Patent Publication Number: US-11046497-B2

Title: Crimped cushioned envelopes and method of forming the same

Description:
BACKGROUND 
     The present disclosure is in the technical field of forming cushioned envelopes. More particularly, the present disclosure is directed to forming cushioned envelopes by crimping areas of a laminated web material to form side seams of the cushioned envelopes. 
     A wide variety of objects, including fragile items, are transported in various types of mailing envelopes. In some cases, these envelopes have cushioning to provide some level of protection for the objects transported therein. The outer walls of cushioned envelopes are typically formed from protective materials, such as Kraft paper, cardstock, polyethylene-coated paper, other paper-based materials, polyethylene film, or other resilient materials. The walls of cushioned envelopes are lined with cushioning materials, such as air cellular material (e.g., BUBBLE WRAP™ air cellular material sold by Sealed Air Corporation), foam sheets, or any other cushioning material. The walls are typically adhered to the cushioning material when forming the cushioned envelopes. 
     There are a number of competing goals with the production of cushioned envelopes. It is desirable for the cushioned envelope to have sufficient strength to withstand the rigors of transportation. At the same time, it is desirable to keep the cost of the cushioned envelope as low as possible. In addition, it is desirable to be able to produce cushioned envelopes at a high rate (e.g., more than 60-100 envelopes per minute), and it can be difficult to produce high-strength, low-cost cushioned envelopes at such a high rate. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     In one embodiment a method of forming a cushioned envelope includes feeding a laminated web material comprising a cushioning web a shell web. Each of the cushioning web and the shell web includes an inner side and an outer side and the outer side of the cushioning web is laminated to the inner side of the shell web. The method further includes applying a crimping adhesive to a first transverse seam of the inner side of the cushioning web and to a second transverse seam of the inner side of the cushioning web and folding the laminated web material so that the first transverse seam on the inner side of the cushioning web is folded in on itself and the second transverse seam on the inner side of the cushioning web is folded in on itself. The method further includes crimping the laminated web material at the first transverse seam and at the second transverse seam after folding the laminated web material and cutting the laminated web material at a location in the first transverse seam and at a location in the second transverse seam after crimping the laminated web material. 
     In one example, the method further includes forming the laminated web material and the forming includes applying a laminating adhesive to at least one of the inner side of the shell web or the outer side of the cushioning web and pressing together the shell web and the cushioning web. In another example, the cushioning web includes a sheet of inflated cells. In another example, the method further includes inflating the sheet of inflated cells before forming the laminated web material. In another example, the crimping adhesive and the laminating adhesive have different formulations. 
     In another example, crimping the laminated web material includes rotating crimping rollers that comprise crimping extensions. In another example, the crimping rollers are arranged so that the crimping extensions are in an interference fit when each of the crimping extensions extends toward another other crimping roller. In another example, rotating the crimping rollers includes controlling a rotational speed of the crimping rollers so that a linear speed of ends of the crimping extensions is substantially similar to a linear speed of the laminated web material. In another example, at least one of the ends of the crimping extensions is convex. 
     In another example, applying the crimping adhesive to the first transverse seam comprises applying an amount of the crimping adhesive in a range from about 1.18 oz/yd 2  to about 3.54 oz/yd 2 . In another example, folding the laminated web material comprises forming an off-center fold in the laminated web material, and the off-center fold defines a short side of the laminated web material and a long side of the laminated web material. In another example, the long side of the laminated web material comprises an adhesive strip. In another example, the short side extends a first distance away from the off-center fold, wherein the adhesive strip is located on the long side at a location that is a second distance away from the off-center fold, and first distance is less than the second distance. 
     In another example, the shell web comprises a paper-based material, and wherein the outer side of the shell web is uncoated. In another example, the shell web includes a polymer-based film. In another example, each of the first transverse seam and the second transverse seam has a seam strength that is greater than or equal to about 3.5 pounds per inch of seam. In another example, the method is performed repeatedly to cause formation of the cushioned envelope at a rate of at least 700 cushioned envelopes per minute. In another example, the cushioning web comprises an air cellular material having a series of transverse rows of inflatable cells, and the method further includes deflating at least one of the transverse rows of inflatable cells before applying the crimping adhesive, where the crimping adhesive is applied to the deflated at least one of the transverse rows of inflatable cells. In another example, the deflating includes peeling back a first layer of the air cellular material to expose a second layer of the air cellular material, and wherein the crimping adhesive is applied to the second layer of the deflated at least one of the transverse rows of inflatable cells. 
     In another embodiment, a cushioned envelope includes a laminated web material, first and second transverse seams, and a crimping adhesive. The laminated web material includes a cushioning web and a shell web, each of the cushioning web and the shell web includes an inner side and an outer side, and the outer side of the cushioning web is laminated to the inner side of the shell web. The first and second transverse seams are on the inner side of the cushioning web. The crimping adhesive is applied to the first and second transverse seams. The laminated web material is folded so that the first transverse seam on the inner side of the cushioning web is folded in on itself and the second transverse seam on the inner side of the cushioning web is folded in on itself. The folded laminated web material is crimped at a location in the first transverse seam and at a location in the second transverse seam so that the crimped locations in the first and second transverse seams form sides of the cushioned envelope. 
     In one example, the cushioning web includes a sheet of inflated cells. In another example, a laminating adhesive applied to at least one of the inner side of the shell web or the outer side of the cushioning web adheres the shell web to the cushioning web. In another example, the crimping adhesive and the laminating adhesive have different formulations. In another example, each of the crimping adhesive and the laminating adhesive has a number average molecular weight between about 500 and about 1400. In another example, each of the crimping adhesive and the laminating adhesive has a molecular weight in a range between about 30,000 and about 60,000. In another example, each of the crimping adhesive and the laminating adhesive has a polydispersity index in a range between about 25 to about 70. In another example, an amount of the crimping adhesive applied to the first and second transverse seams is in a range from about 1.18 oz/yd 2  to about 3.54 oz/yd 2 . 
     In another example, the laminated web material is folded at an off-center fold in the laminated web material, and wherein the off-center fold defines a short side of the laminated web material and a long side of the laminated web material. In another example, the long side comprises an adhesive strip. In another example, the short side extends a first distance away from the off-center fold, wherein the adhesive strip is located on the long side at a location that is a second distance away from the off-center fold, and wherein first distance is less than the second distance. In another example, the shell web comprises a paper-based material, and wherein the outer side of the shell web is uncoated. In another example, each of the first transverse seam and the second transverse seam has a seam strength that is greater than or equal to about 4.5 pounds per inch of seam. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
         FIGS. 1A to 1C  depict front, top cross-sectional, and partial detail views, respectively, of an embodiment of a cushioned envelope that exhibits clam-shelling along its side; 
         FIG. 2  depicts embodiments of a system and a method of forming cushioned envelopes, in accordance with the embodiments disclosed herein; 
         FIGS. 3A and 3B  depict front and bottom views of an embodiment of lamination of a shell web to a cushioning web that are shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 4A and 4B  depict front and bottom views of an embodiment of intermittent application of a crimping adhesive to the inner side of the cushioning web that is shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 5A and 5B  depict front and bottom views of an embodiment of a folding process of the laminated web material that is shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 6A and 6B  depict front and bottom views of an instance of the interaction of the crimping rollers and the laminated web material that are shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 6C and 6D  depict front and bottom views of another instance of the interaction of the crimping rollers and the laminated web material that are shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 7A and 7B  depict front and bottom views of an embodiment of a cutting element arranged to cut the laminated web material shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 8A and 8B  depict front and bottom views of an embodiment of cushioned envelopes formed from the laminated web material shown in  FIG. 2 , in accordance with the embodiments disclosed herein; 
         FIGS. 9A to 9D  depict instances of a method of packaging an object using a cushioned envelope formed by the system and method shown in  FIG. 2 , in accordance with the embodiments disclosed herein; and 
         FIGS. 10A to 10C  depict front, top cross-sectional, and partial detail views, respectively, of the cushioned envelope formed by the system and method shown in  FIG. 2 , including sides of the cushioned envelope that do not exhibit clam-shelling, in accordance with the embodiments disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes embodiments of cushioned mailers with sides formed by crimping. As noted above, it is desirable for cushioned mailers to have high strength and low cost, while being able to be produced at a high rate. Existing systems and methods of producing cushioned envelopes do not meet all of these goals. One example of some of the deficiencies of existing systems and methods of producing cushioned envelopes is shown in  FIGS. 1A to 1C . More particularly,  FIGS. 1A to 1C  depict front, top cross-sectional, and partial detail views, respectively, of an embodiment of a cushioned envelope  100  that exhibits clam-shelling along its side. 
     The cushioned envelope  100  is formed from a laminated web material  102 . The laminated web material  102  includes a shell web  104  laminated to a cushioning web  106 . In particular, a portion of an inner side of the shell web  104  is laminated to an outer side of the cushioning web  106 . In some embodiments, the shell web  104  includes one or more paper-based materials, such as Kraft paper, cardstock, or any other paper-based material. In some embodiments, the cushioning web  106  includes one or more of a web of inflatable cells, a web of sheet foam (e.g., closed-cell foam or open-cell foam), or any other web of cushioning material. 
     The laminated web material  102  is folded about an off-center fold  108 . The off-center fold  108  in the laminated web material  102  defines a short side of the laminated web material  102  and a long side of the laminated web material  102 . In the embodiment shown in  FIG. 1A , the short side is in front of the long side. The laminated web material  102  forms a pocket  110  and a flap  112 . The pocket  110  is formed from the short side of the laminated web material  102  and a portion of the long side of the laminated web material  102 . The flap  112  is formed from a portion of the long side of the laminated web material  102  that extends beyond the pocket  110 . In the depicted embodiment, the cushioning web  106  is laminated to the portion of the shell web  104  that is located in the pocket and the portion of the shell web  104  in the flap  112  is not laminated to the cushioning web  106 . In the depicted embodiment, the flap  112  includes an adhesive strip  116 . The adhesive strip  116  can be used to close the cushioned envelope  100  by folding the flap  112  down and adhering the adhesive strip  116  to the pocket  110 . 
     The pocket  110  of the cushioned envelope  100  includes crushed sides  114 . In some cases, the crushed sides  114  are formed by jaws. The jaws form the crushed sides  114  by holding the sides of the pocket  110  under pressure. In some examples, the jaws are heated to cause melting of a coating (e.g., a polymer-based coating) on the exterior of the shell web  104 . The solidification of the coating after the crushed sides  114  are formed can aid in maintaining the shape of the crushed sides  114 . As can be seen in  FIG. 1B , the cushioning web  106  is crushed between the cushioning web  106  in the area of the crushed sides  114  so that the cushioning web  106  lines the interior of the shell web  104  in the pocket  110 . 
     One issue with cushioned envelopes is clam-shelling along the sides of cushioned envelopes. Clam-shelling refers to the separation of ends on sides of cushioning envelopes. In some cases, clam-shelling can appear to an observer to be the beginning of a complete separation of the sides. An embodiment of clam-shelling is depicted on the cushioning envelope  100  in  FIGS. 1B and 1C . More specifically, the crushed sides  114  are separated at ends  118  of the shell web  104 . In some cases the separation of the crushed sides  114  is a separation of one or both of the shell web  104  or the cushioning web  106  in the crushed sides  114 . The separation of the ends  118  may appear to an observer that the crushed sides  114  are separating or otherwise lack structural integrity. In some cases, the crushed sides  114  do not lack structural integrity, even though the ends  118  of the shell web  104  are somewhat separated and may cause an observer to think otherwise. In some cases, clam-shelling in the cushioned envelope  100  is a result the process of forming the cushioned envelope  100 . 
     A previous attempt to address the problem of clam-shelling included a combination of a polymer-based coating on the inner side of the shell web  104  and the use of heated jaws to cut and seal the ends  118  of the shell web  104  and to form the crushed sides  114 . The laminated web material  102  is formed into an elongated web that is fed by the jaws. As the laminated web material  102  is fed, the jaws are periodically brought together. The jaws have a cutting element to cut the ends  118  of the shell web  104  from the laminated web material  102 . The jaws also have a heating element to heat the shell web  104 . As the jaws are brought together, the jaws cut the ends  118  of the shell web  104  and heat the coating on the inner side of the shell web  104 . The heated coating from both sides of the inner side of the shell web  104  flows together and then, after the jaws are removed, the coating solidifies to form a single bar of the coating that seals the ends  118 . This seal of the coating deters any separation of the ends  118 . 
     There are some drawbacks to the heated jaws approach. In one example, the use of the heated claims requires the shell web  104  to be coated, such as with a polymer-based coating. The coating makes the shell web  104  more expensive than the uncoated version of the shell web  104 . In another example, the use of the heated jaws slows down the process of making the cushioned envelopes. In order to sufficiently heat the coating, the heated jaws must remain in contact with the laminated web material  102  for a period of time. This typically requires the feeding of the laminated web material  102  to be halted during the time that the heated jaws are in contact the laminated web material  102 . This results in the laminated web material  102  being repeatedly moved a short distance and halted for a time, before starting the process again to move the laminated web material  102  another short distance and halt the laminated web material  102  to make another cut and seal. The repeated halting of the laminated web material  102  limits the overall speed with which the cushioned envelopes can be created. 
     What is needed is a process of creating cushioned envelopes that do not exhibit clam-shelling, while not requiring an external coating and not requiring regular stopping of laminated web material during formation of the cushioned envelopes. Disclosed herein are systems and methods of forming cushioned mailers by crimping the sides of the cushioned envelope. In some embodiments disclosed herein, the sides of a cushioned envelope are crimped by crimping rollers before the sides of the cushioned envelope are cut. The embodiments described herein of crimping cushioned envelope sides can be used to produce high-strength cushioned envelopes that can cost less and can be produced at higher rates than the cushioned mailers that are produced using heated jaws to cut and seal their sides. 
     Depicted in  FIG. 2  are embodiments of a system  230  and a method of forming cushioned envelopes  200 . The perspective of  FIG. 2  is from a bottom view of the cushioned envelopes  200 . The system  230  includes a supply  232  of a shell web  204 . Systems for supplying webs of film, paper, and other materials are known in art and may include unwind mechanisms and other features. In some embodiments, the shell web  204  includes a paper-based material, such as Kraft paper, cardstock, or any other paper-based material. In some embodiments, the shell web  204  is a polymer-based film, such as a polythene film. The system  230  also includes a supply  234  of a cushioning web  206 . In some embodiments, the cushioning web  206  includes one or more of a web of inflatable cells, a web of sheet foam (e.g., closed-cell foam or open-cell foam), or any other web of cushioning material. In some embodiments, the supply  234  includes a film of inflatable cells and the system  230  further includes an inflation and seal device that inflates the cells in the film and seals the cells in the inflated state. The system  230  also includes feeding rollers  236  configured to support and direct the shell web  204  and the cushioning web  206 . In some embodiments, the feeding rollers  236  include driving rollers that are powered to feed the shell web  204  and the cushioning web  206 , passive rollers that are moved by the passage of the shell web  204  and the cushioning web  206 , or some combination of driving rollers and passive rollers. In other embodiments, the system  230  includes additional feeding rollers downstream of the feeding rollers  236  in the depiction shown in  FIG. 2 . 
     The system  230  includes an adhesive applicator  238  configured to apply laminating adhesive  220  that is usable to laminate the outer side of the cushioning web  206  to the inner side of the shell web  204 . In the depicted embodiment, the adhesive applicator  238  is positioned to apply the laminating adhesive  220  onto the inner side of the shell web  204 . In other embodiments, the adhesive applicator  238  can be positioned to apply the laminating adhesive  220  onto the outer side of the cushioning web  206 . In some embodiments, the laminating adhesive  220  includes one or more of REYNOLDS 810-C adhesive, REXTAC 2330 adhesive, HENKELTDM 4700 adhesive, HP FULLER NW1137 ZP adhesive, BOSTIC H9689 adhesive, or IFS-6-85-11 adhesive. In some emblements, the laminating adhesive  220  has a number average molecular weight (Mn) between about 500 and about 1400. The number average molecular weight (Mn) is a statistical average of molecular weights of an entire population of the polymer chains in a given sample. In some embodiments, the laminating adhesive  220  has a molecular weight (Mw) in a range between about 30,000 and about 60,000. The molecular weight of a polymer (Mw) takes into account the molecular weight of a chain in the samples, where larger or bigger chains generally correspond to higher average Mw. In some embodiments, the laminating adhesive  220  has a polydispersity index (Mw/Mn) in a range between about 25 to about 70. The polydispersity is a ratio of Mw/Mn and it represents the degree of branching in polymers, where higher polydispersity index generally corresponds with greater branching and degree of entanglement in the polymer. In some embodiments, the laminating adhesive  220  is either an amorphous structure or a semi-crystalline material having a melt point in a range between about 28° C. to about 92° C. 
     In some embodiments, the adhesive applicator  238  is configured to apply the laminating adhesive  220  by one or more of spraying, thermal drop-on-demand depositing, piezoelectric drop-on-demand depositing, electrostatic depositing, or any other form of applying the laminating adhesive  220 . In some embodiments, the laminating adhesive  220  is applied at a temperature in a range from about 300° F. to about 450° F. In some embodiments, the amount of the laminating adhesive  220  applied to the seams is in a range from about 0.059 oz/yd 2  (2 g/m 2 ) to about 0.44 oz/yd 2  (15 g/m 2 ). 
     After the laminating adhesive  220  is applied, the outer side of the cushioning web  206  is laminated to the inner side of the shell web  204 . The lamination of the shell web  204  to the cushioning web  206  is further depicted in front and bottom views shown in  FIGS. 3A and 3B . In the depicted embodiment, the outer side of the cushioning web  206  is laminated to the inner side of the shell web  204  to form a laminated web material  202 . In the depicted embodiment, the cushioning web  206  is a web of inflated hemispherical cells and the outer side of the cushioning web  206  that is laminated to the inner side of the shell web  204  is the rounded side of the inflated hemispherical cells. In other embodiments, the cushioning web  206  could be any other shape of inflated cellular cushioning, foam sheeting, or any other type of cushioning material. 
     As can be seen in  FIG. 3A , the laminated web material  202  includes a laminated portion  210 ′ and a flap  212 . The laminated portion  210 ′ includes the portion of the shell web  204  that is laminated to the cushioning web  206 . The flap  212  includes the portion of the shell web  204  that extends beyond the cushioning web  206 . In the depicted embodiment, the laminating adhesive  220  has been applied to the shell web  204  in the area that is laminated to the cushioning web  206  and becomes the laminated portion  210 ′. In some embodiments, the adhesive applicator  238  applies the laminating adhesive  220  continuously onto the shell web  204 , such as in the continuous application of the laminating adhesive  220  on the shell web  204  in the embodiment depicted in  FIG. 3A . In other embodiments, the adhesive applicator  238  applies the laminating adhesive  220  intermittently to the shell web  204 . In some embodiments, a pressure is applied to the shell web  204  and the cushioning web  206  as they are laminated together, such as a pressure exerted by two of the feeding rollers  236  as the shell web  204  and the cushioning web  206  pass between the two feeding rollers  236 . 
     Referring back to  FIG. 2 , the laminated web material  202  is fed to an adhesive applicator  240  that is configured to apply a crimping adhesive  222  to the laminated web material  202  on the inner side of the cushioning web  206 . In some embodiments, the crimping adhesive  222  includes one or more of REYNOLDS 810-C adhesive, REXTAC 2330 adhesive, HENKELTDM 4700 adhesive, HP FULLER NW1137 ZP adhesive, BOSTIC H9689 adhesive, or IFS-6-85-11 adhesive. In some embodiments, the crimping adhesive  222  has a number average molecular weight (Mn) between about 500 and about 1400. In some embodiments, the crimping adhesive  222  has a molecular weight (Mw) in a range between about 30,000 and about 60,000. In some embodiments, the crimping adhesive  222  has a polydispersity index (Mw/Mn) in a range between about 25 to about 70. In some embodiments, the crimping adhesive  222  is either an amorphous structure or a semi-crystalline material having a melt point in a range between about 28° C. to about 92° C. 
     In some embodiments, the adhesive applicator  240  is configured to apply the crimping adhesive  222  by one or more of spraying, thermal drop-on-demand depositing, piezoelectric drop-on-demand depositing, electrostatic depositing, or any other form of applying the crimping adhesive  222 . In some embodiments, the crimping adhesive  222  is applied at a temperature in a range from about 300° F. to about 450° F. In some embodiments, the crimping adhesive  222  has the formulation as the laminating adhesive  220 . For example, the crimping adhesive  222  and the laminating adhesive  220  may both be REXTAC 2330 adhesive. In some embodiments, the crimping adhesive  222  has a different formulation than the laminating adhesive  220 . For example, the crimping adhesive  222  may be REYNOLDS 810-C adhesive and the laminating adhesive  220  may be HP FULLER NW1137 ZP adhesive. 
     The adhesive applicator  240  is configured to apply the crimping adhesive  222  intermittently to the inner side of the cushioning web  206 . The intermittent application of the crimping adhesive  222  is further depicted in front and bottom views shown in  FIGS. 4A and 4B . As can be seen in  FIG. 4A , the crimping adhesive  222  is applied to transverse seams on the inner side of the crimping adhesive  222 . The transverse seams with the crimping adhesive  222  are spaced apart from each other in a longitudinal direction of the laminated web material  202 . In the depicted embodiment, the crimping adhesive  222  applied to the laminated web material  202  does not cover any portion of the shell web  204 . In some embodiments, the amount of the crimping adhesive  222  applied to the seams is in a range from about 1.18 oz/yd 2  (40 g/m 2 ) to about 3.54 oz/yd 2  (120 g/m 2 ). In some embodiments, the seams covered by the crimping adhesive  222  are about 6.5 inches in length in the transverse direction and about 1 inch in the longitudinal direction. 
     In some embodiments, where the cushioning web  206  is an air cellular material, a portion of the air cellular material may be deflated prior to applying the crimping adhesive  222 . In particular, the portion of the air cellular material that is deflated prior to applying the crimping adhesive may include the area where the crimping adhesive  222  is later applied. In one example, the cushioning web  206  may include a series of transverse rows of inflatable cells, where each transverse row includes inflatable cells that are in fluid communication with each other. In this example, at least one transverse row may be deflated before the crimping adhesive  222  is applied to the deflated at least one transverse row. In some embodiments, deflating a portion of the air cellular material includes peeling back one layer of the air cellular material from the deflated portion such that the other layer of the air cellular material is exposed. In some cases, the exposed layer is adhered to the shell web  204  via the laminating adhesive  220  and then the crimping adhesive  222  is applied to the exposed layer. In this case, anything adhered to the exposed layer of the air cellular material via the crimping adhesive  222  may have a more secure feel because the exposed layer of the air cellular material is also directly adhered to the shell web  204 . 
     Referring back to  FIG. 2 , the laminated web material  202  is fed so that a folding process  242  is performed to fold the laminated web material  202 . The folding process  242  of the laminated web material  202  is further depicted in front and bottom views shown in  FIGS. 5A and 5B . The folding process  242  causes the laminated web material  202  to be folded about a fold  208  with the inner side of the cushioning web  206  folded in on itself. More particularly, the folding process  242  causes each of the seams of the crimping adhesive  222  to be folded in on itself. After the folding process  242  is completed, the transverse seams of the crimping adhesive  222  are no longer visible, but the locations  224  of the transverse seams are depicted by dashed lines in the figures. 
     In the depicted embodiment, the fold  208  is an off-center fold in the laminated web material  202 . The off-centered fold  208  defines a short side of the laminated web material  202  and a long side of the laminated web material  202 . In  FIG. 5A , the short side of the laminated web material  202  is located in front of the long side of the laminated web material  202 . The laminated web material  202  forms a pocket  210  and a flap  212 . The pocket  210  is formed from the short side of the laminated web material  202  and a portion of the long side of the laminated web material  202 . The flap  212  is formed from a portion of the long side of the laminated web material  202  that extends beyond the pocket  210 . In the depicted embodiment, the cushioning web  206  is laminated to the portion of the shell web  204  that is located in the pocket and the portion of the shell web  204  in the flap  212  is not laminated to the cushioning web  206 . In the depicted embodiment, the flap  212  includes an adhesive strip  216  that is usable to close the flap  212 . In the depicted embodiment, the adhesive strip  216  is at a location that is further away from the fold  208  than the short side of the laminated web material  202  extends from the fold  208 . 
     Referring back to  FIG. 2 , the system  230  includes crimping rollers  244 . The laminated web material  202  is fed until it reaches the crimping rollers  244 . The crimping rollers  244  and the laminated web material  202  are further depicted in front and bottom views of one instance shown in  FIGS. 6A and 6B  in front and bottom views of another instance shown in  FIGS. 6C and 6D . Each of the crimping rollers  244  includes a crimping extension  246 . The crimping extensions  246  extend further away from the rotational axis of the crimping rollers  244  than other portions of the crimping rollers  244  extend from the rotational axis. The crimping rollers  244  rotate as the laminated web material  202  is fed linearly. The crimping rollers  244  are arranged so that the crimping extensions  246  periodically contact the laminated web material  202  as the crimping rollers  244  rotate to form crimped areas  214 ′. More specifically, in the instance depicted in  FIGS. 6A and 6B , the crimping extensions  246  extended toward each other to form one of the crimped areas  214 ′. The crimping rollers  244  continue to rotate and the laminated web material  202  is fed while the crimping rollers  244  are not in contact with the laminated web material  202 , as shown in  FIGS. 6C and 6D . In this way, the crimped areas  214 ′ are longitudinally-spaced from each other in the laminated web material  202 . 
     In the depicted embodiment, the crimped areas  214 ′ are formed at the locations  224  of the transverse seams where the crimped adhesive  222  is located. In some embodiments, the rotational speed of the crimping rollers  244  and/or the linear speed of the laminated web material  202  are controlled in order to control locations of the crimped areas  214 ′ in the laminated web material  202 . In some embodiments, the rotational speed of the crimping rollers  244  is controlled so that a linear speed of the ends of the crimping extensions  246  is substantially similar to a linear speed of the laminated web material  202  when the crimping extensions  246  come into contact with the laminated web material  202 . In the depicted embodiment, the ends of the crimping extensions  246  are convex. In some cases, the convex ends enable the crimping extensions  246  to remain close to each other as they are rotated through the position depicted in the instance shown in  FIGS. 6A and 6B . In some embodiments, the crimping rollers  244  are located in an interference fit when each of the crimping extensions  246  extends toward another the other of the crimping rollers  244 . In an interference fit, the distance between the two rotational axes of the crimping rollers  244  is less than the sum of the distance from the rotational axis of one of the crimping rollers  244  to the end of its crimping extension  246  and the distance from the rotational axis of the other of the crimping rollers  244  to the end of its crimping extension  246 . In some embodiments, the interference is less than or equal to about 0.010 inches (0.25 mm). In some embodiments, the interference is about 0.004 inches (0.10 mm). 
     Referring back to  FIG. 2 , the system  230  further includes a cutting element  248 . In some embodiments, the cutting element  248  includes one or more of a linear blade, a rotary blade, a heat element, or any other cutting mechanism. The cutting element  248  and the laminated web material  202  are further depicted in front and bottom views shown in  FIGS. 7A and 7B . The cutting element  248  is configured to make transverse cuts in the laminated web material  202 . In the depicted embodiment, the cutting element  248  is configured to make transverse cuts in the crimped areas  214 ′ to form crimped sides  214  on either side of each cut. In some embodiments, the timing of the transverse cuts by the cutting element  248  is dependent on the rotation of the crimping rollers  244  so that the cutting element  248  makes a transverse cut once per rotation of the crimping rollers  244 . As shown in the depicted embodiments, the cutting element  248  is configured to cut through the laminated web material  202 , including the shell web  204  and the cushioning web  206 , and the adhesive strip  216 . 
     After subsequent transverse cuts are formed by the cutting element  248 , the portion of the laminated web material  202  between two cuts forms a cushioned envelope  200 . A number of cushioned envelopes  200  are shown in  FIGS. 2, 7A, and 7B , and are further depicted in front and bottom views shown in  FIGS. 8A and 8B . The cushioned envelope  200  is formed from the laminated web material  202 , which includes the shell web  204  laminated to the cushioning web  206 . The laminated web material  202  is folded about the off-center fold  208 . In the embodiment shown in  FIG. 8A , the short side is in front of the long side. The laminated web material  202  forms the pocket  210  and the flap  212 . The pocket  210  of the cushioned envelope  200  includes crimped sides  214 . In the depicted embodiment, the flap  212  includes an adhesive strip  216 . As is discussed in greater detail below, the adhesive strip  216  can be used to close the cushioned envelope  200 . 
     Depicted in  FIGS. 9A to 9D  are instances of a method of using the cushioned envelope  200  to packaging an object  260 . The cushioned envelope  200  includes those features mentioned above with respect to  FIGS. 8A and 8B . In the depicted embodiments, the object  260  is a tablet computing device. In other embodiments, the object  260  can be any item or collection of items capable of being placed inside the cushioned envelope  200 . 
     In  FIG. 9A , the object  260  is located near the cushioned envelope  200 . The flap  212  is open and the pocket  210  is unfilled. In  FIG. 9B , the object  260  has been partially inserted into the pocket  210 . In  FIG. 9C , the object  260  has been fully inserted into the pocket  210 . The adhesive strip  216  is also being prepared for use in closing the flap  212 . In the depicted embodiment, the adhesive strip  216  includes a removable liner  226  that is located over a closure adhesive  228 . As shown in  FIG. 9C , the removable liner  226  is being removed from the closure adhesive  228 . Once the removable liner  226  is completely removed from the closure adhesive  228 , the flap  212  can be folded over and adhered to the front of the pocket  210 . In  FIG. 9D , the flap  212  is in a closed state with the flap  212  folded over and adhered to the front of the pocket  210 . In other embodiments, the adhesive strip  216  has other forms, such as a press-and-seal adhesive that does not adhere to another surface until the press-and-seal adhesive is pressed against the other surface, a moistenable adhesive that does not adhere to another surface until it has been moistened, or any other form of adhesive. 
     In some embodiments, the cushioned envelope  200  addresses the problem of the clam-shelling even if the shell web  204  is uncoated.  FIGS. 10A to 10C  depict front, top cross-sectional, and partial detail views, respectively, of the cushioned envelope  200  that does not exhibit clam-shelling along its side. In the depicted embodiment, the shell web  204  is made from a paper-based material that is uncoated (e.g., the shell web  204  is made from Kraft paper that does not have a polymer-based coating). 
     The crimped sides  214  have been formed from the crimping of a number of layers. More particularly, as described above, the laminated web material  202  is formed from a layer of the shell web  204 , a layer of the laminating adhesive  220 , and a layer of the cushioning web  206 . Transverse seams of the crimping adhesive  222  are then applied to the cushioning web  206  of the laminated web material  202 . Then, the laminated web material  202  is folded so that the transverse seams of the crimping adhesive  222  are folded in on themselves. As a result, the cross-section of the locations  224  of the seams includes one layer of the shell web  204 , one layer of the laminating adhesive  220 , one layer of the cushioning web  206 , two layers of the crimping adhesive  222 , another layer of the cushioning web  206 , another layer of the laminating adhesive  220 , and another layer of the shell web  204 . The locations  224  of the seams are then crimped to form crimped areas  214 ′ that are then cut to form the crimped sides  214 . 
     In the depicted embodiment, ends  218  of the crimped sides  214  do not exhibit clam-shelling. In some embodiments, the ends  218  of the crimped sides  214  are held together by one or both of the laminating adhesive  220  or the crimping adhesive  222 . In some cases, the strength of the seam at the crimped sides  214  is due to one or more of the formulation of the laminating adhesive  220 , the temperature at which the laminating adhesive  220  is applied to the shell web  204  and/or the cushioning web  206 , the formulation of the crimping adhesive  222 , the temperature at which the crimping adhesive  222  is applied to the laminated web material, the force with which the crimping rollers  244  form the crimped areas  214 ′, the temperature at which the crimping rollers  244  form the crimped areas  214 ′, or the temperature at which the cutting element  248  cuts the crimped areas  214 ′ to form the crimped sides  214 . In some embodiments, the strength of the seam is greater than or equal to about 3.5 pounds per inch (0.63 kilograms per centimeter) of the seam. In some embodiments, the strength of the seam is greater than or equal to about 4.5 pounds per inch (0.80 kilograms per centimeter) of the seam. 
     One benefit of the system  230  and the method depicted in  FIG. 2  is the speed with which the cushioned envelopes  200  can be created. In some embodiments, the system  230  and the method depicted in  FIG. 2  are capable of producing the cushioned envelopes  200  at a rate of equal to or greater than 100 of the cushioned envelopes  200  per minute. In some embodiments, the system  230  and the method depicted in  FIG. 2  are capable of producing the cushioned envelopes  200  at a rate of equal to or greater than 700 or 1000 of the cushioned envelopes  200  per minute. In some embodiments, the system  230  and the method depicted in  FIG. 2  are capable of producing the cushioned envelopes  200  at a rate of equal to or greater than 150 of the cushioned envelopes  200  per minute. The rate at which the system  230  and the method depicted in  FIG. 2  can produce the cushioned envelopes  200  may be greater than a rate at which the cushioned envelope  100  can be produced. As noted above, the cushioned envelope  100  can be made in a process that requires the laminated web material  102  to be halted repeatedly as it is fed. Such repeated halting of the laminated web material  102  slows the process of creating the cushioned envelopes  100 . In contrast, the crimping rollers  244  are able to form the crimped areas  214 ′ without halting the laminated web material  202 . 
     For purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value. 
     The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.