Patent Publication Number: US-11390445-B1

Title: Packaging products and associated material

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. patent application Ser. No. 15/720,538 filed on Sep. 29, 2017, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates to packaging, and more particularly to structure and function of packaging structures for shipping products. 
     Many common packaging products, such as, for example, padded envelopes (e.g, “jiffy mailers” or “bubble mailers”), are made from a combination of paper-based materials and plastic-based materials bonded together. While the paper-based materials of the packaging product may be recyclable in a paper-based recycling facility and the plastic-based materials may be recyclable in a plastic-based recycling facility, such products need to be separated into their paper-based and plastic-based materials prior to depositing them into a recycling bin, at least in most areas or municipalities. Thus, such products, as received by a consumer or other recipient, are not considered “curbside recyclable.” Unfortunately, such packaging products often find their way into landfills or other garbage disposal sites. 
     The inventors of the present disclosure have identified that imparting deformations in prior art paper-based packaging products, such as rigid corrugated paperboard (also referred to as “cardboard” or “corrugate”), results in impairment of performance of such products because rigidity becomes compromised. After rigid corrugated paperboard is folded, creased, and/or bent, portions thereof have localized weaknesses that can impair its protective functionality which relies substantially on rigidity. For example, certain types of corrugate possess a high compressive strength yet, should a crease be formed therein, the corrugate no longer exhibits protective functionality because its strength is compromised. Moreover, while certain features can be incorporated into paper-based packaging products to enhance strength, such features add complexity, and thus cost, to such packaging products. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description will be better understood when read in conjunction with the appended drawings, in which there is shown in the drawings example embodiments for the purposes of illustration. It should be understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings: 
         FIG. 1  shows an exploded perspective view of constituent layers of a packaging cushion, including a cushion layer having a mesh, such as a paper-based mesh, according to an embodiment of the present disclosure; 
         FIG. 2  shows a top plan view of a packaging cushion including a mesh, with an outer layer of material omitted for visualization purposes, wherein the packaging cushion is similar to that shown in  FIG. 1 , and the mesh is formed in a single piece of corrugate, according to an embodiment of the present disclosure; 
         FIG. 3  shows a top view of a portion of the mesh of  FIG. 2  in an initial mesh configuration; 
         FIG. 4  shows a perspective view of a portion of the mesh of  FIG. 2  in the initial mesh configuration; 
         FIG. 5  shows a top view of a portion of the mesh of  FIG. 2  in a first expanded configuration; 
         FIG. 6  shows a perspective view of a portion of the mesh of  FIG. 5 ; 
         FIG. 7  shows a top view of a portion of the mesh of  FIG. 2  in a second expanded configuration; 
         FIG. 8  shows a perspective view of a portion of the mesh of  FIG. 7 ; 
         FIG. 9  shows a top view of a portion of a mesh according to another embodiment of present disclosure, wherein the mesh is formed in a piece of kraft paper, and is shown in an initial mesh configuration. 
         FIG. 10  shows a top view of the portion of the mesh of  FIG. 9  in an expanded mesh configuration; 
         FIG. 11  shows a perspective view of the portion of the mesh of  FIG. 10 ; 
         FIG. 12  shows an exploded perspective view of a padded envelope employing a cushioning layer, according to an embodiment of the present disclosure; 
         FIG. 13  shows a perspective view of a pair of padded envelopes employing a mesh cushioning layer; 
         FIG. 14  shows an end sectional view of a single-panel package employing a mesh packaging cushion, according to an embodiment of the present disclosure; and 
         FIG. 15  shows a schematic plan diagram of a system for making a mesh packaging cushion, according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments of the present disclosure pertain to packaging products and material used to form the padded mailer that includes a mesh cushion layer that provides multi-directional flexibility and may also be curbside-recyclable at least with only trivial preparation. The embodiments of the present disclosure include padded envelopes, for example, that employ such cushion layers and are optionally curbside-recyclable. As used herein with respect to packaging products or portions thereof (such as a cushion or a cushioning layer, for example), the terms “resilient”, “resilience”, “resiliency”, and derivatives thereof refer to an ability to at least partially recover one&#39;s size and shape after deformation, particularly (though not exclusively) deformation responsive to compressive stress. 
     Referring to  FIG. 1 , a packaging cushion  2  includes a cushion layer  4  disposed between a first outer layer of material  6  and a second outer layer of material  8  such that the layers  4 ,  6 ,  8  define a laminar or “sandwich” structure. The outer layers  6 ,  8  can be referred to as an “outer liner” and an “inner liner”, or vice versa.  FIG. 1  depicts the packaging cushion  2  in an initial, substantially flat configuration, in which the outer layers  6 ,  8  and the cushion layer  4  are each elongated in substantially planar manner along a longitudinal direction X and a lateral direction Y that are substantially perpendicular to each other. The layers  4 ,  6 ,  8  also each have a thickness in a transverse direction Z that is substantially perpendicular to the longitudinal and lateral directions X, Y. The transverse direction Z is denoted as the “Z” direction because it extends across the sandwich structure of the layers  4 ,  6 ,  8 . It is to be appreciated that the packaging cushion  2  can be flexible; thus, with respect to any location  10  on the packaging cushion  2 , the packaging cushion  2  defines a transverse axis  11  oriented along the transverse direction Z at the location  10 , such that the transverse direction Z is substantially orthogonal to the outer layers  6 ,  8  at the location  10 . When the packing cushion  2  is in the initial configuration, the transverse direction Z is substantially perpendicular to the longitudinal and lateral directions X, Y. 
     The cushion layer  4  includes a flexible mesh  12  (also referred to herein as a “mesh”), which includes a plurality of legs  14  extending between a plurality of nodes  16 , as also shown in  FIG. 2 . Flexible mesh  12  may be made of paper, metal, plastic, and/or other materials. The plurality of legs  14  can interconnect the plurality of nodes  16 . The legs  14  and nodes  16  can define a plurality of voids or “cells”  18  in the mesh  12  extending between adjacent legs  14  and nodes  16  along the longitudinal and lateral directions X, Y. The legs  14  and nodes  16  can be arranged into patterns in a manner such that the cells  18  are also arranged into patterns, as set forth in more detail below. It is to be appreciated that the packaging cushion  2  can itself be characterized as a piece of corrugate, with the outer layers  6 ,  8  fulfilling the role of the outer and inner liners and the mesh  12  fulfilling the role of the fluting. 
     In some embodiments, such as the present embodiment, the layers  4 ,  6 ,  8  of the packaging cushion  2  can each be formed of one or more paper-based materials that are curbside recyclable. As used herein, the term “curbside recyclable” means capable of being recycled in a recycling facility and/or in a recycling process available to the public through most municipal recycling programs. In some such embodiments, each of the outer layers  6 ,  8  can be formed substantially entirely of a packaging paper, such as kraft paper or paperboard, by way of non-limiting examples. Additionally, the mesh  12  can be formed substantially entirely of kraft paper, paperboard, or corrugated paperboard (i.e., “cardboard” or “corrugate”). Thus, the packaging cushion  2  can be paper-recyclable. 
     A binder  20  can, for example, be disposed around a periphery  22  of the mesh  12  in a manner attaching the mesh  12  to one or both of the outer layers  6 ,  8 . The binder  20  can be applied so as to contact the mesh  12  primarily at peripheral nodes  16 , as shown. However, in other embodiments, the binder  20  can be applied so as to contact peripheral legs  14 , or both peripheral legs  14  and peripheral nodes  16 . In further embodiments, the binder  20  can be applied so as to contact non-peripheral legs  14  and/or non-peripheral nodes  16 . It is to be appreciated that the binder  20  can be applied so as to contact any combination of legs  14  and/or nodes  16 . The binder  20  can be an adhesive, such an adhesive strip (or strips), and/or a liquid-based adhesive, such as an epoxy or glue, by way of non-limiting examples. Adhesive may alternatively or additionally be applied via aerosol dispersed throughout at least a portion of the space between the mesh  12  and the adjacent outer layers  6 ,  8 . In further embodiments, adhesive can be applied to one or both of the inner surfaces  24  of the outer layers  6 ,  8  in an evenly and/or unevenly distributed manner. For example, an even coating of adhesive can be applied to one or both of the inner surfaces  24  of the outer layers  6 ,  8 , which coating can adhere to the opposite side of the mesh  12 . In yet other embodiments, adhesive can be applied to one or both of the inner surfaces  24  of the outer layers  6 ,  8  in a pattern, such as a zig-zag pattern, for example. Such a zig-zag pattern can optionally correspond to a pattern defined by the mesh  12 . 
     The binder  20  may include recyclable and/or non-recyclable components. Many municipalities provide residential curbside recyclability for packaging that includes small amounts of non-recyclable materials. For this reason, binder  20  may include conventional adhesives, such as those used in prior art corrugate boxes. Alternatively, or additionally, binder  20  may be a PLA-capable adhesive. In other embodiments, the binder  20  can include an adhesive cord or string, such as a cotton and/or hemp-based adhesive string, for example. The binder  20  can consist of one or more materials that are recyclable, such as Recycling Compatible Adhesives (“RCAs”), such as Corvinax (e.g., Corvinax 324-39, Corvinax 379-05, Corvinax 418-01), for example. 
     Referring now to  FIG. 2 , a cushion layer  4  is shown with the first outer layer  6  removed. The mesh  12  is shown attached to a support surface  24  of the second outer layer  8  by the binder  20  extending around the periphery  22  of the mesh  12 . A second binder  26  can be disposed adjacent a periphery  28  of the second outer layer  8  and can be configured to bind the second outer layer  8  to the first outer layer  6 . As with the first binder  20 , the second binder  26  can optionally be substantially 100 percent paper-recyclable. 
     With reference to  FIGS. 3 through 11 , the mesh  12  can have multi-directional flexibility, as well as improved resiliency relative to prior art corrugate, in at least one of the longitudinal, lateral, and transverse directions X, Y, Z. In the illustrated embodiments, the mesh  12  is flexible in each of the longitudinal, lateral, and transverse directions X, Y, Z. In the embodiment illustrated in  FIG. 2 , the mesh  12  is formed in a single piece of corrugate  30 . The legs  14  and nodes  16  can be formed in the corrugate  30  mechanically, such as by a cutting machine. By way of non-limiting example, in such a cutting machine, the piece of corrugate  30  can be inserted along the longitudinal direction X into an induction end of the machine and can be directed over a bladed roller (i.e., a cylinder with outwardly extending blades) or between a pair of bladed rollers. The bladed roller(s) can carry blades oriented along the longitudinal direction X, for example, and can cut a repeating pattern of through-cuts in the corrugate  30  so as to transform the corrugate  30  into the mesh  12 . It is to be appreciated that the foregoing cutting machine represents merely one example of a mechanism for forming the legs  14  and nodes  16  in the mesh  12 , and other mechanisms are within the scope of the present disclosure. 
     Referring now to  FIGS. 3 and 4 , a portion of the mesh  12  of  FIG. 2  is shown in an initial, unexpanded mesh configuration, such as when the mesh  12  exits the cutting machine, for example. In  FIG. 3 , some of the nodes  16  are identified by dashed areas for visualization purposes. The nodes  16  can include peripheral nodes  16   a  located at the periphery  22  of the mesh  12 , as well as non-peripheral or internal nodes  16   b  inward of the periphery  22 . The mesh  12  portion defines an area in the longitudinal and lateral directions X, Y, which area is defined by a first length L 1  along the longitudinal direction X and a first width W 1  along the lateral direction Y. 
     Lateral edges of the legs  14  and nodes  16  of the mesh  12  can be defined by through-cuts  32  in the corrugate  30 . The mesh pattern can be configured such that the nodes  16  are arranged in rows  34  of nodes  16  and columns  36  of nodes  16 . The nodes  16  of each row  34  can be substantially aligned along a row axis  38  extending along the lateral direction Y. Adjacent rows  34  can be spaced from each other along the longitudinal direction X by a distance greater than zero. The nodes of each column  36  can be substantially aligned along a column axis  40  extending along the longitudinal direction X. At least in the initial mesh configuration, the nodes  16  in adjacent node columns  36  can overlap each other with respect to the lateral direction Y. 
     With reference to  FIG. 3 , one or more of the nodes  16  can define first and second lateral edges  42 ,  44  spaced from each other along the lateral direction Y, as well as first and second longitudinal ends  46 ,  48  spaced from each other along the longitudinal direction X. Each respective node  16  can be connected to an adjacent node  16  by one or more legs  14 . In the example embodiment illustrated in  FIG. 3 , each node  16  has eight legs  14  extending therefrom, with two legs  14  connecting each node  16  to an adjacent node  16 . It is to be appreciated that other leg  14 /node  16  quantities and/or geometries can be employed. 
     Each of the legs  14  can be elongated so as to define a longitudinal leg axis  50 . In the illustrated embodiment, when the mesh  12  is in the initial mesh configuration, the longitudinal leg axes  50  of each of the legs  14  can be substantially parallel with one another. Additionally, in the initial mesh configuration, the longitudinal leg axes  50  of each of the legs  14  can be oriented substantially along the longitudinal direction X. As shown, in the initial mesh configuration, laterally adjacent nodes  16  and laterally adjacent legs  14  can have minimal, if any, gaps therebetween along the lateral direction Y. 
     Referring now to  FIG. 4 , the piece of corrugate  30 , and thus the mesh  12  also, defines a top mesh surface  52  and an opposed bottom mesh surface  54  opposite each other substantially along the transverse direction Z. Fluting  56  is disposed between the top and bottom mesh surfaces  52 ,  54 . Each of the nodes  16  can define a top node surface  58  that is defined by the top mesh surface  52 , as well as an opposed bottom node surface  60  that is defined by the bottom mesh surface  54 . Each node  16  also defines a transverse node axis  62  that is oriented substantially normal to the top and bottom node surfaces  58 ,  60 . As shown in  FIG. 4 , in the initial mesh configuration, the transverse node axes  62  extend generally near alignment with the transverse direction Z. Additionally, each of the legs  14  can define a top leg surface  64  that is defined by the top mesh surface  52 , as well as an opposed bottom leg surface  66  that is defined by the bottom mesh surface  54 . Each leg  14  also defines a transverse leg axis  68  that is oriented substantially normal to the top and bottom leg surfaces  64 ,  66 . As shown in  FIG. 4 , in the initial mesh configuration, the transverse leg axes  68  extend generally near alignment with the transverse direction Z. 
     Referring now to  FIG. 5 , the mesh  12  portion shown in  FIG. 3  is now shown in a first expanded configuration. In the first expanded configuration, the mesh portion  12  can define an area having a second length L 2  along the longitudinal direction X and a second width W 2  along the lateral direction Y. In the illustrated embodiments, the second width W 2  is greater than the first width W 1 , while the second length L 2  is slightly less than the first length L 1 . Thus, in the first expanded configuration, the mesh  12  portion is expanded or enlarged by stretching along the lateral direction Y and slightly contracted along the longitudinal direction X as a result of the stretching. In the illustrated embodiments, the lateral expansion is greater than the longitudinal contraction. In this manner, the area of the mesh  12  portion increases from the initial configuration to the first expanded configuration. 
     As shown, in the first expanded configuration, the longitudinal leg axes  50  can be offset from the longitudinal direction X. As the mesh  12  expands laterally, the some of the through-cuts  32  expand into primary gaps  70  between the adjacent nodes  16  and/or legs  14 . As the mesh  12  is expands laterally, the primary gaps  70  increase in width along the lateral direction Y so as to define the boundaries of primary ones  18   a  of the cells  18 . In the illustrated embodiment, others of the through-cuts  32  expand into secondary gaps  72  that also increase in width between the pairs of legs  14  that interconnect each node  16  with an adjacent node  16 . The secondary gaps  72  define secondary cells  18   b  that are narrower than the primary cells  18   a . As shown, the primary cells  18   a  (which can constitute a majority of the cells  18 ) can each have a substantially hexagonal shape, providing the mesh  12  with a substantially honeycomb pattern of primary cells  18   a . In particular, the six sides of a hexagon primary cell  18   a  can be defined by (moving clockwise) a first leg  14   a  extending from a first node  16   c , the first lateral edge  42  of the first node  16   c , a second leg  14   b  extending from the first node  16   c , a third leg  14   c  extending from a second node  16   d  that is laterally spaced form the first node  16   c , the second lateral edge  44  of the second node  16   d , and a fourth leg  14   d  extending from the second node  16   d . It is to be appreciated that patterns and other cell geometries are within the scope of the present disclosure. 
     Referring now to  FIGS. 4 and 6 , as the mesh  12  moves from the initial configuration to the first expanded configuration, the transverse node axes  62  (that is, normal projections thereof in a plane extending along the lateral and transverse directions Y, Z) rotate away from substantially near alignment with the transverse direction Z ( FIG. 4 ) to a wider oblique angle α offset from the transverse direction Z ( FIG. 6 ). Similarly, as the mesh  12  moves from the initial configuration to the first expanded configuration, the transverse leg axes  68  (or at least projections thereof in the lateral, transverse plane Y-Z) also rotate away from substantially near alignment with the transverse direction Z ( FIG. 4 ) to a wider oblique angle β offset from the transverse direction Z ( FIG. 6 ). Preferably, oblique angles α and β are substantially equivalent. 
     Referring now to  FIG. 7 , the mesh  12  portion is now shown in a second expanded configuration, in which the lateral expansion is greater than that of the first expanded configuration. In the second expanded configuration, the area of the mesh portion  12  has a third width W 2  along the lateral direction Y that is greater than the second width W 2 , as well as third length L 2  along the longitudinal direction X that is slightly less than the second length L 2 . Thus, in the second expanded configuration, the mesh  12  portion is expanded (by stretching) along the lateral direction Y and slightly contracted along the longitudinal direction X relative to the first expanded configuration. As before, the lateral expansion is greater than the longitudinal contraction so that the area of the mesh  12  portion increases from the first to the second expanded configuration. Additionally, the primary and secondary gaps  70 ,  72  in the mesh  12  are wider along the lateral direction Y in the second expanded configuration than in the first expanded configuration. 
     Referring now to  FIGS. 6 and 8 , as the mesh  12  moves from the first to the second expanded configuration, the respective oblique angles α, β of the transverse node axes  62  and transverse leg axes  14  increase. In this manner, as the mesh  12  is stretched laterally, the transverse axes  62 ,  68  of the nodes  16  and legs  14  (or at least some, or preferably no less than a majority of the nodes and legs) are each reoriented. Accordingly, as the mesh  12  is laterally stretched, the legs  14  and nodes  16  transition from a configuration in which the top and bottom node surfaces  58 ,  60  and the top and bottom leg surfaces  64 ,  66  become less parallel with, and more perpendicular to, the outer layers  6 ,  8  of the packaging cushion  2 . As shown in  FIGS. 6, and 8 , in the first and second expanded configurations, the points of contact between the mesh  12  and the outer layers  6 ,  8  occur at least primarily at the first and second lateral edges  42 ,  44  of the nodes  16 , increasing the compressive strength of the mesh  12  at each node  16 . The compressive strength of the mesh  12  at each node  16  increases with the increased perpendicularity between the top and bottom node surfaces  58 ,  60  and the outer layers  6 ,  8 . Additionally, it has been observed that the average compressive strength of the mesh  12  increases with increasing lateral expansion of the mesh  12 . It has also been observed that the multi-directional flexibility of the mesh  12  responsive to compressive forces along the transverse direction Z increases with increased lateral expansion of the mesh  12 . Prior art corrugate, at least in some configurations, may have similar compressive strength relative to the packaging cushions  2  disclosed herein. However, when a fold or crease is formed in prior art corrugate that, for example, extends transversely through the corrugate layer, the corrugate exhibits localized weakness in the area of the fold or crease. Prior art corrugate also has preferred bending along the flutes, which has limitations in packaging that needs to be bent in multiple directions. In contrast to prior art corrugate, the inventors have observed that, in each of the embodiments disclosed herein, the packaging cushion  2  exhibits multi-directional flexibility responsive to each of transverse, lateral and longitudinal compressive forces, as well as to torsional forces. This multi-directional flexibility enables these embodiments to bend without significantly impairing the performance of the packaging cushion  2 . 
     Referring now to  FIGS. 9 and 10 , an additional embodiment of the mesh  12 ′ is shown. The mesh  12 ′ may comprise packaging paper, such as kraft paper, for example. The mesh  12 ′ of the present embodiment can be configured generally similarly to the mesh  12  described above with reference to  FIGS. 2 through 8 . In particular, the mesh  12 ′ includes a plurality of legs  14 ′ extending between a plurality of nodes  16 ′ so as to define a plurality of voids/cells  18 ′ in the mesh  12 ′. Some of the nodes  16 ′ in  FIG. 9  are indicated by dashed areas for visualization purposes. As above, one or more of the nodes  16 ′ can define first and second lateral edges  42 ′,  44 ′ spaced from each other along the lateral direction Y, as well as first and second longitudinal ends  46 ′,  48 ′ spaced from each other along the longitudinal direction X. In the illustrated embodiment, each respective node  16 ′ can be connected to an adjacent node  16 ′ by a single leg  14 ′, with each internal node  16   b ′ having four legs  14  extending therefrom. 
     The edges of the legs  14 ′ and nodes  16 ′ of the mesh  12 ′ can be defined by through-cuts  32 ′ formed therein by a cutting machine (for example, a paper-cutting machine). As above, the legs  14 ′ and nodes  16 ′ can be arranged such that, as the mesh  12 ′ is stretched laterally, the through-cuts  32 ′ expand into gaps  70 ′ so as to define the cells  18 . The cells  18 ′ can each be hexagonal so as to define a honeycomb pattern in the mesh  12 ′, although other cell geometries and other patterns are within the scope of the present disclosure. 
     Each of the nodes  16 ′ can define a top node surface  52 ′ and a bottom node surface  54 ′ that are respectively defined by top and bottom surfaces  52 ′,  54 ′ of the packaging from which the mesh  12 ′ was formed. Each node  16 ′ also defines a transverse node axis  62 ′ that is oriented substantially normal to the top and bottom node surfaces  52 ′,  54 ′. Each of the legs  14 ′ can define a top leg surface  64 ′ and a bottom leg surface  66 ′ that are respectively defined by top and bottom surfaces  52 ′,  54 ′ of the packaging. Each leg  14 ′ also defines a transverse leg axis  68 ′ that is oriented substantially normal to the top and bottom leg surfaces  64 ′,  66 ′. 
     As above, the mesh  12 ′ can be expanded laterally, such as by stretching, so that an area of the mesh  12 ′ increases. As shown in  FIG. 9 , in an initial mesh configuration, the mesh  12 ′ defines a first length L 1 ′ along the longitudinal direction X and a first width W 1 ′ along the lateral direction Y. As shown in  FIG. 10 , the mesh  12 ′ can be expanded to an expanded mesh configuration, wherein the mesh  12 ′ defines a second length L 2 ′ that is slightly less than the first length L 1 ′ and a second width W 2 ′ that is greater than the first width W 1 ′. 
     Referring now to  FIG. 11 , in a similar manner to that described above with reference to  FIGS. 6 and 8 , as the mesh  12 ′ is expanded laterally, respective oblique angles α′, β′ of the transverse node axes  62 ′ and transverse leg axes  14 ′ increase. In this manner, the top and bottom node surfaces  58 ′,  60 ′ and the top and bottom leg surfaces  64 ′,  66 ′ each become less parallel with, and more perpendicular to, the outer layers  6 ,  8  of the packaging cushion  2 . Accordingly, the inventors have observed that a packaging cushion  2  employing the mesh  12 ′ of the present embodiment exhibits similar multi-directional flexibility benefits to those set forth above with reference to  FIGS. 3 through 8 . 
     It is to be appreciated that while the illustrated embodiments show meshes  12 ,  12 ′ may be formed of corrugate and packaging paper (such as kraft paper), a mesh can similarly be formed of other materials, including paperboard, other paper-based packaging materials, metal, and plastic, such as recyclable plastic. 
     Referring now to  FIG. 12 , a package, such as a padded envelope  100 , can employ one or more packaging cushions  2  that are configured as set forth above. While a padded envelope  100  is described herein, it is to be appreciated that virtually any type of package can employ one or more of the packaging cushions  2 . The padded envelope  100  can include a first panel  102  overlaying a second panel  104 . Each panel  102 ,  104  can include a packaging cushion  2  having a cushion layer  4  disposed between a first or outer liner  6  and a second or inner liner  8 . The cushion layer  4  of each panel  102 ,  104  can include a mesh  12  coupled to the liners  6 ,  8  with a binder  20 . The mesh  12  and binder  20  can each be configured according to any of the respective embodiments set forth above. 
     The outer liners  6  can each define an outer surface  106  of the respective panel  102 ,  104  and the inner liners  8  can each define an inner surface  108  of the respective panel  102 ,  104 . Each panel  102 ,  104  can define a transverse liner axis  110  that extends substantially normal to the respective outer and inner surfaces  106 ,  108  (in  FIG. 12 , the transverse liner axes  110  of the first and second panels  102 ,  104  are coextensive). The inner liners  8  of the panels  102 ,  104  can collectively define an internal storage compartment  112  of the envelope  100 . The inner liners  8  can be attached together with a package bond  114 , which can employ any of the types of binders  20 ,  26  set forth above. Each of the liners  6 ,  8 , meshes  12 , and binders  20  of the panels  102 ,  104  can be formed of one or more paper-based materials that are curbside recyclable. Additionally, any labels applied to the package, as well as the adhesives used therewith, can also be curbside recyclable. In this manner, the padded envelope  100  can be curbside recyclable. 
     Referring now to  FIGS. 13 and 14 , padded packages  120  according to additional embodiments can include a single packaging cushion  122  wrapped around an item  124  ( FIG. 14 ). As above, the packaging cushion  122  can include an outer liner  126 , an inner liner  128 , and a mesh  12  disposed in between the liners  126 ,  128 . In  FIG. 13 , one such padded package  120   a  having a kraft mesh  12 ′ is shown alongside another such padded package  120   b  having a corrugate mesh  12 . In  FIG. 13 , portions of the outer liners  126  are transparent so that the meshes  12 ,  12 ′ are visible. As above, each of the padded packages can be curbside recyclable. It is to be appreciated that other packaging products incorporating packaging cushions  2  are within the scope of the present disclosure. 
     Referring now to  FIG. 15 , an example system  200  for making a cushioning layer  2  can include a first zone  202  in which a supply  204  of paper-based product is located, such as a z-fold stack of raw corrugate  30 , or example. A second zone  206  can include a cutting machine  208  employing bladed rollers  210 , for example, to form the mesh  12 . A third zone  212  can include one or more stretching rollers  214  to expand the mesh  12  into an expanded configuration. A fourth zone  216  can include a glue vat roller  218  for disposing glue on a bottom surface of the mesh  12 . A fifth zone  220  can include a supply of kraft paper  222  for lamination on the bottom surface of the mesh. A sixth zone  224  can include another glue vat roller  226  for disposing glue on the top surface of the mesh  12 . A seventh zone  228  can include another supply of kraft paper  230  for lamination on the top surface of the mesh  12 . An eighth zone  232  can define a fully formed paper-based packaging cushion  2 . The foregoing example system  200  represents merely one example of various system configurations for making a paper-based packaging cushion  2 . 
     It should be noted that the illustrations and descriptions of the embodiments shown in the figures are for exemplary purposes only, and should not be construed limiting the disclosure. One skilled in the art will appreciate that the present disclosure contemplates various embodiments. Additionally, it should be understood that the concepts described above with the above-described embodiments may be employed alone or in combination with any of the other embodiments described above. It should further be appreciated that the various alternative embodiments described above with respect to one illustrated embodiment can apply to all embodiments as described herein, unless otherwise indicated. Also, the present invention is not intended to be limited by any description of drawbacks or problems with any prior art device. 
     Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about” or “approximately” preceded the value or range. 
     It should be understood that the steps of exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various embodiments. 
     Although the elements in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence.