640   b  proximate to the corresponding second end. Each of the male rollers  1620   a ,b can further comprise one or more of the socket collars  1650  defining the socket projections  324  oriented centrally between the first and second smooth collars  1640   a , b . The male roller  1620   c  (shown in  FIG.  15 B ) can comprise the socket collars  1650  extending from the first end  1625  to the second end, and does not comprise any of the smooth collars  1640  in the present aspect. In other aspects, however, the male roller  1620   c  may comprise the smooth collars  1640 . 
     According to example aspects, any of the rollers  1560  and/or collars  1635  can be selectively removed and replaced with rollers  1560  and/or collars  1635  having varying patterns, varying sizes, and/or other varying features. In one example, the rollers  1560  and/or collars  1635  can be replaced with rollers  1560  and/or collars  1635  defining larger or smaller socket indentations  314  and/or socket projections  324 . In another example, the rollers  1560  and/or collars  1635  can be replaced with rollers  1560  and/or collars  1635  defining socket indentations  314  and/or socket projections  324  defining an alternative shape (e.g., cuboidal instead of semi-spherical). In another example, some or all of the smooth collars  1640  can be replaced with socket collars  1650  as desired, or vice versa. 
     According to example aspects, each of the female and male rollers  1610 ,  1620  can be about equal in length. In other aspects, some or all of the female and male rollers  1610 ,  1620  can define varying lengths. Additionally, as shown, each of the smooth collars  1640  can be about equal in size, and each of the socket collars  1650  can be about equal in size. In other aspects, the smooth collars  1640  and/or socket collars  1650  can define varying sizes. In the present aspect, the male rollers  1620   b  can define more of the socket collars  1650  and fewer of the smooth collars  1640  than the male rollers  1620   a . Similarly, the male rollers  1620   c  (shown in  FIG.  15 B ) can define more of the socket collars  1650  and fewer of the smooth collars  1640  than the male rollers  1620   b . As such, a length L s  of the stack of socket collars  1650  of the male rollers  1620   a  can be less than the length L s  of the stack of socket collars  1650  of the male rollers  1620   b , and the length L s  of the stack of socket collars  1650  of the male rollers  1620   b  can be less than the length L s  of the stack of socket collars  1650  of the male rollers  1620   c . As described above, each of the collars  1635  can be selectively removed and replaced, and thus, the length L s  can be selectively adjusted. Additionally, in some aspects, a height to which the socket projections  324  extend away from the corresponding socket collars  1650  can vary between some or all of the male rollers  1620   a , b , c . For example, in some aspects, the socket projections  324  of the male roller  1620   a  can extend to a height that is less that a height of socket projections  324  of the male roller  1620   b , and the socket projections  324  of the male roller  1620   b  can extend to a height that is less than a height of the socket projections  324  of the male roller  1620   c . In other aspects, the socket projections  324  of each of the male rollers  1620   a , b , c  can be about equal in height. 
     According to example aspects, each of the first and second layers  100 ,  200  (shown in  FIG.  14   ) can be fed through the corresponding layer rolling devices  300  in the direction from the male roller  1620   a  to the male roller  1620   c . The centrally-oriented socket collars  1650  of the male roller  1620   a  can form a center set  1912  (shown in  FIG.  19   ) of the first and second sockets  130 ,  230  at and around a center  1910  (shown in  FIG.  19   ) of the first and second layers  100 ,  200 , respectively. The socket collars  1650  of the male roller  1620   b  can then form first and second intermediate sets  1914   a , b  (shown in  FIG.  19   ) of the first and second sockets  130 ,  230  on either side of the center set  1912 . Finally, the socket collars  1650  of the male roller  1620   c  can form first and second outer sets  1916   a , b  (shown in  FIG.  19   ) of the first and second sockets  130 ,  230  adjacent to the first and second intermediate sets  1914   a , b  and distal to the center set  1912 . 
     In some aspects, each of the male rollers  1620  can define one or more spacer areas  1660  extending about a circumference of the male roller  1620 . For example, in the present aspect, each of the male rollers  1620  can define one of the spacer areas  1660  oriented about centrally along the length of the male roller  1620 . In other aspects, each of the male rollers  1620  can define additional spacer areas  1660  and/or the spacer area(s)  1660  can be positioned anywhere along the length of the male roller  1620 . As shown, each of the spacer areas  1660  can be substantially smooth and does not define the socket projections  324 . In the present aspect, each of the spacer areas  1660  of the male rollers  1620  can be provided by a spacer collar  1662  positioned between adjacent socket collars  1650 . In some aspects, the spacer collar  1662  can be similar to the smooth collars  1640 . Furthermore, the spacer area  1660  of the male roller  1620   a  can be aligned with corresponding spacer areas  1660  of the male rollers  1620   b ,  1620   c . According to example aspects, the spacer areas  1660  can define cutting portions extending lengthwise along the first and second layers  100 , 200 , which can be substantially planar and which do not define the corresponding first and second sockets  130 ,  230 . The cutting portions of the first and second layers  100 ,  200  can be aligned on the finished cushioning sheet  700 , such that the cushioning sheet  700  can be cut lengthwise along the cutting portions without piercing any of the cushioning inserts  400  or voids  830 . However, other aspects of the male rollers  1620  may not comprise the spacer areas  1660 . 
     In some aspects, as shown, each of the female rollers  1610  can also define one or more of the spacer areas  1660 . For example, in the present aspect, each of the female rollers  1610  can define one of the spacer areas  1660  oriented about centrally along a length of the female roller  1610 . Each of the spacer areas  1660  of the female rollers  1610  can be formed as a smooth circumferential region  1664  of the cylindrical outer surface  312  of the female roller  1610 . The smooth circumferential region  1664  of the female roller  1610  can be configured to align with the spacer collars  1662  of the male rollers  1620 . In other aspects, however, the female rollers  1610  may not comprise the corresponding spacer areas  1660 . The roller assembly  1410  can further comprise the sheet rolling device  900 . According to example aspects, the sheet rolling device  900  can comprise each of the female rollers  1610  of the layer rolling devices  300 . Thus, the female rollers  1610  of the layer rolling devices  300  can serve as the first and second sheet rollers  910 ,  920 , and the corresponding socket indentations  314  of the female rollers  1610  can serve as the indentations  914 ,  924 . The first and second sheet rollers  910 ,  920  can confront another, and each of the first and second layers  100 , 200  can be simultaneously fed therebetween. As described above, each of the indentations  914  of the first sheet roller  910  can align with a corresponding one of the indentations  924  of the second sheet roller  920  as the first and second sheet rollers  910 ,  920  are concurrently rotated. The first sockets  130  of the first layer  100  can extend into the indentations  914  of the first sheet roller  910 , and the second sockets  230  of the second layer  200  can extend into the indentations  924  of the second sheet roller  920 , allowing the voids  830  (shown in  FIG.  8   ) therebetween to maintain their shape and preventing the cushioning inserts  400  (shown in  FIG.  4   ) from being compressed or crushed therein. Additionally, as described above, the cylindrical outer surfaces  912 ,  922  (shown in  FIG.  9   ) of the first and second sheet rollers  910 ,  920  surrounding the corresponding indentations  914 ,  924  can press the second lower surface  224  (shown in  FIG.  2   ) of the second layer  200  into contact with the first upper surface  122  (shown in  FIG.  1   ) of the first layer  100 . The adhesive  240  (shown in  FIG.  2   ) applied to the second lower surface  224  of the second layer  200  can adhere to the first upper surface  122  of the first layer  100  to secure the first and second layers  100 ,  200  together with the cushioning inserts  400  received in the voids  830 , thereby defining the cushioning sheet  700  (shown in  FIG.  7   ). The cushioning sheet  700  can then exit the roller assembly  1410  and can be wrapped around itself to define the finished roll  1515  (shown in  FIG.  15 B ). 
     Thus, a method of forming the cushioning sheet  700  can comprise forming the plurality of first sockets  130  in the first layer  100 , and forming the plurality of second sockets  230  in the second layer  200 , wherein each of the second sockets  230  can correspond to a one of the first sockets  130 . The method can further comprise positioning one of the cushioning inserts  400  within the void  830  defined between each corresponding pair of the first and second sockets  130 , 230 , and coupling the first layer  100  to the second layer  200 . 
       FIGS.  17 - 19    illustrate a cushioned mailer  1700 , in accordance with an example aspect of the present disclosure. Referring to  FIG.  17   , example aspects of the cushioned mailer  1700  can comprise an outer sheet  1710  defining an inner surface  1712  and an outer surface  1714 . The outer sheet  1710  can be a substantially planar paper sheet in the present aspect, though in other aspects, the outer sheet  1710  can comprise any other suitable material and/or configuration. According to example aspect, the inner surface  1712  of the outer sheet  1710  can define an outer cavity  1816  (shown in  FIG.  18   ). The cushioned mailer  1700  can further comprise the cushioning sheet  700  (shown in  FIG.  19   ), which can be an inner sheet  1920  (shown in  FIG.  19   ) in the present aspect, positioned within the outer cavity  1816  and coupled to the inner surface  1712  of the outer sheet  1710 . For example, the cushioning sheet  700  can be coupled to the inner surface  1712  by an adhesive, such as, for example, glue, or any other suitable fastener known in the art. Other aspects of the cushioning sheet  700  may not be coupled to the outer sheet  1710  and can be loosely received within the outer cavity  1816 . According to example aspects, the cushioning sheet  700  can define an inner cavity  1826 , which can include portions of the outer cavity  1816 . The cushioned mailer  1700  can be configurable in a folded configuration, as shown in  FIGS.  17  and  18   , and an unfolded configuration, as shown in  FIG.  19   . The cushioned mailer  1700  can further be configurable in an open orientation, as shown in  FIGS.  17  and  18   , and a closed orientation (not shown). 
     In the folded configuration, the cushioned mailer  1700  can define a front panel  1730  and a rear panel  1740  opposite the front panel  1730 . The cushioning sheet  700  can define a front inner portion  1932  (shown in  FIG.  19   ) of the front panel  1730 , and the outer sheet  1710  can define a front outer portion  1734  of the front panel  1730  opposite the front inner portion  1932 . Similarly, the cushioning sheet  700  (i.e., the inner sheet  1920 ) can define a rear inner portion  1942  (shown in  FIG.  19   ) of the rear panel  1740 , and the outer sheet  1710  can define a rear outer portion  1744  of the rear panel  1740  opposite the rear inner portion  1942 . The front inner portion  1932  of the cushioning sheet  700  can face the rear inner portion  1942  of the cushioning sheet  700 , and the inner cavity  1826  can be substantially defined therebetween. The inner cavity  1826  can be configured to receive contents  1800  (shown in  FIG.  18   ) therein, which can be substantially surrounded and cushioned by the cushioning sheet  700 . 
     Example aspects of the cushioned mailer  1700  can further define a left side  1750 , a right side  1752  opposite the left side  1750 , a bottom end  1754 , and a top end  1756  opposite the bottom end  1754 . The front panel  1730  of the cushioned mailer  1700  can be hingedly coupled to the rear panel  1740  of the cushioned mailer  1700  at the bottom end  1754  at a bottom fold line  1755 , as shown. As such, both the outer cavity  1816  and the inner cavity  1826  can be closed at the bottom end  1754  of the cushioned mailer  1700 . The bottom fold line  1755  can be defined in at least the outer sheet  1710 , and in some aspects, can further be defined in the cushioning sheet  700 . In other aspects, the cushioning sheet  700  can define a cut  1925  (shown in  FIG.  19   ) at the bottom end  1754  of the cushioned mailer  1700 . Example aspects of the cushioned mailer  1700  can also be sealed at each of the left side  1750  and the right side  1752 . For example, in some aspects, the inner surface  1712  of the outer sheet  1710  can be sealed to itself by an adhesive at the left and right sides  1750 ,  1752 , thereby closing the outer cavity  1816  and the inner cavity  1826  at the left and right sides  1750 ,  1752 . The adhesive can be, for example, glue or any other suitable adhesive known in the art. In other aspects, the left and right sides  1750 ,  1752  can be sealed by any other suitable fastener. Furthermore, in other aspects, the cushioning sheet  700  can be sealed to itself or to the outer sheet  1710  to close the outer cavity  1816  and/or inner cavity  1826  at the left and right sides  1750 , 1752 . 
     Example aspects of the cushioned mailer  1700  can further be oriented in the open orientation, as shown, and the closed orientation. In the open orientation, an opening  1760  can be defined at the top end  1756  of the cushioned mailer  1700  to allow access to inner cavity  1826 . In the closed orientation, the inner cavity  1826  can be selectively closed at the top end  1756 . In some aspects, the cushioned mailer  1700  can define a closure flap  1770  for selectively covering the opening  1760  and sealing the top end  1756  of the cushioned mailer  1700  in the closed orientation, thereby securing the contents  1800  within the inner cavity  1826 . In the present aspect, the rear outer portion  1744  of the rear panel  1740  of the cushioned mailer  1700  can define the closure flap  1770  extending from the top end  1756  thereof. Thus, the closure flap  1770  can be defined by the outer sheet  1710 , as shown. The closure flap  1770  can define an adhesive strip  1772  extending substantially from the left side  1750  to the right side  1752  of the cushioned mailer  1700 . The adhesive strip  1772  can be selectively covered by a peelable backing  1774  in some aspects, which can be peeled away from the cushioned mailer  1700  to reveal the adhesive strip  1772 . With the peelable backing  1774  removed, the closure flap  1770  can be folded over the top end  1756  of the cushioned mailer  1700 , and the adhesive strip  1772  can be adhered to the front outer portion  1734  of the front panel  1730  of the cushioned mailer  1700 .  FIG.  18    illustrates the contents  1800  (for example, a small box  1805 , as shown) being inserted into the inner cavity  1826  of the cushioned mailer  1700  through the top end  1756  thereof in the open orientation. 
       FIG.  19    illustrates the cushioned mailer  1700  in the unfolded configuration. As shown, the cushioning sheet  700  can be adhered to the inner surface  1712  of the outer sheet  1710 . In the present aspect, the first layer  100  (shown in  FIG.  14   ) of the cushioning sheet  700  can be adhered to the outer sheet  1710 , and the second layer  200  of the cushioning sheet  700  can face away from the outer sheet  1710 . As such, the second layer  200  of the cushioning sheet  700  can at least partially surround and define the inner cavity  1826  (shown in  FIG.  18   ) in the folded configuration. The cushioning sheet  700  can further comprise the cushioning inserts  400  received in the voids  830  (shown in  FIG.  8   ) between the first layer  100  and the second layer  200 , and the cushioning inserts  400  can provide cushioned protection to the contents  1800  (shown in  FIG.  18   ) received in the inner cavity  1826 . The cushioning sheet  700  can further define the cut  1925  at the bottom end  1754  of the cushioned mailer  1700  to separate the cushioning sheet  700  into the front inner portion  1932  and the rear inner portion  1942 . In other aspects, the cushioning sheet  700  can define the bottom fold line  1755  (shown in  FIG.  17   ) between the front inner portion  1932  and the rear inner portion  1942 . The cut  1925  can facilitate folding the cushioned mailer  1700  from the unfolded configuration to the folded configuration. As shown, in example aspects, the outer sheet  1710  can define left and right sealing flaps  1930   a ,b extending beyond the cushioning sheet  700  at the left and right sides  1750 ,  1752  of the cushioned mailer  1700 . In the folded orientation, the portions of the left and right sealing flaps  1930   a ,b proximate to the front inner portion  1932  can be coupled to the portions of the left and right sealing flaps  1930   a ,b, respectively, proximate to the rear inner portion  1942  to seal the left and right sides  1750 , 1752  of the cushioned mailer  1700 . 
       FIG.  20    illustrates a front perspective view of the cushioned mailer  1700  in accordance with another example aspect of the present disclosure. The cushioned mailer  1700  can be a textured mailer  20100  in the present aspect, as described in further detail below. In  FIG.  20   , the textured mailer  20100  is shown in a folded configuration. The textured mailer  20100  can be similar to the cushioned According to example aspects, the textured mailer  20100  can comprise an outer layer  20120  and an inner layer  22320  (shown in  FIG.  22   ). Other aspects of the textured mailer  20100  can comprise more or fewer layers; for example, in another aspect, the textured mailer  20100  can comprise the outer layer  20120 , the inner layer  22320 , and an intermediate layer therebetween. The outer layer  20120  can define an inner surface  20122  and an outer surface  20124 . The outer layer  20120  can comprise a paper material, and thus, the outer layer  20120  can be a paper outer layer  20120 . In some aspects, the paper material can be recyclable, and in some aspects the paper material can be single stream repulpable. Additionally, in some aspects, the paper material can be a tissue-grade paper material. Furthermore, in some aspects, a coating can be applied to the paper material of the outer layer  20120  to increase the strength of the outer layer  20120  while maintaining flexibility. The coating can be, for example and without limitation, a starch-based coating. In some aspects, the paper material can be extensible, such that the outer layer  20120  can be stretchable. In other aspects, the outer layer  20120  can comprise any other suitable material known in the art, may or may not comprise the coating, and/or can be inextensible. 
     Example aspects of the outer layer  20120  can comprise an outer front panel  20126  and an outer rear panel  21228  (shown in  FIG.  21   ). The outer front panel  20126  can be folded towards the outer rear panel  21228  at a lower outer bend line  20130 , as shown, such that the outer front panel  20126  can be disposed at a front side  20102  of the textured mailer  20100  and the outer rear panel  21228  can be disposed at a rear side  20104  of the textured mailer  20100 . The outer front panel  20126  and the outer rear panel  21228  can be oriented about parallel with one another. In example aspects, the outer front panel  20126  can be substantially smooth and planar, and the outer rear panel  21228  can be textured, as described in further detail below. The smoothness of the outer front panel  20126  can allow for sticker labels to be easily adhered to the outer front panel  20126  and/or can allow for easy writing of mailing addresses or other information thereon. In other aspects, the outer front panel  20126  can be textured, and the outer rear panel  21228  can be substantially smooth and planar. In other aspects, both of the outer front panel  20126  and the outer rear panel  21228  can be textured, or both of the outer front panel  20126  and the outer rear panel  21228  can be substantially smooth and planar. 
     The inner surface  20122  of the outer layer  20120  can define an outer cavity  20135  between the outer front panel  20126  and the outer rear panel  21228 . The outer cavity  20135  can be sealed at a lower end  20106  of the textured mailed by the lower outer bend line  20130 . Each of the outer front panel  20126  and the outer rear panel  21228  can define a left sealing portion  20140  extending along a left edge  20144  thereof and a right sealing portion  21242  (shown in  FIG.  21   ) extending along a right edge  20146  thereof. According to example aspects, the left sealing portion  20140  of the outer front panel  20126  can be coupled to the left sealing portion  20140  of the rear front panel to define a left seam  20114  and to seal the outer cavity  20135  at a left side  20110  of the textured mailer  20100 . Similarly, the right sealing portion  21242  of the outer front panel  20126  can be coupled to the right sealing portion  21242  of the outer rear panel  21228  to define a right seam  20116  and to seal the outer cavity  20135  at a right side  20112  of the textured mailer  20100 . In example aspects, the right sealing portions  21242  can be secured together at the right side  20112  by an adhesive, and the left sealing portions  20140  can be secured together at the left side  20110  by an adhesive. The adhesives can be, for example, glue or tape. In other aspects, the right sealing portions  21242  can be secured together and the left sealing portions  20140  can be secured together by any other suitable fastener or fastening technique known in the art. According to example aspects, the textured mailer  20100  can further comprise the inner layer  22320  (shown in  FIG.  22   ), which can be disposed substantially within the outer cavity  20135  in the folded configuration. In example aspects, the inner layer  22320  can be secured to the outer layer  20120  in an unfolded configuration, and then the textured mailer  20100  can be folded to the folded configuration, as described in further detail below. 
     A cavity opening  20136  can be defined generally at or near an upper end  20108  of the textured mailer  20100 . The inner layer  22320  can be inserted into the outer cavity  20135  through the cavity opening  20136 . Example aspects of the textured mailer  20100  can be configured in an unsealed configuration, as shown, and a sealed configuration. In the unsealed configuration, the cavity opening  20136  can be uncovered to allow access to the outer cavity  20135 . In the sealed configuration, the cavity opening  20136  can be covered by a sealing flap  20150  of the textured mailer  20100  to seal the outer cavity  20135  at the upper end  20108 , thereby containing contents received within the textured mailer  20100 . According to example aspects, the sealing flap  20150  can extend substantially upward, relative to the orientation shown, from the outer rear panel  21228 . In some aspects, a tape strip  20152  can be applied substantially along a length of the sealing flap  20150  on the inner surface  20122 . To seal the textured mailer  20100  in the sealed configuration, the sealing flap  20150  can be folded relative to the outer rear panel  21228  over the cavity opening  20136 , and the tape strip  20152  can be adhered to the outer front panel  20126  on the outer surface  20124 . In some aspects, a backing can cover the tape strip  20152  in the unsealed configuration and can be peeled off to expose the tape strip  20152  prior to sealing the textured mailer  20100 . In other aspects, the sealing flap  20150  can be secured to the outer front panel  20126  by any other suitable fastener or fastening technique. Moreover, in some aspects, the sealing flap  20150  can comprise a tear strip  20154  disposed between the tape strip  20152  and the outer rear panel  21228 , and extending along the length of the sealing flap  20150 . The tear strip  20154  can be torn away from the textured mailer  20100  to facilitate opening the textured mailer  20100  from the sealed configuration. Other aspects of the textured mailer  20100  may not comprise the tear strip  20154  and/or the tape strip  20152 . 
       FIG.  21    is a top plan view of the outer layer  20120  of the textured mailer  20100  (shown in  FIG.  20   ) in an unfolded configuration, illustrating the inner surface  20122  thereof. As shown, the outer front panel  20126  can be hingedly coupled to the outer rear panel  21228  by the lower outer bend line  20130 . Each of the outer front panel  20126  and the outer rear panel  21228  can define the corresponding left sealing portion  20140  and right sealing portion  21242 . The sealing flap  20150  can extend from the outer rear panel  21228 , opposite the outer front panel  20126 . In some aspects, the sealing flap  20150  can be hingedly connected to the outer rear panel  21228  at an upper outer bend line  21256 . The sealing flap  20150  can define both the tape strip  20152  and the tear strip  20154 . According to example aspects, the outer front panel  20126  can be substantially smooth and planar, and the outer rear panel  21228  can be textured. For example, the textured outer rear panel  21228  can define a plurality of spaced-apart outer sockets  21260  formed therein, similar to the sockets  130 ,  230  previously described. 
     In the present aspect, each of the outer sockets  21260  can be formed as a substantially semi-spherical dome  21262  defining a substantially semi-spherical recess  21264 . Furthermore, each of the outer sockets  21260  can be substantially uniform in size and shape, and can extend in the same direction. For example, each of the outer sockets  21260  can extend rearwardly from the rear side  20104  (shown in  FIG.  23 A ) of the textured mailer  20100 . As such, the outer sockets  21260  can extend into the page in the present view. In other aspects, however, the outer sockets  21260  can vary in size and/or shape, and/or the outer sockets  21260  can vary in direction (i.e., some of the outer sockets  21260  can extend rearwardly from the rear side  20104  of the textured mailer  20100  and some of the outer sockets  21260  can extend forwardly towards the front side  20102  - shown in  FIG.  23 A  - of the textured mailer  20100 ). The outer sockets  21260  can also be arranged in any suitable pattern, such as in diagonal lines, as shown. According to example aspects, outer sockets  21260  can be formed in the outer layer  20120  by the rolling machine  1400 . 
       FIG.  22    is a top plan view of the inner layer  22320  in an unfolded configuration. According to example aspects, the inner layer  22320  can be similar to the outer layer  20120  (shown in  FIG.  20   ). For example, like the outer layer  20120 , the inner layer  22320  can comprise a paper material, and thus, the inner layer  22320  can be a paper inner layer  22320 . In some aspects, the paper material can be recyclable, and in some aspects, the paper material can be single stream repulpable. Additionally, in some aspects, the paper material can be a tissue-grade paper material. Furthermore, in some aspects, a coating can be applied to the paper material of the inner layer  22320  to increase the strength of the inner layer  22320  while maintaining flexibility. The coating can be, for example and without limitation, a starch-based coating. In some aspects, the paper material can be extensible, such that the outer layer  20120  can be stretchable. In other aspects, the inner layer  22320  can comprise any other suitable material known in the art, may or may not comprise the coating, and/or can be inextensible. 
     The inner layer  22320  can define an inner surface  22322  and an outer surface  23424  (shown in  FIG.  23 A ). Example aspects of the inner layer  22320  can comprise an inner front panel  22326  and an inner rear panel  22328 . The inner front panel  22326  can be hingedly connected to the inner rear panel  22328  at a lower inner bend line  22330 , as shown. Each of the inner front panel  22326  and the inner rear panel  22328  can define a left coupling portion  22340  extending along a left edge  22344  thereof and a right coupling portion  22342  extending along a right edge  22346  thereof. Furthermore, according to example aspects, the inner rear panel  22328  can be substantially smooth and planar, and the inner front panel  22326  can be textured. In other aspects, the inner rear panel  22328  can be textured, and the inner front panel  22326  can be substantially smooth and planar. In other aspects, both of the inner front panel  22326  and the inner rear panel  22328  can be textured, or both of the inner front panel  22326  and the inner rear panel  22328  can be substantially smooth and planar. Like, the textured outer rear panel  21228  (shown in  FIG.  21   ) of the outer layer  20120 , the textured inner front panel  22326  of the inner layer  22320  can define a plurality of spaced-apart inner sockets  22360  formed therein. 
     The inner sockets  22360  can be substantially similar to the outer sockets  21260 . As described above, example aspects of the inner sockets  22360  can be formed as the substantially semi-spherical domes  21262 , each dome  21262  defining one of the substantially semi-spherical recesses  21264 . The inner sockets  22360  can be substantially uniform in size and shape, and can extend in the same direction. For example, when assembled with the outer layer  20120 , each of the inner sockets  22360  can extend rearwardly towards the rear side  20104  (shown in  FIG.  23 A ) of the textured mailer  20100 , as is illustrated in  FIG.  23 A . As such, the inner sockets  22360  can extend out of the page in the present view. In other aspects, each of the inner sockets  22360  can extend forwardly towards the front side  20102  (shown in  FIG.  23 A ) of the textured mailer  20100 , as is illustrated in  FIG.  23 B . In other aspects, the inner sockets  22360  can vary in size and/or shape, and/or the inner sockets  22360  can vary in direction (i.e., some of the inner sockets  22360  can extend rearwardly towards the rear side  20104  of the textured mailer  20100  and some of the inner sockets  22360  can extend forwardly towards the front side  20102  of the textured mailer  20100 ). The inner sockets  22360  can also be arranged in any suitable pattern, such as in diagonal lines, as shown. The inner sockets  22360  can be formed by the same method as the outer sockets  21260 , such as by a rolling machine. 
       FIG.  23 A  illustrates a cross-sectional view of the textured mailer  20100  comprising the inner layer  22320  and the outer layer  20120 . The textured mailer  20100  is shown in a partially folded configuration as the textured mailer  20100  is being folded to the folded configuration of  FIG.  20   . In the folded configuration, the inner layer  22320  can be substantially disposed within the outer cavity  20135  defined by the outer layer  20120 . According to example aspects, the inner layer  22320  can be secured to the outer layer  20120  while each of the outer and inner layers  20120 , 22320  are in the unfolded configuration (shown in  FIGS.  21  and  22   ). For example, the outer surface  23424  of the inner layer  22320  can be secured to the inner surface  20122  of the outer layer  20120  by any suitable fastener, such as by an adhesive, for example and without limitation. Specifically, the inner rear panel  22328  can be secured to the outer rear panel  21228 , and the inner front panel  22326  can be secured to the outer front panel  20126 . The adhesive can be applied to the outer surface  23424  of the inner layer  22320  only, to the inner surface  20122  of the outer layer  20120  only, or to both of the outer surface  23424  and the inner surface  20122 . In some aspects, the adhesive can fully cover the outer surface  23424  of the inner layer  22320  and/or the inner surface  20122  of the outer layer  20120 , and in other aspects, the adhesive can only partially cover the outer surface  23424  and/or the inner surface  20122 . In other aspects, the inner layer  22320  can be secured to the outer layer  20120  by any other suitable fastener or fastening technique. 
     Furthermore, the left and right coupling portions  22340 , 22342  (shown in  FIG.  22   ) of the inner layer  22320  can overlay the corresponding left and right sealing portions  20140 , 21242  (shown in  FIG.  21   ) of the outer layer  20120 . The inner front panel  22326  of the inner layer  22320  can then be folded towards the inner rear panel  22328  of the inner layer  22320 , such that the inner front panel  22326  and the outer front panel  20126  can be disposed generally at the front side  20102  of the textured mailer  20100  and the inner rear panel  22328  and the outer rear panel  21228  can be disposed generally at the rear side  20104  of the textured mailer  20100 . The left coupling portions  22340  of the inner front panel  22326  and the inner rear panel  22328  can be captured and sealed between the left sealing portions  20140  of the outer front panel  20126  and the outer rear panel  21228  at the left seam  20114  (shown in  FIG.  20   ). Similarly, the right coupling portions  22342  of the inner front panel  22326  and the inner rear panel  22328  can be captured and sealed between the right sealing portions  21242  of the outer front panel  20126  and the outer rear panel  21228  at the right seam  20116  (shown in  FIG.  20   ). The adhesive for sealing the left seam  20114  and the right seam  20116  can be applied to the left and right coupling portions  22340 , 22342  only, the left and right sealing portions  20140 , 21242  only, or to both the left and right coupling portions  22340 , 22342  and the left and right sealing portions  20140 , 21242 . In other aspects, the inner layer  22320  can be secured to the outer layer  20120  only at the left and right seams  20114 , 20116 . Other aspects of the inner layer  22320  may not be coupled to the outer layer  20120  at all and can be loosely received within the outer cavity  20135 . 
     The inner surface  22322  of the inner layer  22320  can define an inner cavity  23435  between the inner front panel  22326  and the inner rear panel  22328 , which can overlap and include portions of the outer cavity  20135 . The cavity opening  20136  can be defined generally at or near the upper end  20108  of the textured mailer  20100  and can allow access to the inner cavity  23435  in the unsealed configuration, as shown. Contents can be inserted into the inner cavity  23435  of the textured mailer  20100  through the cavity opening  20136 . In the present aspect, the inner sockets  22360  of the inner front panel  22326  can extend into the inner cavity  23435  and can cushion the textured mailer  20100  at the front side  20102  thereof. The inner rear panel  22328  can be substantially smooth and planar, which can facilitate sliding contents (e.g., greeting cards, paper documents, etc.) into the inner cavity  23435 . The outer sockets  21260  of the outer rear panel  21228  can extend away from the inner rear panel  22328  and can cushion the textured mailer  20100  at the rear side  20104  thereof. Thus, the inner cavity  23435  and the contents therein can be substantially surrounded by the textured outer rear panel  21228  and the texture inner front panel  22326 . 
     The inner cavity  23435  can be sealed at the lower end  20106  of the textured mailer  20100  by the lower inner bend line  22330 . The inner cavity  23435  can further be sealed at the left side  20110  and the right side  20112  by the left seam  20114  and the right seam  20116 , respectively. The sealing flap  20150  of the outer layer  20120  can extend upward from the outer rear panel  21228 , relative to the orientation shown, beyond the inner rear panel  22328 . As described above, the sealing flap  20150  can be folded over the cavity opening  20136  and secured to the outer front panel  20126  to seal the inner cavity  23435  at the upper end  20108  of the textured mailer  20100  and to retain the contents therein. 
       FIG.  23 B  illustrates a cross-sectional view of the textured mailer  20100  according to another example aspect of the present disclosure, wherein the inner sockets  22360  of the inner front panel  22326  can extend away from the inner cavity  23435  towards the outer front panel  20126 . As shown, the outer sockets  21260  of the outer rear panel  21228  can extend away from the inner rear panel  22328 ; however, in other aspects, the outer sockets  21260  can extend towards the inner rear panel  22328 . 
       FIG.  24    illustrates a top perspective view of the textured mailer  20100 , showing the inner sockets  22360  extending into the inner cavity  23435 .  FIG.  25    illustrates a rear perspective view of the textured mailer  20100  showing the outer sockets  21260  extending rearwardly from the rear side  20104  of the textured mailer  20100 .  FIGS.  26 A and  26 B  illustrate example dimensions of the inner sockets  22360 , wherein the outer sockets  21260  (shown in  FIG.  21   ) can define the same dimensions or different dimensions. The dimensions disclosed herein are merely exemplary and should not be considered limiting. 
       FIG.  27    illustrates a monolithic (i.e., formed as a singular component that constitutes a single material without joints or seams) first sheet  27800  comprising a plurality of the outer layers  20120 , which can be produced by a rolling machine. The first sheet  27800  can be fed through the rolling machine in the direction indicated by the directional arrow at the top of the page. In the present aspect, the first sheet  27800  can comprise at least a first one of the outer layers  20120   a  and a second one of the outer layers  20120   b . An upper edge  27822  of the sealing flap  20150  of the first outer layer  20120   a  can meet and extend along the upper edge  27822  of the sealing flap  20150  of the second outer layer  20120   b . The upper edges  27822  of the first and second outer layers  20120   a ,b can generally define a cut line  27824  or a cut region. To separate the first outer layer  20120   a  from the second outer layer  20120   b , the first sheet  27800  can be cut along the cut line  27824 . 
     As shown, the first sheet  27800  can define a width W1. The width W1 can extend from a distal edge  27826  of the outer front panel  20126  of the first outer layer  20120   a  to the opposing distal edge  27826  of the outer front panel  20126  of the second outer layer  20120   b . Thus, in the present aspect, the first sheet  27800  can be two outer layers  20120  wide. In other aspects, first sheet  27800  can be more or fewer outer layers  20120  wide. Additionally, as shown, the first sheet  27800  can define a length L1. In the present aspect, the first sheet  27800  can be one outer layer  20120  long. However, as shown in  FIG.  28   , the first sheet  27800  can comprise additional outer layers  20120  along its length in other aspects. 
     Also illustrated in  FIG.  27    is a second sheet  27850  comprising a plurality of the inner layers  22320 , which can be produced by a roller machine. The second sheet  27850  can be fed through the rolling machine in the direction indicated by the directional arrow at the top of the page. In the present aspect, the second sheet  27850  can comprise at least a first one of the inner layers  22320   a  and a second one of the inner layers  22320   b . In example aspects, the second sheet  27850  can be a monolithic sheet prior to being fed through the rolling machine. However, in the present aspect, the rolling machine can be configured to cut out a center section of the second sheet  27850  between the first inner layer  22320   a  and the second outer layer  20120   b  to define a gap  27852  therebetween, thereby dividing the second sheet  27850  into two separate parts. 
     As shown, the second sheet  27850  can define a width W2. The width W2 can extend from a distal edge  27856  of the inner front panel  22326  of the first inner layer  22320   a  to the opposing distal edge  27856  of the inner front panel  22326  of the second inner layer  22320   b . Thus, in the present aspect, the second sheet  27850  can be two inner layers  22320  wide, including the gap  27852  defined therebetween. The width W2 can equal the width W1 in the present aspect. In other aspects, the second sheet  27850  can be more or fewer inner layers  22320  wide and/or the width W2 can be different than the width W1. Additionally, as shown, the second sheet  27850  can define a length L2. In the present aspect, the second sheet  27850  can be one inner layer  22320  long and the length L2 can equal the length L1. However, as shown in  FIG.  10   , the second sheet  27850  can comprise additional inner layers  22320  along its length in other aspects and/or the length L2 can be different than the length L1. The various dimensions disclosed in  FIG.  27    are merely exemplary and should not be considered limiting. 
       FIG.  30    illustrates the first sheet  27800  and the second sheet  27850  of the textured mailer  20100  (shown in  FIG.  20   ), in accordance with another aspect of the present disclosure. The first sheet  27800  can comprise a pair of the outer layers  20120  and the second sheet  27850  can comprise a pair of the inner layers  22320 . Each of the outer layers  20120  can be substantially the same as the outer layers  20120  previously described. Additionally, each of the inner layers  22320  can be similar to the inner layers  22320  previously described; however, in the present aspect, the inner layers  22320  do not comprise the corresponding left and right coupling portions  22340 , 22342  (shown in  FIG.  22   ). Thus, a width W4 of each of the inner layers  22320  can be less than a width W3 of each of the outer layers  20120 . It should be noted that the various dimensions disclosed in  FIG.  30    are merely exemplary and should not be considered limiting. 
     To secure the inner layer  22320  to the outer layer  20120 , the outer surface  23424  (shown in  FIG.  23   ) of the inner layer  22320  can be coupled to the inner surface  20122  of the outer layer  20120 , as described above. Specifically, the inner front panel  22326  of the inner layer  22320  can be coupled to the outer front panel  20126  of the corresponding outer layer  20120  between the left and right sealing portions  20140 , 21242  of the outer layer  20120 . Similarly, the inner rear panel  22328  can be coupled to the corresponding outer rear panel  21228  between the left and right sealing portions  20140 , 21242 . The left sealing portion  20140  of the outer front panel  20126  can be adhered directly to the left sealing portion  20140  of the outer rear panel  21228  to define the left seam  20114  (shown in  FIG.  20   ), and the right sealing portion  21242  of the outer front panel  20126  can be adhered directly to the right sealing portion  21242  of the outer rear panel  21228  to define the right seam  20116  (shown in  FIG.  20   ). 
       FIG.  31    illustrates the cushioned mailer  1700  according to another example aspect of the disclosure. As shown, the cushioned mailer  1700  can comprise the outer sheet  1710  defining the inner surface  1712  (shown in  FIG.  17   ) and the outer surface  1714 . The cushioned mailer  1700  can further comprise the inner sheet  1920  (shown in  FIG.  34   ) defining an inner surface  34112  and an outer surface  34114  (both shown in  FIG.  34   ). The outer surface  34114  of the inner sheet  1920  can generally define the inner cavity  1826  (shown in  FIG.  18   ) of the cushioned mailer  1700 , within which contents  1800  (shown in  FIG.  18   ) can be received. In the present aspect, both the outer sheet  1710  and the inner sheet  1920  of the cushioned mailer  1700  can be formed as a substantially planar paper sheet. In other aspects, the outer sheet  1710  and/or the inner sheet  1920  can comprise any other suitable material and/or configuration. For example, in other aspects, the outer sheet  1710  and/or the inner sheet  1920  may define cushioning sockets  42110  (such as the first and second sockets  130 , 230 ), as shown in  FIG.  42   . The cushioned mailer  1700  can further comprise an intermediate cushioning layer  31110  disposed between the outer sheet  1710  and the inner sheet  1920 . Example aspects of the cushioned mailer  1700  can define a first side, such as the left side  1750 , and an opposite second side, such as the right side  1752 . The cushioned mailer  1700  can also define the bottom end  1754  and the top end  1756  opposite the bottom end  1754 . 
     According to example aspects, the intermediate cushioning layer  31110  can comprise a plurality of the cushioning inserts  400  disposed between the inner sheet  1920  and the outer sheet  1710  to provide cushioning to the cushioned mailer  1700 . For illustrative purposes, a portion of the outer sheet  1710  is removed at Detail A to show the cushioning inserts  400  behind the outer sheet  1710 . In example aspects, the plurality of cushioning inserts  400  can be arranged side by side in a single layer between the outer and inner sheets  1710 , 1920 . Adjacent cushioning inserts  400  may confront or contact one another, or clearance may be provided between adjacent cushioning inserts  400 . In some aspects, each of the cushioning inserts  400  can be coupled to either or both of the inner sheet  1920  and the outer sheet  1710 , such as by an adhesive (e.g., glue) or any other suitable fastener known in the art. For example, in the present aspect, each of the cushioning inserts  400  can be adhered to both the outer sheet  1710  and the inner sheet  1920 , as described in further detail below. 
     Furthermore, the inner surface  34112  of the inner sheet  1920  can be coupled to the inner surface  1712  of the outer sheet  1710  to retain the intermediate cushioning layer  31110  therebetween. For example, the inner sheet  1920  can be coupled to the outer sheet  1710  by an adhesive, such as, for example, glue, or by any other suitable fastener known in the art. In the present aspect, the inner sheet  1920  can be coupled to the outer sheet  1710  at first and second sealing ends  31112 , 31114  of the cushioned mailer  1700 . In the present aspect, the first sealing end  31112  can further be folded towards and coupled to the second sealing end  31114  to define a continuous mailer sidewall  31116  wrapping around the sides of the inner cavity  1826 . Each of the first sealing end  31112  and the second sealing end  31114  can extend substantially vertically from the top end  1756  of the cushioned mailer  1700  to the bottom end  1754  of the cushioned mailer  1700 . In the present view, the first sealing end  31112  can be folded over and overlap the second sealing end  31114 , such that the first sealing end  31112  can be externally visible. The second sealing end  31114  is not externally visible in the present view; however, a dashed line generally indicating the unseen second sealing end  31114  beneath the first sealing end  31112  is shown for the sake of clarity. Moreover, in some aspects, an externally-visible crease may be formed in the cushioned mailer  1700  at an edge of the second sealing end  31114  (generally where the dashed line is shown).  FIG.  35   , described in further detail below, illustrates how the first sealing end  31112  overlaps the second sealing end  31114 . 
     As shown, each of the left side  1750  and the right side  1752  of the cushioned mailer  1700  can extend substantially vertically between the top end  1756  and the bottom end  1754 , relative to the orientation shown. In some aspects, the cushioned mailer  1700  can define first and second gussets  34120 , 34122  (shown in  FIG.  34   ) at the left and right sides  1750 , 1752  thereof, respectively. In other aspects, the cushioned mailer  1700  may not define the first and second gussets  34120 , 34122  and can simply be folded at the left and right sides  1750 , 1752  thereof to define left and right bend lines  36110 , 36112  (shown in  FIG.  36   ), respectively. Example aspects of the cushioned mailer  1700  can further define the front panel  1730  and the rear panel  1740  (shown in  FIG.  34   ) extending between the left and right sides  1750 , 1752 . In the present aspect, the first sealing end  31112  can overlap and be affixed to the second sealing end  31114  at the front panel  1730 . However, in other aspects, the first and second sealing ends  31112 , 31114  can be oriented within the first gusset  34120  or the second gusset  34122 , or at the rear panel  1740 . 
     The inner sheet  1920  can define the front inner portion  1932  (shown in  FIG.  34   ) of the front panel  1730 , and the outer sheet  1710  can define the front outer portion  1734  of the front panel  1730 . Similarly, the inner sheet  1920  can define the rear inner portion  1942  (shown in  FIG.  34   ) of the rear panel  1740 , and the outer sheet  1710  can define the rear outer portion  1744  (shown in  FIG.  34   ) of the rear panel  1740  opposite the rear inner portion  1942 . The front inner portion  1932  of the cushioned mailer  1700  can face the rear inner portion  1942  of the cushioning sheet  700 , and the inner cavity  1826  can be generally defined therebetween. 
     A bottom sealing flap  31120  can extend from the bottom end  1754  of the cushioned mailer  1700 . Specifically, in the present aspect, the bottom sealing flap  31120  can extend from the rear outer portion  1744  of the outer sheet  1710 . The bottom sealing flap  31120  can be configured to fold relative to the rear outer portion  1744  at a bottom flap fold line  31122 . Furthermore, the bottom sealing flap  31120  can be attached to the front outer portion  1734  of the outer sheet  1710 , as shown, to enclose the inner cavity  1826  at the bottom end  1754  of the cushioned mailer  1700 . For example, the bottom sealing flap  31120  can be attached to the front outer portion  1734  by an adhesive, such as glue, for example and without limitation. In other aspects, the bottom sealing flap  31120  can be attached to the front outer portion  1734  by any other suitable fasteners or fastening techniques. Moreover, in other aspects, the bottom sealing flap  31120  can extend from the front outer portion  1734  of the outer sheet  1710  and can be attached to the rear outer portion  1744  to enclose the inner cavity  1826  at the bottom end  1754 . 
     The cushioned mailer  1700  can be oriented in the open orientation (shown) and the closed orientation (shown in  FIG.  47   ). The opening  1760  can be defined at the top end  1756  of the cushioned mailer  1700 , which can allow access to inner cavity  1826 . In the open orientation, access to the inner cavity  1826  through the opening  1760  can be permitted, while in the closed orientation, the opening  1760  can be sealed to prohibit access to the inner cavity  1826 . The cushioned mailer  1700  can define the closure flap  1770  for selectively covering and uncovering the opening  1760  in the open and closed orientations, respectively. The closure flap  1770  can extend from the top end  1756  of the cushioned mailer  1700 . Specifically, in the present aspect, the closure flap  1770  can extend from the rear outer portion  1744  of the outer sheet  1710  at the top end  1756 . The closure flap  1770  can be configured to fold relative to the rear outer portion  1744  at a top flap fold line  31130  to cover the opening  1760 . The closure flap  1770  can then be attached to the front outer portion  1734  of the outer sheet  1710 , as shown in  FIG.  47   , to enclose the inner cavity  1826  at the top end  1756 . For example, the closure flap  1770  can be attached to the front outer portion  1734  to retain the cushioned mailer  1700  in the closed orientation. In other aspects, the closure flap  1700  can extend from the front outer portion  1734  of the outer sheet  1710  and can be attached to the rear outer portion  1744  to enclose the inner cavity  1826  at the top end  1756 . 
     In some aspects, a width of the closure flap  1770  can taper generally from the top end  1756  of the cushioned mailer  1700  to a distal flap end  31132  of the closure flap  1770 . However, in other aspects, the width of the closure flap  1770  may not be tapered. In example aspects, the closure flap  1770  can comprise one or more of the adhesive strips  1772  extending substantially along the width of the closure flap  1770 , generally from the left side  1750  to the right side  1752  of the cushioned mailer  1700 . In the present aspect, the closure flap  1770  can comprise two of the adhesive strips  1772  - an inner adhesive strip  1772   a  proximate to the top end  1756  and an outer adhesive strip  1772   b  proximate to the distal flap end  31132 . The tear strip  20154  can be formed between the inner and outer adhesive strips  1772   a ,b, as shown, and can extend substantially along the width of the closure flap  1770 . Each of the adhesive strips  1772  can be covered by a peelable backing  1774 , which can be peeled away from the closure flap  1770  to expose the adhesive strip  1772 . 
     The two adhesive strips  1772  can allow the cushioned mailer  1700  to be sealed in the closed orientation on two separate occasions. For example, the cushioned mailer  1700  can be sealed in the closed orientation on a first occasion with the outer adhesive strip  1772   b . The tear strip  20154  can then be torn away from the cushioned mailer  1700  to facilitate opening the cushioned mailer  1700  from the sealed configuration. The cushioned mailer  1700  can then be re-sealed in the closed orientation on a second occasion with the inner adhesive strip  1772   a . In other aspects, the closure flap  1770  can be sealed in the closed orientation by any other suitable fastener or fastening technique. In other aspects, the closure flap  1770  can comprise more or fewer of the adhesive strips  1772  and/or the tear strips  20154 . 
       FIG.  32    illustrates Detail A taken from  FIG.  32   , showing an example arrangement of the cushioning inserts  400  between the outer and inner sheets  1710 , 1920  (shown in  FIG.  31   ) of the cushioned mailer  1700  (shown in  FIG.  31   ). In example aspects, the cushioning inserts  400  can comprise a starch material, as previously described. Moreover, in example aspects, the cushioning inserts  400  can be substantially spherical in shape. In other aspects, the cushioning inserts  400  can comprise any other suitable material and/or can define any other suitable shape. In example aspects, as shown, the cushioning inserts  400  can be arranged in a single layer in a plurality of rows and columns and can substantially confront or contact adjacent ones of cushioning inserts  400 . In other aspects, the cushioning inserts  400  may be stacked to define more than one layer of the cushioning inserts  400 , and/or the cushioning inserts  400  can be arranged in any suitable pattern, and/or the cushioning inserts  400  can be spaced from adjacent cushioning inserts  400 . 
       FIG.  33    illustrates a detail view of the bottom end  1754  of the cushioned mailer  1700 . As shown, the bottom sealing flap  31120  can be folded at the bottom end  1754  to define the bottom flap fold line  31122 . The bottom sealing flap  31120  can be folded upward towards the front outer portion  1734  of the outer sheet  1710  and attached thereto to enclose the inner cavity  1826  (shown in  FIG.  34   ) at the bottom end  1754 . Also visible in  FIG.  33    is the first sealing end  31112  of the cushioned mailer  1700 , which can be folded over and secured to the second sealing end  31114  (indicated by the dashed line), as previously described to define the continuous mailer sidewall  31116  encircling the inner cavity  1826 . 
       FIG.  34    illustrates a cross-sectional view of the cushioned mailer  1700  taken along line  34 - 34  in  FIG.  31   . The cushioned mailer  1700  can comprise the inner sheet  1920  and the outer sheet  1710 . The inner sheet  1920  can define the inner surface  34112  and the outer surface  34114 , and the outer sheet  1710  can define the inner surface  1712  and the outer surface  1714 . The outer surface  34114  of the inner sheet  1920  can define the inner cavity  1826 . The cushioning inserts  400  can be disposed between the inner sheet  1920  and the outer sheet  1710 . The inner surface  34112  of the inner sheet  1920  and the inner surface  1712  of the outer sheet  1710  can face the cushioning inserts  400 , as shown. As described previously, in some aspects, the cushioning inserts  400  can be attached to either or both of the outer and inner sheets  1710 ,  1920 , such as by an adhesive, for example and without limitation. 
     The cushioned mailer  1700  can define the front panel  1730  and the rear panel  1740  extending generally between the left and right sides  1750 ,  1752 . The inner sheet  1920  can define the front inner portion  1932  of the front panel  1730 , and the outer sheet  1710  can define the front outer portion  1734  of the front panel  1730 . The inner sheet  1920  can define the rear inner portion  1942  of the rear panel  1740 , and the outer sheet  1710  can define the rear outer portion  1744  of the rear panel  1740 . Additionally, in example aspects, the first and second gussets  34120 ,  34122  can be formed at the left and right sides  1750 ,  1752 , respectively, of the cushioned mailer  1700 . Each of the first and second gussets  34120 ,  34122  can define a substantially V-shaped cross-section extending inward towards inner cavity  1826 . The first and second gussets  34120 ,  34122  can allow for a depth D of the cushioned mailer  1700  to be adjusted to accommodate contents  1800  (shown in  FIG.  18   ) of varying dimensions. Other aspects of the cushioned mailer  1700  may not comprise the first and second gussets  34120 , 34122 . 
     According to example aspects, the first sealing end  31112  (shown in  FIG.  35   ) of the cushioned mailer  1700  can be coupled to the second sealing end  31114  (shown in  FIG.  35   ) of the cushioned mailer  1700  at Detail B of the front panel  1730 . Referring to  FIG.  35   , which illustrates Detail B, a first outer sealing edge  35110  of the outer sheet  1710  can be sealed to a first inner sealing edge  35112  of the inner sheet  1920  to seal the cushioned mailer  1700  at the first sealing end  31112  thereof. For example, the first outer sealing edge  35110  can be sealed to the first inner sealing edge  35112  by an adhesive, such as glue for example and without limitation, or any other suitable fastener known in the art. Similarly, a second outer sealing edge  35114  of the outer sheet  1710  can be sealed to a second inner sealing edge  35116  of the inner sheet  1920  to seal the cushioned mailer  1700  at the second sealing end  31114  thereof, such as with an adhesive or any other suitable fastener. The first and second sealing ends  31112 ,  31114  of the cushioned mailer  1700  can aid in retaining the cushioning inserts  400  between the outer sheet  1710  and the inner sheet  1920 . 
     To form the continuous mailer sidewall  31116  (shown in  FIG.  31   ) of the cushioned mailer  1700  (shown in  FIG.  31   ) and to encircle the inner cavity  1826  thereof, the first sealing end  31112  can be folded over the second sealing end  31114 , as shown. The overlapping first and second sealing ends  31112 ,  31114  can define an outer sealing seam  35118  and an inner sealing seam  35120 . The first sealing end  31112  can further be secured to the second sealing end  31114 , such as by an adhesive, for example and without limitation, or any other suitable fastener known in the art. In some aspects, the first and second sealing ends  31112 ,  31114  can be compressed or crushed, as shown, to reduce or taper a thickness of each of the first and second sealing ends  31112 ,  31114 . Compressing or crushing the first and second sealing ends  31112 ,  31114  can compress any of the cushioning inserts  400  disposed between the outer sheet  1710  and the inner sheet  1920  at the first and second sealing ends  31112 ,  31114 , as shown, thereby allowing the overlapping first and second sealing ends  31112 ,  31114  to lie substantially flush with the remainder of the front panel  1730 . 
       FIG.  36    illustrates a cross-sectional view of the cushioned mailer  1700  according to another aspect of the present disclosure, wherein the cushioned mailer  1700  does not comprise the first and second gussets  34120 ,  34122  (shown in  FIG.  34   ) at the left and right sides  1750 , 1752  thereof. Rather, in the present aspect, the cushioned mailer  1700  can be folded to form the simple left bend line  36110  between the front and rear panels  1730 ,  7140  at the left side  1750  and the simple right bend line  36112  between the front and rear panels  1730 ,  1740  at the right side  1752 . 
       FIG.  37    illustrates a perspective view of the rolling machine  1400  and  FIG.  38    illustrates a schematic of the rolling machine  1400 , in accordance with another example aspect of the disclosure. The rolling machine  1400  of the present aspect can be configured to produce another example aspect of the cushioning sheet  700 , which can then be formed into the cushioned mailer  1700  (shown in  FIG.  31   ). In example aspects, the outer sheet  1710  of the cushioned mailer  1700  can be formed from the first layer  100 , and the inner sheet  1920  of the cushioned mailer  1700  can be formed from the second layer  200 . Each of the first and second layers  100 ,  200  can be simultaneously fed into the rolling machine  1400  as previously described. Furthermore, each of the first and second layers  100 ,  200  can be substantially smooth prior to passing through the rolling machine  1400 . In some aspects, the first and second layers  100 , 200  can also remain substantially smooth after passing through the rolling machine  1400 . According to example aspects, the rolling machine  1400  can comprise the pair of first layer rollers  310 , which can be the female rollers  1610 . In some aspects, the first layer rollers  310  can define the socket indentations  314  (shown in  FIG.  3   ), as previously described. In other aspects, however, the first layer rollers  310  can be substantially smooth. In the present aspect, the rolling machine  1400  does not comprise the second layer rollers  320  (i.e., the male rollers  1620 , both shown in  FIG.  16   ). 
     The rolling machine  1400  can further comprise a pair of the adhesive rollers  1554  configured to apply the adhesive  240  (shown in  FIG.  2   ) to the first and second layers  100 ,  200 . More specifically, as shown, the first layer  100  can be fed between a first one of the adhesive rollers  1554   a  and a first one of the female rollers  1610   a  to apply the adhesive  240  to the inner surface  1712  of the first layer  100  (i.e., the outer sheet  1710 ). Likewise, the second layer  200  can be fed between a second one of the adhesive rollers  1554   b  and a second one of the female rollers  1610   b  to apply the adhesive  240  to the inner surface  34112  of the second layer  200  (i.e., the inner sheet  1920 ). In the present aspect, the adhesive rollers  1554  can be gravure rollers  37120  (i.e., engraved rollers), which can deposit strips of the adhesive  240  onto the first and second layers  100 ,  200 . In the present aspect, neither the first layer  100  nor the second layer  200  is biased into the socket indentations  314  of the corresponding female roller  1610  when fed between the corresponding adhesive roller  1554  and female roller  1610 , and the first and second layers 100 ,  200  can thereby remain substantially smooth upon passing therebetween. 
     Once the strips of adhesive  240  have been applied to the first layer  100  and the second layer  200  by the corresponding adhesive rollers  1554 , the cushioning inserts  400  (shown in  FIG.  38   ) can be deposited onto the inner surface  1712  of the first layer  100 . Example aspects of the rolling machine  1400  can comprise the vacuum roller  600  for picking up the cushioning inserts  400  from the conveyor belt  1542  and depositing them onto the first layer  100 . The conveyor belt  1542  may or may not be configured to vibrate as previously described. The cushioning inserts  400  can be transported along the conveyor belt  1542  and can be suctioned into the corresponding insert indentations  604  (shown in  FIG.  6   ) of the vacuum roller  600 . The vacuum roller  600  can then rotate the cushioning inserts  400  towards the first layer  100 . Once the cushioning inserts  400  are proximate to or in contact with the inner surface  1712  of the first layer  100 , the suction force can be reduced or paused to release the cushioning inserts  400  from the corresponding insert indentations  604  onto the inner surface  1712  of the first layer  100 . The cushioning inserts  400  can further adhere to the strips of the adhesive  240  applied to the inner surface  1712  of the first layer  100  to retain the cushioning inserts  400  on the first layer  100 . 
     Once the cushioning inserts  400  have been deposited on the first layer  100 , each of the first and second layers  100 ,  200  can be simultaneously passed between the pair of first layer rollers  310  (i.e., the female rollers  1610 ), as previously described. The strips of adhesive  240  applied to the inner surface  34112  of the second layer  200  can adhere to the cushioning inserts  400 , such that cushioning inserts  400  can be attached to both the first and second layers  100 ,  200  (i.e., the outer and inner sheets  1710 ,  1920 ). In example aspects, the pair of female rollers  1610  can be spaced to only lightly contact the outer surfaces  1712 ,  34114  of the smooth first and second layers  100 ,  200 , respectively, without (or only minimally) pressing the first and second layers  100 ,  200  into the corresponding socket indentations  314 . The first and second layers  100 , 200  can thereby remain substantially smooth after passing between the female rollers  1610 , as shown in  FIG.  41   , and the cushioning inserts  400  can retain their volume. 
     In other aspects, however, the female rollers  1610  can be positioned closer together to bias the first and second layers  100 , 200  into the socket indentations  314 . In some aspects, the inner surface  1712  of the first layer  100  can be adhered to the inner surface  34112  of the second layer between adjacent cushioning inserts  400 , thereby forming the cushioning sockets  42110  (shown in  FIG.  42   ) in the first and second layers  100 ,  200 . Each of the cushioning inserts  400  can be received in a corresponding one of the cushioning sockets  42110  as previously described. In other aspects, the first layer rollers  310  may or may not define the socket indentations  604 , and the first layer rollers  310  can be configured to crush or compress the cushioning inserts  400  between the first and second layers  100 , 200 , without forming the cushioning sockets  42110 . That is, the cushioning inserts  400  can be compressed without adhering the first and second layers  100 ,  200  together between adjacent cushioning inserts  400 . Thus, the first and second layers  100 ,  200  can remain substantially smooth with the cushioning inserts  400  compressed therebetween to reduce an overall thickness of the cushioning sheet  700 . 
     The cushioning sheet  700  can then be fed between a pair of center nip rollers  37130  and a pair of outer nip rollers  37140 . The center nip rollers  37130  can press the first and second layers  100 ,  200  together along a centerline  37110  of the cushioning sheet  700 , and first and second layers  100 ,  200  can be sealed together along the centerline  37110  by the adhesive  240  applied thereto. Similarly, the outer nip rollers  37140  can press and seal the first and second layers  100 ,  200  together along opposing first and second sheet sides  37112   a ,b of the cushioning sheet  700 . ( FIG.  41   , described in further detail below, illustrates a cross-sectional view of the cushioning sheet  700  after passing between the center nip rollers  37130  and the outer nip rollers  37140 .) 
     The cushioning sheet  700  can then be fed between a pair of slicing rollers  37150 , which can cut the cushioning sheet  700  lengthwise along the centerline  37110  into elongated first and second sheet strips  37114   a ,b. The slicing rollers  37150  can also trim the first and second sheet sides  37112   a ,b of the cushioning sheet  700  in some aspects. According to example aspects, the rolling machine  1400  can comprise a tensioner  37160  disposed between the outer nip rollers  37140  and the slicing rollers  37150 . The tensioner  37160  can be configured to engage and tension the cushioning sheet  700  prior to slicing the cushioning sheet  700  with the slicing rollers  37150 . In example aspects, each of the sheet strips  37114   a ,b can be about 12″ wide; however, in other aspects, the width of the sheet strips  37114   a ,b can vary. In other aspects, the cushioning sheet  700  can be cut into additional sheet strips  37114   a ,b, and/or the cushioning sheet  700  may not be cut into the sheet strips  37114   a ,b. Moreover, in other aspects, the first and second layers  100 , 200  may not be sealed together along the centerline  37110  and may only be sealed at the first and second sheet sides  37112   a ,b. 
       FIG.  39    illustrates a perspective view of the vacuum roller  600  according to another example aspect of the present disclosure, and  FIG.  40    illustrates a cross-sectional view of the vacuum roller  600  taken along line  40 - 40  in  FIG.  39   . The vacuum roller  600  can define the substantially cylindrical outer surface  602  and the plurality of insert indentations  604  formed therein, each of which can be configured to pick up and retain one of the cushioning inserts  400  (shown in  FIG.  4   ). Each of the insert indentations  604  can comprise the vacuum port  606  configured to suction a corresponding one of the cushioning inserts  400  into the insert indentation  604 . In example aspects, the vacuum roller  600  can define substantially smooth opposing first and second outer roller ends  39110   a , b  and a substantially smooth center roller portion  39112 , where none of the insert indentations  604  are formed. The center roller portion  39112  of the vacuum roller  600  can be configured to align along the centerline  37110  (shown in  FIG.  37   ) of the cushioning sheet  700  (shown in  FIG.  37   ) such that none of the cushioning inserts  400  are deposited along the centerline  37110 , which can facilitate pressing and sealing the first and second layers  100 , 200  (shown in  FIG.  37   ) together along the centerline  37110 . Similarly, the opposing first and second outer roller ends  39110   a , b  of the vacuum roller  600  can be configured to align along the opposing first and second sheet sides  37112   a , b  (shown in  FIG.  37   ) of the cushioning sheet  700  such that none of the cushioning inserts  400  are deposited along the first and second sheet sides  37112   a , b , which can facilitate pressing and sealing the first and second layers  100 , 200  together along the first and second sheet sides  37112   a , b . 
       FIG.  41    illustrates a cross-sectional view of the cushioning sheet  700  sectioned into the first and second sheet strips  37114   a , b . As shown, the cushioning sheet  700  can comprise the first layer  100  (e.g., the outer sheet  1710 ), the second layer  200  (e.g., the inner sheet  1920 ), and the plurality of the cushioning inserts  400  disposed therebetween. In the present aspect, each of the first and second layers  100 ,  200  can be substantially smooth and do not define the cushioning sockets  42110  (shown in  FIG.  42   ). The first and second layers  100 ,  200  can be sealed together along the centerline  37110  of the cushioning sheet  700  and at the opposing first and second sheet sides  37112   a , b , as previously described. In example aspects, the cushioning sheet  700  can further be cut along the centerline  37110  to separate the first sheet strip  37114   a  from the second sheet strip  37114   b . 
     The cushioning sheet  700  can be used to form the cushioned mailer  1700  (shown in  FIG.  31   ). In example aspects, the first layer  100  of the cushioning sheet  700  can define the outer sheet  1710  of the cushioned mailer  1700 , and the second layer  200  of the cushioning sheet  700  can define the inner sheet  1920  of the cushioned mailer  1700 . When the cushioning sheet  700  is sliced along the centerline  37110  to separate the first and second sheet strips  37114   a ,b, the first sheet strip  37114   a  can be used to form a first one of the cushioned mailers  1700 , and the second sheet strip  37114   b  can be used to form a second one of the cushioned mailers  1700 . 
       FIG.  42    illustrates a cross-sectional view of the cushioning sheet  700  sectioned into the first and second sheet strips  37114   a ,b according to another example aspect of the disclosure. In the present aspect, the first and second layers  100 ,  200  can define the cushioning sockets  42110  (e.g., the first sockets  130  in the first layer  100  and the second sockets  230  in the second layer  200 ) for receiving the cushioning inserts  400  therein. In some aspects, the first and second layers  100 ,  200  can be sealed together between adjacent cushioning inserts  400 , such as by the adhesive  240  (shown in  FIG.  2   ). In other aspects, the first and second layers  100 ,  200  may not be sealed together between adjacent cushioning inserts  400 , but can simply can be biased towards one another between the adjacent cushioning inserts  400  to define less pronounced cushioning sockets  42110 . 
       FIG.  43    illustrates a top view of the cushioning sheet  700  being fed through the center nip rollers  37130  to press and seal the first and second layers  100 ,  200  (second layer  200  shown in  FIG.  37   ) together along the centerline  37110  and the outer nip rollers  37140  to press and seal the first and second layers  100 ,  200  together along the opposing first and second sheet sides  37112   a , b . Each of the center nip rollers  37130  can comprise a center wheel  43130 , and the first and second layers  100 , 200  can be pressed together along the centerline  37110  between the center wheels  43130 . Similarly, each of the outer nip rollers  37140  can define a first outer wheel  43140  and an opposite second outer wheel  43142 . The first and second layers  100 , 200  can be pressed together at the first sheet side  37112   a  between the first outer wheels  43140  and at the second sheet side  37112   b  between the second outer wheels  43142 . In some aspects, each of the outer nip rollers  37140  can also comprise a secondary center wheel  43144  to further press the first and second layers  100 , 200  together along the centerline  37110 . However, other aspects of the outer nip rollers  37140  may not comprise the secondary center wheels  43144 . 
       FIG.  43    also shows the cushioning sheet  700  being fed through the slicing rollers  37150  to cut the cushioning sheet  700  along the centerline  37110  and to trim the cushioning sheet  700  at the first and second sheet sides  37112   a ,b. As shown, either or both of the slicing rollers  37150  can comprise a slicing wheel  43150  configured to cut the cushioning sheet  700  into the first and second sheet strips  37114   a , b . Either or both of the slicing rollers  37150  can also comprise a first outer trim wheel  43152  and a second outer trim wheel  43154 . The first outer trim wheel(s)  43152  can trim the cushioning sheet  700  along the first sheet side  37112   a  thereof, and the second outer trim wheel(s)  43154  can trim the cushioning sheet  700  along the second sheet side  37112   b  thereof. 
       FIGS.  44 - 47    illustrate the cushioned mailer  1700  according to another example aspect of the present disclosure. Similar to the cushioned mailer  1700  of  FIG.  31   , the present cushioned mailer  1700  can comprise the outer sheet  1710  and the inner sheet  1920  (shown in  FIG.  46   ). The inner sheet  1920  can generally define the inner cavity  1826  (shown in  FIG.  46   ) of the cushioned mailer  1700 , within which contents  1800  (shown in  FIG.  18   ) can be received. In the present aspect, both the outer sheet  1710  and the inner sheet  1920  can be formed as a substantially planar paper sheet, though in other aspects, the outer sheet  1710  and/or the inner sheet  1920  can define the cushioning sockets  42110  (shown in  FIG.  42   ). The cushioned mailer  1700  can further comprise the intermediate cushioning layer  31110  (shown in  FIG.  45   ) disposed between the outer sheet  1710  and the inner sheet  1920 , which in the present aspect can comprise the plurality of the cushioning inserts  400  (shown in  FIG.  45   ). A flap portion  45110  of the outer sheet  1710  is folded back in the present view to show the cushioning inserts  400 . 
     Example aspects of the cushioned mailer  1700  can define the left side  1750 , the right side  1752 , the bottom end  1754 , and the top end  1756 . As shown, each of the left side  1750  and the right side  1752  of the cushioned mailer  1700  can extend substantially vertically between the top end  1756  and the bottom end  1754 . The first and second gussets  34120 , 34122  (shown in  FIG.  46   ) can be formed at the left and right sides  1750 , 1752 , respectively. The cushioned mailer  1700  can further define the front panel  1730  and the rear panel  1740  (shown in  FIG.  46   ) extending between the left and right sides  1750 , 1752 . The opening  1760  can be defined at the top end  1756  of the cushioned mailer  1700 , which can allow access to inner cavity  1826 . The cushioned mailer  1700  can define the closure flap  1770  extending from the top end  1756  thereof for selectively covering and uncovering the opening  1760  in the open and closed orientations, respectively. 
     The closure flap  1770  can comprise one or more of the adhesive strips  1772  extending substantially from the left side  1750  to the right side  1752  of the cushioned mailer  1700 . In the present aspect, the closure flap  1770  comprises the inner adhesive strip  1772   a  proximate to the top end  1756  and the outer adhesive strip  1772   b  proximate to the distal flap end  31132 . The tear strip  20154  can be formed between the inner and outer adhesive strips  1772   a , b , as shown. Each of the adhesive strips  1772  can be selectively covered by the peelable backing  1774 , which can be peeled away from the cushioned mailer  1700  to expose the adhesive strip  1772 . The cushioned mailer  1700  can be sealed in the closed orientation on a first occasion with the outer adhesive strip  1772   b . The tear strip  20154  can then be torn away from the cushioned mailer  1700  to facilitate opening the cushioned mailer  1700  from the sealed configuration. The cushioned mailer  1700  can then be re-sealed in the closed orientation on a second occasion with the inner adhesive strip  1772   a . 
     In the present aspect, the cushioned mailer  1700  does not comprise the bottom sealing flap  31120  (shown in  FIG.  31   ). Furthermore, the first sealing end  31112  (shown in  FIG.  31   ) is not folded over and coupled to the second sealing end  31114  (shown in  FIG.  31   ) at the front panel  1730 , as previously described. Rather, in the present aspect, the cushioned sheet  700  forming the cushioned mailer  1700  can be folded over onto itself at the bottom end  1754  and sealed at the left side  1750  and the right side  1752 , similar to the embodiment shown in  FIGS.  17 - 19   . As shown, the cushioned mailer  1700  can define the bottom fold line  1755  at the bottom end  1754  thereof. Moreover, the left and right sealing flaps  1930   a ,b (shown in  FIG.  58   ) can be defined at the left and right sides  1750 ,  1752 , respectively. 
     In the present aspect, a first edge portion  58120  (shown in  FIG.  58   ) of the outer sheet  1710  can extend outward beyond the inner sheet  1720  and the intermediate cushioning layer  31110  to define the left sealing flap  1930   a , and a second edge portion  58122  (shown in  FIG.  58   ) of the outer sheet  1710  can extend outward beyond the inner sheet  1720  and the intermediate cushioning layer  31110  to define the right sealing flap  1930   b . As previously described, in the folded orientation, the left sealing flap  1930   a  can be folded over and secured to itself to seal the cushioned mailer  1700  at the left side  1750  thereof, and the right sealing flap  1930   b  can be folded over and secured to itself to seal the cushioned mailer  1700  at the right side  1752  thereof. The cushioned mailer  1700  can be sealed at the left and right sides  1750 ,  1752  thereof by an adhesive, such as glue for example, or any other suitable fastener or fastening technique known in the art. 
     As shown in  FIG.  46   , the cushioned mailer  1700  can further be folded inward at the left and right sides  1750 ,  1752  thereof to define the first and second gussets  34120 ,  34122 .  FIG.  47    illustrates the cushioned mailer  1700 , wherein the closure flap  1770  can be folded over the opening  1760  (shown in  FIG.  46   ) of the inner cavity  1826  (shown in  FIG.  46   ). In example aspects, each of the peelable backings  1774  can extend outward beyond the closure flap  1770  in the present aspect, as described in further detail below with respect to  FIGS.  48 - 50   . One of the peelable backings  1774  can be removed from the corresponding adhesive strip  1772  (shown in  FIG.  44   ) and sealed to the front panel  1730  in the closed orientation. 
       FIGS.  48 - 50    illustrate the closure flap  1770  of the cushioned mailer  1700  according to another example aspect of the present disclosure. As shown, the closure flap  1700  can comprise the tear strip  20154  and one or more of the adhesive strips  1772 . For example, in the present aspect, the closure flap  1770  comprises the inner adhesive strip  1772   a  only, though other aspects of the closure flap  1770  can comprise additional adhesive strips  1772 . The inner adhesive strip  1772   a  can be disposed proximate to the opening  1760 , and the tear strip  20154  can be disposed distal to the opening  1760 , proximate to the distal flap end  31132 . 
     In example aspects, one or more hanging holes  48110  can be formed through the tear strip  20154 . The hanging holes  48110  can be configured to receive a hanger device therethrough to suspend the cushioned mailer  1700  therefrom in an upright, vertical orientation (i.e., with the top end  1756  of the cushioned mailer  1700  vertically above the bottom end  1754 , shown in  FIG.  17   ). Hanging the cushioned mailer  1700  in such a vertical orientation can facilitate locating and retrieving the cushioned mailer  1700  for use. Additionally, hanging the cushioned mailer  1700  in the vertical orientation can facilitate inserting contents  1800  (shown in  FIG.  18   ) downwardly into the inner cavity  1826  (shown in  FIG.  46   ) through the opening  1760 , such as at a packaging facility. Once the contents  1800  have been loaded into the inner cavity  1826 , the cushioned mailer  1700  can be separated from the tear strip  20154  to dismount the cushioned mailer  1700  from the hanger device. In some aspects, the tear strip  20154  can remain attached to the hanger device when the cushioned mailer  1700  is separated therefrom. In other aspects, the cushioned mailer  1700  can be removed from the hanger device with the tear strip  20154  still attached thereto, and the tear strip  20154  can later be separated from the cushioned mailer  1700 . Two of the hanging holes  48110  are shown in the present aspect; however, in other aspects, the closure flap  1770  can comprise more or fewer hanging holes  48110 . 
     As shown, the adhesive strip  1772  can be covered by the peelable backing  1774  prior to sealing the cushioned mailer  1700  in the closed orientation. In example aspects, the peelable backing  1774  can define an overhanging tab  48120  at a first backing end  48122  of the peelable backing  1774 . The overhanging tab  48120  can extend beyond a flap side edge  48130  of the closure flap  1770 , such that the overhanging tab  48120  is exposed at both a front backing side  48124  and an opposite rear backing side  49126  (shown in  FIG.  49   ) of the peelable backing  1774 . The overhanging tab  48120  of the peelable backing  1774  can be easily gripped and pulled by a user to facilitate removing the peelable backing  1774  from the adhesive strip  1772 .  FIG.  50    illustrates the overhanging tab  48120  being pulled away from the adhesive strip  1772 . 
       FIG.  51    illustrates the cushioned mailer  1700  according to another example aspect of the present disclosure. The cushioned mailer  1700  of  FIG.  51    can be substantially similar to the cushioned mailer  1700  of  FIGS.  44 - 47   ; however, in the present aspect, the intermediate cushioning layer  31110  disposed between the outer sheet  1710  and the inner sheet  1920  (shown in  FIG.  19   ) can comprise a textured sheet  51110  instead of the cushioning inserts  400  (shown in  FIG.  45   ). The textured sheet  51110  can be formed as previously described. A flap portion  51120  of the outer sheet  1710  is folded back in the present view to show the textured sheet  51110 . The textured sheet  51110  can comprise a plurality of the cushioning sockets  42110 . For example, the textured sheet  51110  can be substantially the same as or similar to the first layer  100  comprising first sockets  130  (shown in  FIG.  1   ) or the second layer  200  comprising the second sockets  230  (shown in  FIG.  2   ). In some aspects, additional layers of the textured sheets  51110  may disposed between the outer sheet  1710  and the inner sheet  1920 . 
     As shown in  FIG.  52   , the cushioning sockets  42110  can extend from a sheet base  52110  of the textured sheet  51110 , similar to the first base  120  of the first layer  100  (shown in  FIG.  1   ) or the second base  220  of the second layer  200  (shown in  FIG.  2   ). The sheet base  52110  can be substantially planar in example aspects. Furthermore, in some aspects, each of the cushioning sockets  42110  can define a substantially cylindrical socket sidewall  52120  extending from the sheet base  52110  and a substantially domed or semi-spherical socket end  52122  extending from the socket sidewall  52120  opposite the sheet base  52110 . In other aspects, each of the cushioning sockets  42110  can be substantially semi-spherical like the first and second sockets  130 , 230 . In other aspects, the cushioning sockets  42110  can define any other suitable shape. 
       FIG.  53    illustrates the cushioned mailer  1700  in a blank configuration, in accordance with one example aspect of the present disclosure. As shown, the cushioned mailer  1700  can define the rear panel  1740  and the first and second gussets  34120 ,  34122  disposed at either side of the rear panel  1740 . In the blank configuration, the front panel  1730  can define a first front flap  53110  extending from the first gusset  34120  opposite the rear panel  1740  and a second front flap  53112  extending from the second gusset  34122  opposite the rear panel  1740 . The first front flap  53110  can define the first sealing end  31112 , and the second front flap  53112  can define the second sealing end  31114 . In the present aspect, a front sealing adhesive  53114 , such as glue, can be applied to the first sealing end  31112  for attaching the first sealing end  31112  to the second sealing end  31114 . The front sealing adhesive  53114  can seal the first front flap  53110  to the second front flap  53112  to form the front panel  1730  when the cushioned mailer  1700  is in an assembled configuration (shown in  FIG.  54   ). 
     According to example aspects, each of the first and second gussets  34120 ,  34122  can define a rear gusset flap  53120  connected to the rear panel  1740  at a rear flap bend line  53122  and a front gusset flap  53130  connected to the front panel  1730  at a front flap bend line  53132 . The rear and front gusset flaps  53120 ,  53130  can be configured to fold inward at the rear and front flap bend lines  53122 ,  53132 , respectively, towards the inner cavity  1826  (shown in  FIG.  18   ). Furthermore, the rear gusset flap  53120  can be connected to the corresponding front gusset flap  53130  at a side gusset bend line  53140 . The rear gusset flap  53120  can be configured to fold towards the front gusset flap  53130  at the side gusset bend line  53140  to define the V-shaped cross-section of the corresponding first and second gussets  34120 ,  34122 , as previously described. 
     Additionally, the bottom sealing flap  31120  can extend from the rear panel  1740  at the bottom end  1754  of the cushioned mailer  1700 , and the closure flap  1770  can extend from the rear panel  1740  at the top end  1756  of the cushioned mailer  1700 . A bottom sealing adhesive  53150 , such as glue, can be applied to the bottom sealing flap  31120  to seal the bottom sealing flap  31120  to the front panel  1730  when the cushioned mailer  1700  is in the assembled configuration. The closure flap  1770  can comprise the inner and outer adhesive strips  1772   a ,b and the tear strip  20154  disposed therebetween. Example dimensions of the cushioned mailer  1700  are shown in inches in  FIG.  53   . The dimensions disclosed herein are merely exemplary and should not be construed as limiting. 
       FIG.  54    illustrates the cushioned mailer  1700  of  FIG.  54    in the assembled configuration. In the assembled configuration, the first sealing end  31112  can be folded over and sealed to the second sealing end  31114  (shown in  FIG.  53   ) to join the first front flap  53110  to the second front flap  53112  and to form the continuous mailer sidewall  31116 . The first front flap  53110  and the second front flap  53112  can together define the front panel  1730 , as shown. Furthermore, the bottom sealing flap  31120  extending from the rear panel  1740  (shown in  FIG.  53   ) can be folded over and sealed to the front panel  1730  at the bottom end  1754  of the cushioned mailer  1700  to seal the inner cavity  1826  (shown in  FIG.  46   ) at the bottom end  1754 . In the present view, a portion of the outer sheet  1710  is removed to show the intermediate cushioning layer  31110  disposed between the outer sheet  1710  and the inner sheet  1920  (shown in  FIG.  55   ). In the present aspect, the intermediate cushioning layer  31110  can be the textured sheet  51110 . The various example dimensions shown in  FIG.  54    are in inches. The dimensions disclosed herein are merely exemplary and should not be construed as limiting 
       FIG.  55    illustrates a cross-sectional view and a detailed cross-sectional view of the cushioned mailer  1700  taken along line  55 - 55  in  FIG.  54   . As shown, the textured sheet  51110  can be disposed between the outer sheet  1710  and the inner sheet  1920 . Both the outer sheet  1710  and the inner sheet  1920  can be substantially smooth. In example aspects, the cushioning sockets  42110  can extend inward towards the inner sheet  1920 , as shown. In example aspects, extending the cushioning sockets  42110  inward towards the inner sheet  1920  can aid in maintaining the smoothness of the outer sheet  1710 . In some aspects, the domed socket end  52122  (shown in  FIG.  52   ) of each cushioning socket  42110  can be adhered to the inner sheet  1920  and/or the sheet base  52110  (shown in  FIG.  52   ) of the textured sheet  51110  can be adhered to the outer layer  1710 . In other aspects, the cushioning sockets  42110  can extend outward towards the outer sheet  1710 . 
       FIG.  56    the cushioned mailer  1700  in the assembled configuration, in accordance with another example aspect of the present disclosure. The cushioned mailer  1700  of  FIG.  56    can be assembled from the blank configuration in the same manner as the cushioned mailer  1700  of  FIGS.  53 - 55   . However, in the present aspect, the intermediate cushioning layer  31110  can comprise the cushioning inserts  400 . The various example dimensions of the cushioned mailer  1700  shown in  FIG.  56    are in inches. The dimensions disclosed herein are merely exemplary and should not be construed as limiting.  FIG.  57    illustrates a cross-sectional view and a detailed cross-sectional view of the cushioned mailer  1700  taken along line  57 - 57  in  FIG.  56   . As shown, the cushioning inserts  400  can be disposed between the outer sheet  1710  and the inner sheet  1920 . Both the outer sheet  1710  and the inner sheet  1920  can be substantially smooth. In other aspects, the outer sheet  1710  and/or the inner sheet  1920  can define the cushioning sockets  42110 . In example aspects, the cushioning inserts  400  can confront, and in some instances may contact, adjacent ones of the cushioning inserts  400 . In other aspects, the cushioning inserts  400  can be spaced from adjacent cushioning inserts  400 . 
       FIG.  58    illustrates the cushioned mailer  1700  in the blank configuration, in accordance with another example aspect of the present disclosure. The cushioned mailer  1700  of the present aspect can define the rear panel  1740  and the front panel  1730 . The front panel  1730  can be connected to the rear panel  1740  by the bottom fold line  1755 . The front panel  1730  can be folded relative to the rear panel  1740  at the bottom fold line  1755  to substantially confront the rear panel  1740  and to define the inner cavity  1826  (shown in  FIG.  18   ) therebetween in the assembled configuration. The cushioned mailer  1700  can define the first and second gussets  34120 ,  34122 . In the present aspect, each of the first and second gussets  34120 ,  34122  can comprise one of the rear gusset flaps  53120  connected to the rear panel  1740  at the rear flap bend line  53122  and one of the front gusset flaps  53130  connected to the front panel  1730  at the front flap bend line  53132 . 
     Each of the rear gusset flaps  53120  can be hingedly connected to the corresponding front gusset flap  53130  at a bottom gusset bend line  58124 . In example aspects, each of bottom gusset bend lines  58124  can be formed as an extension of the bottom fold line  1755 . Each of the front gusset flaps  53130  can be folded towards the corresponding rear gusset flap  53120  at the bottom gusset bend line  58124  as the front panel  1730  is folded towards the rear panel  1740  at the bottom fold line  1755 . Furthermore, the left and right sealing flaps  1930   a ,b can extend along an outer gusset edge  58126  of the first and second gussets  34120 ,  34122 , respectively. 
     In some aspects, the intermediate cushioning layer  31110  (shown in  FIG.  31   ) and/or the inner sheet  1920  can terminate at the outer gusset edges  58126 . For example, in the present aspect, the left and right sealing flaps  1930   a ,b, can be defined by the outer sheet  1710  only. The first edge portion  58120  of the outer sheet  1710  can extend outward beyond the first gusset  34120  to define the left sealing flap  1930   a , and the second edge portion  58122  of the outer sheet  1710  can extend outward beyond the second gusset  34122  to define the right sealing flap  1930   b . In other aspects, the inner sheet  1920  and/or the intermediate cushioning layer  31110  can also extend outward beyond the outer gusset edges  58126  to partially define the left and right sealing flaps  1930   a , b . 
     A gusset adhesive  58128 , such as glue for example and without limitation, can be applied to each of the left and right sealing flaps  1930   a , b . When the cushioned mailer  1700  is folded to the assembled configuration, a front flap portion  58130  of each of the left and right sealing flaps  1930   a ,b adjacent to the corresponding front gusset flap  53130  can be adhered to a rear flap portion  58132  of the corresponding left or right sealing flap  1930   a ,b adjacent to the corresponding rear gusset flap  53120 . Moreover, in the assembled configuration, the side gusset bend lines  53140  (shown in  FIG.  53   ) can be formed at the outer gusset edges  58126 , and the first and second gussets  34120 ,  34122  can fold inward towards the inner cavity  1826  (shown in  FIG.  18   ) in the assembled configuration, as previously described. The various example dimensions of the cushioned mailer  1700  shown in  FIG.  58    are in inches. The dimensions disclosed herein are merely exemplary and should not be construed as limiting. 
       FIG.  59    is an exploded view of an example aspect of the cushioned mailer  1700 , illustrating the textured sheet  51110  disposed between the outer sheet  1710  and the inner sheet  1920 . In the present aspect, first edge portions  58120   a ,b,c and second edge portions  58122   a , b , c  of the inner sheet  1920 , the textured sheet  51110 , and the outer sheet  1710  can cooperate to define the left and right sealing flaps  1930   a ,b (shown in  FIG.  58   ). In some aspects, the first edge portions  58120   a , b , c  and the second edge portions  58122   a ,b,c of the inner sheet  1920 , the textured sheet  51110 , and the outer sheet  1710  can be substantially smooth to facilitate adhering the inner sheet  1920 , the textured sheet  51110 , and the outer sheet  1710  together and forming substantially smooth left and right sealing flaps  1930   a , b . 
       FIG.  60    is a cross-sectional view of the top end  1756  of the cushioned mailer  1700  taken along line  60 - 60  in  FIG.  55   . In some aspects, as shown, the front inner portion  1932  of the inner sheet  1920  can be sealed to the front outer portion  1734  of the outer sheet  1710  at the top end  1756  of the cushioned mailer  1700  to define a front top seam  60110 . Similarly, the rear inner portion  1942  of the inner sheet  1920  can be sealed to the rear outer portion  1744  of the outer sheet  1710  at the top end  1756  of the cushioned mailer  1700  to define a rear top seam  60112 . In some aspects, the inner sheet  1920  and/or the outer sheet  1710  can also or alternatively be sealed to the intermediate cushioning layer  31110  at the top end  1756 . However, in other aspects, as shown in  FIGS.  23 A and  23 B , the inner sheet  1920  may not be sealed to the outer sheet  1710  at the top end  1756  of the cushioned mailer  1700 . 
       FIG.  61    illustrates the textured sheet  51110  in accordance with another example aspect of the disclosure. In example aspects, one or more of the textured sheets  51110  and/or cushioning sheets  700  (shown in  FIG.  7   ) can be as cushioning and/or insulation in packaging applications other than mailers. For example, in the present aspect, first and second textured sheets  511   10   a , b  can be received within an interior box cavity  61122  of a box  61120  to cushion and/or insulate contents  1800  (shown in  FIG.  18   ) received in the interior box cavity  61122 . In example aspects, each of the first and second textured sheets  51110   a , b  can be folded into a C-shape. 
     The first textured sheet  51110   a  can define a first center liner panel  61114   a  disposed between a first side liner panel  61118   a  and a second side liner panel  61118   b . A first side fold  61116   a  can be defined between the first side liner panel  61118   a  and the first center liner panel  61114   a , and a second side fold  61116   b  can be defined between the second side liner panel  61118   b  and the first center liner panel  61114   a . Similarly, the second textured sheet  51110   b  can define a second center liner panel  61114   b  disposed between a third side liner panel  61118   c  and a fourth side liner panel  61118   d . A third side fold  61116   c  can be defined between the third side liner panel  61118   c  and the second center liner panel  61114   b , and a fourth side fold  61116   d  can be defined between the fourth side liner panel  61118   d  and the second center liner panel  61114   b . 
     The box  61120  can define a bottom box panel  61124  and an open top box end  61126  opposite the bottom box panel  61124 . In other aspects, a top box panel (not shown) can be formed at the top box end  61126 . The box  61120  can further define first, second, third, and fourth box side panels  61128   a , b , c , d . When the first and second textured sheets  51110   a , b  are assembled with the box  61120 , each of the first, second, third, and fourth side liner panel  61118   a , b , c , d  can be configured to confront a corresponding one of the first, second, third, and fourth box side panels  61128   a , b , c , d , respectively. Additionally, the first center liner panel  61114   a  can be disposed at the top box end  61126 , and the second center liner panel  61114   b  can confront the bottom box panel  61124 . In other aspects, the textured sheets  51110  and/or cushioning sheets  700  can be utilized in any other suitable packaging application. 
     One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. 
     It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.