Patent Publication Number: US-11390444-B2

Title: Packing material and method of manufacturing the packing material

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 17/197,837, filed Mar. 10, 2021. U.S. patent application Ser. No. 17/197,837 claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/054,853, filed Jul. 22, 2020, and titled “PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKING MATERIAL,” the entirety of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to packing material, particularly packing material that includes a plurality of discrete cushioning elements made from paper. The invention is also related to methods of manufacturing the same. 
     BACKGROUND OF THE INVENTION 
     Various packing materials are used to secure items in shipping containers, including cardboard boxes, to thereby prevent damage to these items if they move within the shipping container during shipment or other impacts during shipping, such as being dropped or hit. Such packing materials include bubble wrap, expanded polystyrene (polystyrene foam), and other plastic foam packing, which may be molded into blocks or into other shapes, peanuts, and inflated plastic bags (also known as air pillows). These plastic products may be discarded as waste after they have been used during shipping. Plastic waste takes a long time to decompose and produces carbon dioxide in the decomposition process. In addition, polystyrene foam does not readily biodegrade, and may take many, many years to break down. With an increased awareness of the negative effects of plastics and polystyrene foam on the environment, however, consumers are increasingly seeking to use environmentally-friendly, recyclable, and biodegradable products as a packing material. There are desired environmentally-friendly, recyclable, and biodegradable products that provide sufficient cushioning effects at an affordable cost. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention relates to a packing material including a plurality of discrete cushioning elements and a flexible linkage connecting the plurality of discrete cushioning elements. The plurality of discrete cushioning elements is arrayed in a first direction and have an order with each cushioning element of the plurality of discrete cushioning elements is adjacent to at least one other cushioning element of the plurality of discrete cushioning elements. The at least one other cushioning element of the plurality of discrete cushioning elements is a first adjacent cushioning element, and each cushioning element is spaced apart from a respective first adjacent cushioning element with a first gap formed between each cushioning element and the respective first adjacent cushioning element. Each cushioning element is connected to the respective first adjacent cushioning element by the flexible linkage. The flexible linkage spans the first gap between each cushioning element and the respective first adjacent cushioning element. 
     In another aspect, the invention relates to a packing material including a plurality of cellulosic cushioning elements, a top cellulosic sheet arranged one side of the plurality of cellulosic cushioning elements, and a bottom cellulosic sheet arranged on an opposite side of the plurality of cellulosic cushioning elements. Each cellulosic cushioning element of the plurality of cellulosic cushioning elements have a plurality of folds and are formed into a shape. The bottom cellulosic sheet is connected to the top cellulosic sheet with the plurality of cellulosic cushioning elements positioned between the top cellulosic sheet and the bottom cellulosic sheet. 
     In a further aspect, the invention relates to a method of manufacturing packing material. The method includes filling a plurality of pockets of a first cellulosic sheet with a plurality of cellulosic cushioning elements. Each pocket has an opening through which the pocket is filled. The method further includes applying an aqueous slurry of cellulosic fibers and adhesive to the plurality of cellulosic cushioning elements in each pocket of the first cellulosic sheet, drying the aqueous slurry and the plurality of cellulosic cushioning elements, and bonding a second cellulosic sheet to the first cellulosic sheet to cover the openings of the plurality of pockets in the first cellulosic sheet. 
     These and other aspects of the invention will become apparent from the following disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  shows a cellulosic cushioning element that can be used as a packing material according to a preferred embodiment of the invention.  FIG. 1B  shows an alternative cellulosic cushioning element that can be used as the packing material. 
         FIG. 2  is a shipping box containing an item and a plurality of the cellulosic cushioning elements in  FIG. 1A . 
         FIGS. 3A-3D  show a method and machine used to manufacture the cellulosic cushioning element shown in  FIG. 1A .  FIG. 3A  shows a first step,  FIG. 3B  shows a second step,  FIG. 3C  shows a third step, and  FIG. 3D  shows a fourth step. 
         FIGS. 4A-4D  show an alternate method and machine used to manufacture the cellulosic cushioning element shown in  FIG. 1A .  FIG. 4A  shows a first step,  FIG. 4B  shows a second step,  FIG. 4C  shows a third step, and  FIG. 4D  shows a fourth step. 
         FIG. 5  is a perspective view of feeding rollers that may be used with the method and apparatus shown in  FIGS. 4A-4D . 
         FIGS. 6A and 6B  are cellulosic cushioning elements that may be produced by the method and apparatus shown in  FIGS. 4A-4D .  FIG. 6A  is a cellulosic cushioning element that is produced without shaping by the feeding rollers, and  FIG. 6B  is a cellulosic cushioning element that is produced with the feeding rollers shown in  FIG. 5 . 
         FIGS. 7A and 7B  each show a packing material with linkages connecting discrete cushioning elements. The packing material in  FIGS. 7A and 7B  use the cellulosic cushioning elements shown in  FIG. 1A  as discrete cushioning elements.  FIG. 7A  shows one way the linkage is attached to the cellulosic cushioning elements, and  FIG. 7B  shows another way the linkage is attached to the cellulosic cushioning elements. 
         FIG. 8  shows the packing material of  FIG. 7B  with alternative discrete cushioning elements. 
         FIG. 9  shows the packing material of  FIG. 7A  with alternative linkages. 
         FIG. 10  shows another packing material with linkages connecting discrete cushioning elements. The packing material in  FIG. 10  uses the cellulosic cushioning elements shown in  FIG. 1A  as discrete cushioning elements. 
         FIG. 11  shows the packing material of  FIG. 10  used on a bottle. 
         FIG. 12  shows a method of manufacturing the packing material shown in  FIG. 9 . 
         FIG. 13  shows another packing material using the cellulosic cushioning elements shown in  FIG. 1A  as discrete cushioning elements. 
         FIG. 14  shows further packing material using the cellulosic cushioning elements shown in  FIG. 1A  as discrete cushioning elements. 
         FIG. 15  is a cross-sectional view of the packing material shown in  FIG. 14  taken along line  15 - 15  in  FIG. 14 . 
         FIG. 16  is an alternate cross-sectional view of the packing material shown in  FIG. 14  taken along line  15 - 15  in  FIG. 14 . 
         FIG. 17  shows a variation of the packing material shown in  FIG. 14 . 
         FIG. 18  shows another variation of the packing material shown in  FIG. 14 . 
         FIG. 19  shows a method and machine used to manufacture the packing material shown in  FIG. 14 . 
         FIG. 20  shows a further packing material using the cellulosic cushioning elements shown in  FIG. 1A . 
         FIG. 21  is a cross-sectional view of the packing material shown in  FIG. 20  taken along line  21 - 21  in  FIG. 20 . 
         FIG. 22  shows a method and machine used to manufacture the packing material shown in  FIG. 20 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The packing materials disclosed herein utilize a cushioning element  100  as a base material.  FIG. 1A  shows a preferred cushioning element  100  that may be used in the packing materials discussed further below. This cushioning element  100  is preferably a cellulosic cushioning element  110 , being formed from paper composed of cellulosic fibers. Other suitable cushioning elements  100 , as will be described in certain embodiments below, may also be used in the packing materials discussed herein. Paper is a preferred material used for the cellulosic cushioning element  110 , as paper is biodegradable. The paper used herein is preferably recycled paper (e.g., previously-used paper). Various suitable basis weights and thicknesses may be used for the cellulosic cushioning elements  110  discussed herein and they may be varied depending upon application. As will be described further below, the paper is preferably crumpled into a shape that is preferably ball-like or sphere-like or cylindrical. The cellulosic cushioning element  110  may be relatively small in size, such as approximately 0.25 inch in diameter, or relatively large in size, such as approximately one inch in diameter. But such sizes are exemplary, and various other suitable diameters may be used. The crumpled cellulosic cushioning element  110  thus includes a plurality of folds and crevices or air pockets formed between the folds of the cellulosic cushioning element  110 . 
     An alternative cellulosic cushioning element  111  is shown in  FIG. 1B . The paper used to form the alternative cellulosic cushioning element  111  may be cut into thin strips (for example, 0.25 inch in width) and then folded a plurality of times into a shape to form the alternative cellulosic cushioning element  111 . The alternative cellulosic cushioning element  111  is thus folded to form a geometric shape, such as the square, shown in  FIG. 1B . But other suitable geometric shapes may be formed. As with the cellulosic cushioning element  110 , the alternative cellulosic cushioning element  111  includes a plurality of folds and air pockets formed between the folds and strips of paper. 
     The invention is not limited, however, to the sizes and shapes described above and shown in  FIGS. 1A and 1B . The cellulosic cushioning element  110  and alternative cellulosic cushioning element  111  may also be crumpled or folded to form elements having other shapes or forms including, for example, the form shown in  FIG. 6A , below. The alternative cellulosic cushioning element  111  may be used in place of the crumpled cellulosic cushioning element  110  in each of the packing materials discussed further below. 
     These cellulosic cushioning elements  110  may be used on their own as packing material.  FIG. 2  shows, for example, a shipping box  102  that has an item-to-be-shipped  104  placed therein. The shipping box  102  may be any suitable shipping box including a carboard box. The cellulosic cushioning element  110  may be placed in the shipping box  102  to surround the item-to-be-shipped  104 . The cellulosic cushioning element  110  is elastically deformable to absorb energy and protect the item-to-be-shipped  104  but, even when crushed, provides additional energy (shock) absorbing to protect the item-to-be-shipped  104 . Factors impacting the amount of energy absorbed that may be modified for the desired protection include the weight of the paper, the volume or size (e.g., diameter) of the cellulosic cushioning element  110 , and the density of the cellulosic cushioning element  110 . 
     A method of forming the cellulosic cushioning element  110  and a machine assembly  200  used in this method will be described with reference to  FIGS. 3A-3D . Initially a sheet  112  of paper is fed on top of a die  210  and, in this embodiment, between a cover plate  212  and the die  210 . The sheet  112  includes a face surface  114  with a surface area. The sheet  112  also has a thickness, which as discussed above, can be any suitable thickness. The sheet has a thickness direction and an orthogonal direction that is orthogonal to the thickness direction. In  FIG. 3A , the sheet  112  is fed in the orthogonal direction of the sheet  112 . The sheet  112  is nipped and fed by a feed roller  202 . The feed roller  202  forms a nip with a nip forming member, which in this embodiment is a feed plate  204 , but any suitable nip forming member may be used such as another roller. In this embodiment, the sheet  112  is a continuous sheet from a roll  116 . However, the sheet  112  may be provided in other suitable forms such a stack of sheets  112  that cut to size and fed one-by-one to the die  210 . 
     The die  210  has a cylindrical hole  214  with a taper  216  at the entrance of the die  210  forming a funnel shape. The sheet  112  is pressed through the die  210  with a plunger  220 . The plunger  220  has a shape that corresponds to the shape of the die  210 . In this embodiment, the plunger  220  is cylindrical with a spherical tip  222 , but any suitable shape may be used. The cylindrical hole  214  of the die  210  has a diameter, and the diameter of the plunger  220  is smaller than the diameter of the cylindrical hole  214  so that the plunger  220  can be inserted into the cylindrical hole  214 . The plunger  220  is lowered moving through a hole  218  in the cover plate  212  to press the sheet  112  in a direction crossing the orthogonal direction of the sheet  112 , which is the thickness direction in this embodiment. The tip  222  of the plunger  220  contacts the face surface  114  of the sheet  112  and pushes the sheet  112  into the cylindrical hole  214  of the die  210 . The sheet  112  has a surface area that is greater than the surface area of the cylindrical hole  214  at the exit of the die  210 . As the plunger  220  pushes presses the sheet  112  into the taper  216  and the cylindrical hole  214  of the die  210 , the sheet  112  conforms to the shape of the die  210  and the plunger  220  to form a shaped cellulosic sheet  118 . Thus, in this embodiment, the shaped cellulosic sheet  118  has a hollow, cylindrical shape with a spherical tip. The plunger  220  is inserted into the cylindrical hole  214  of the die  210  such that the plunger  220  discharges the shaped cellulosic sheet  118  from the exit (bottom) of the die  210 . 
     When the sheet  112  is supplied by the roll  116  a cutter  224  may be used to cut the sheet  112  to the appropriate length. In this embodiment, the cutter  224  is configured to move with the plunger  220  between the top of the die  210  and the feed plate  204 . The cutter  224  cuts the sheet  112  just before or as the tip  222  contacts the face surface  114  of the sheet  112  to push the sheet  112  into the die  210 . 
     After the shaped cellulosic sheet  118  exits the die  210 , the shaped cellulosic sheet  118  passes between a first portion  230 A and a second portion  230 B of a form  230  as shown in  FIG. 3B . The first portion  230 A and the second portion  230 B of the form  230  are then brought into contact with each other to compress the shaped cellulosic sheet  118  within a cavity  232  of the form  230  as shown in  FIG. 3C . Each of the first portion  230 A and the second portion  230 B of the form  230  have a concavity  234  formed therein that, when the first portion  230 A and the second portion  230 B are brought together, form a spherical cavity  232 . In this embodiment each concavity  234  is hemispherical to form the cavity  232 . 
     The form  230  also includes a catcher  240  to help catch the shaped cellulosic sheet  118  as it passes between the first portion  230 A and the second portion  230 B of the form  230 . The catcher  240  of this embodiment includes a plurality of teeth  242  that are splayed outward from contacting portions of the first portion  230 A and the second portion  230 B of the form  230 . The diverging angles of the teeth  242  help compress and guide the shaped cellulosic sheet  118  into the cavity  232  as the first portion  230 A and the second portion  230 B are brought together. In this embodiment, the teeth  242  are interlocking teeth  242  such that the teeth  242  of the first portion  230 A mesh with the teeth  242  of the second portion  230 B. 
     With the shaped cellulosic sheet  118  compressed within the cavity  232  the first portion  230 A and the second portion  230 B may be rotated about an axis extending in the direction in which the first portion  230 A and the second portion  230 B are brought together (or separated). Rotating the first portion  230 A and the second portion  230 B of the form  230  twists the shaped cellulosic sheet  118  and may help create additional folds and pockets in the resulting the cellulosic cushioning element  110 . To facilitate this process, each concavity  234  includes an outer surface  236  that is serrated. Compressing and twisting the shaped cellulosic sheet  118  forms the cellulosic cushioning element  110 . After the first portion  230 A and the second portion  230 B are rotated, the first portion  230 A and the second portion  230 B are separated by being moved in a direction opposite to the direction in which they were brought together. The cellulosic cushioning element  110  is ejected from the form  230  as the first portion  230 A and the second portion  230 B are separated as shown in  FIG. 3D . These steps are repeated to form additional cellulosic cushioning elements  110 . 
       FIGS. 4A-4D  show an alternate method for forming the cellulosic cushioning element  110  and a machine assembly  300  used in this method. As in the method and machine assembly  200  described above, a sheet  112  of paper is used to form the cellulosic cushioning element  110 . Although the sheet  112  may be similar to those discussed above, the sheet  112  of this embodiment is preferably a strip of paper having a length (as will be further discussed below) longer than its width. The sheet  112  is nipped and fed by a pair of feed rollers (a first feed roller  302  and a second feed roller  304 ) and fed into an arcuate-shaped cylinder  310  (herein arcuate cylinder  310 ), as shown in  FIG. 4A .  FIG. 5  is a perspective view of the first feed roller  302 , the second feed roller  304 , and the arcuate cylinder  310 . 
     The first feed roller  302  and the second feed roller  304  may have smooth outer surfaces, but they also may be configured to shape the sheet  112  in the thickness direction as the sheet  112  is fed. As shown in  FIG. 5 , for example, the first feed roller  302  includes a groove  306 . The groove  306  of this embodiment is v-shaped, but any suitable shape may be used, including, for example a u-shape or a w-shape. The second feed roller  304  has a corresponding surface, which in this embodiment is a v-shaped protrusion  308 . The protrusion  308  presses the sheet  112  into the groove  306  to impart a shape corresponding to the groove  306  and protrusion  308  to the sheet.  FIG. 6A  shows the cellulosic cushioning element  110  produced using this method and machine assembly  300  when the sheet  112  is fed with the first feed roller  302  and the second feed roller  304  having smooth outer surfaces. The cellulosic cushioning element  110  sheet shown in  FIG. 6A  has a plurality of folds with gaps therebetween.  FIG. 6B  shows the cellulosic cushioning element  110  produced using this method and machine assembly  300  when the sheet  112  is fed with the first feed roller  302  and the second feed roller  304  shown in  FIG. 5 . The cellulosic cushioning element  110  sheet shown in  FIG. 6B  is similar to the cellulosic cushioning element  110  shown in  FIG. 1A , having a plurality of folds, but with a more cylindrical shape instead of spherical. 
     As shown in  FIG. 4A , the arcuate cylinder  310  has a channel  312  formed therein with an inlet  314  and an outlet  316 . The sheet  112  is fed into the channel  312  through the inlet  314  and then slides through the channel  312  until it contacts a ram  322  located at the outlet  316 . In this embodiment, the sheet  112  (strip of paper) is fed into the channel  312  to have a length longer than the length of the channel  312  and the sheet  112  waves back and forth within the channel  312 . However, the length of the sheet  112  is not so limited and it may be shorter, for example. 
     When the sheet  112  reaches the desired length, it is cut with a cutter  324 . In this embedment, the cutter  324  is formed between an edge of the inlet  314  of the arcuate cylinder  310  and a plunger  326 . The plunger  326  is connected to a rotor  328  to rotate in a circle. As shown in  FIG. 4B , the plunger  326  enters the inlet  314  of the arcuate cylinder  310  and cuts the sheet  112  as it does so. The plunger  326  rotates as it moves along the channel  312  compressing the sheet against the ram  322  the plunger  326 . The ram  322  and the plunger  326  of this embodiment are similar to the first portion  230 A of the form  230  and second portion  230 B of the form  230  discussed above. The ram  322  and the plunger  326  each include a hemispherical concavity  234  and, when brought together as shown in  FIG. 4C , form a cavity  232  to compress the sheet  112  and form the cellulosic cushioning element  110 . As the plunger  326  continues to rotate, the ram  322  pivots to open the cavity  232  and eject the cellulosic cushioning element  110  as shown in  FIG. 4D . 
     The process shown in  FIGS. 4A-4D  repeats to form additional cellulosic cushioning elements  110 . As can be seen in  FIG. 4C , the next sheet  112  is fed into the inlet  314  of the arcuate cylinder  310  after the plunger  326  passes the inlet  314 . Accordingly, the next sheet  112  is being fed as the previous sheet  112  is being compressed ( FIG. 4C ) and ejected as the cellulosic cushioning element  110  ( FIG. 4D ). 
     While the plurality of cellulosic cushioning elements  110  are used in a shipping box  102  (as discussed above with reference to in  FIG. 2 ), such a configuration can be messy. When packing or unpacking the item-to-be-shipped  104  the individual cellulosic cushioning elements  110  can easily spill and scatter, requiring the need to clean up. To avoid this issue, each cellulosic cushioning element  110  of a plurality of cellulosic cushioning elements  110  can be connected to one another as shown in  FIGS. 7A and 7B .  FIGS. 7A and 7B  show a packing material according to a preferred embodiment of the invention. For clarity with the other packing materials discussed herein, the packing material of this embodiment is referred to as a rope-like packing material  120 . 
     The rope-like packing material  120  includes a plurality of discrete cushioning elements  100  that are arrayed in a length direction A. Each discrete cushioning element  100  of this embodiment is the cellulosic cushioning element  110  discussed above, but they are not so limited. Instead, each discrete cushioning element  100  may be, for example, a packing peanut  106  as shown in  FIG. 8 . The packing peanut  106  may be a foamed polymer resin material such as the s-shaped polystyrene foam. Other packing peanuts  106  may be used including biodegradable packing peanuts that are made from resin material of a starch such as corn. 
     The rope-like packing material  120  will be further described with reference to  FIGS. 7A and 7B , but it also applies to the other cushioning elements  100  shown in  FIG. 8 . The cellulosic cushioning element  110  is arrayed in length direction A in an order.  FIGS. 7A and 7B  show five cellulosic cushioning elements  110  each appended with a different letter (a-e). Each cellulosic cushioning element  110  is adjacent to at least one other cellulosic cushioning element  110 . For example, cellulosic cushioning element  110   a  is adjacent to cellulosic cushioning element  110   b , and cellulosic cushioning element  110   b  is adjacent to both cellulosic cushioning element  110   a  and cellulosic cushioning element  110   c . In this embodiment, the adjacent cellulosic cushioning elements  110  are spaced apart from each other with a gap (referred to as a first gap  122 , herein) formed between the adjacent cellulosic cushioning elements  110 , although other suitable embodiments may be possible where, for example, adjacent cellulosic cushioning elements  110  contact one another. 
     The adjacent cellulosic cushioning elements  110  are connected to each other by a flexible linkage  124 . The flexible linkage  124  is connected to each cellulosic cushioning element  110  and spans the first gap  122  between adjacent cellulosic cushioning element  110 . In this embodiment the flexible linkage  124  is a string. The cellulosic cushioning elements  110  may be attached to the flexible linkage  124  using any suitable method, for example an adhesive. In  FIG. 7A , the flexible linkage  124  (string) is wrapped around each cellulosic cushioning element  110  at least one time. In  FIG. 7B , each cellulosic cushioning element  110  has a hole  126  formed through the diameter (central portion) of the cellulosic cushioning element  110 , and the flexible linkage  124  (string) runs through the hole  126 . 
     Other suitable flexible linkages  124  may be used.  FIG. 9  shows an example of the rope-like packing material  120  with an alternative flexible linkage  124 . The flexible linkage  124  of this embodiment includes an upper tape  132  and a lower tape  134 . Although any suitable tape can be used, each of the upper tape  132  and lower tape  134  is preferably a paper (or cellulosic) strip that has a length much greater than its width (see  FIG. 10 ). Paper is preferred, particularly when used with the cellulosic cushioning element  110  so that the entire rope-like packing material  120  can be biodegradable and recyclable. In this embodiment, the upper tape  132  and the lower tape  134  are aligned with each other and sandwich the cellulosic cushioning element  110  therebetween. An adhesive  136  is preferably applied to the inner sides of each of the upper tape  132  and the lower tape  134  to bond the upper tape  132  and the lower tape  134  to each other and to the cellulosic cushioning element  110 . Any suitable adhesive  136  may be used, but in this embodiment, it is preferably a biodegradable adhesive. 
     In this embodiment, both the upper tape  132  and the lower tape  134  are used, but it is not so limited and the cellulosic cushioning element  110  may be connected by a single tape (e.g., either the upper tape  132  or the lower tape  134 ). In such a case, it is preferable to omit or remove the adhesive  136  from the portion of the tape in the first gap  122 . 
     The flexible linkage  124  discussed above may be used with the discrete cushioning elements  100  to form other packing materials.  FIG. 10  shows another packing material using the flexible linkage  124  discusses above. For clarity with the other packing materials discussed herein, the packing material of this embodiment is referred to as a net-like packing material  140 . As with the other embodiments the cushioning element  100  elements may be any suitable cushioning element, but in this embodiment, the cushioning element  100  is cellulosic cushioning element  110 . 
     The cellulosic cushioning elements  110  of the net-like packing material  140  are arrayed in two directions. The cellulosic cushioning elements  110  are arrayed in the length direction A, as discussed above, and also are arrayed in a width direction B in an order. For example, the cellulosic cushioning element  110   b  is adjacent to the cellulosic cushioning element  110   y  and the cellulosic cushioning element  110   z  in the width direction B, in addition to the cellulosic cushioning element  110   a  and the cellulosic cushioning element  110   c  in the length direction A. The width direction B is a direction crossing the length direction A, and in this embodiment, the width direction B is perpendicular to the length direction A. 
     The cellulosic cushioning elements  110  are also spaced apart with a gap (a second gap  142 ) formed between adjacent cellulosic cushioning elements  110  in the width direction B. One flexible linkage  124 , a first flexible linkage  144  connects the cellulosic cushioning elements  110  in the length direction A and another flexible linkage  124 , a second flexible linkage  146 ) connects the cellulosic cushioning elements  110  in the width direction B. In this embodiment, there are a plurality of first flexible linkages  144  and a plurality of second flexible linkages  146  that are connected together to form the net-like structure of the net-like packing material  140 .  FIG. 10  shows the first flexible linkage  144  and the second flexible linkage  146  with constructed using the tape (e.g., the upper tape  132  and the lower tape  134 ), but other suitable flexible linkages  124 , such as string, may be used as discussed above. 
     The net-like packing material  140  may be used to pack an item-to-be-shipped  104  in the manner shown above in  FIG. 1A , but it may also be used in other suitable packing arrangements. For example, the net-like packing material  140  may be used similarly to bubble wrap and be wrapped around an item-to-be-shipped  104  such as a bottle  108 , as shown in  FIG. 11 . 
     A method of forming the rope-like packing material  120  is shown in  FIG. 9 , and a machine assembly  400  used in this method will be described with reference to  FIG. 12 . The cellulosic cushioning element  110  may be formed using any suitable method or machine including the machine assembly  200  and machine assembly  300  discussed above. The machine assembly  200  is shown in  FIG. 12 , for example. The machine assembly  400  shown in  FIG. 12  includes a first roll  402  of a strip of paper which will become the upper tape  132  and a second roll  404  of a strip of paper which will become the lower tape  134 . 
     The upper tape  132  is stretched between the first roll  402  and a first laminating roller  412 , and the lower tape  134  is stretched between the second roll  404  and a second laminating roller  414 . Each of the first laminating roller  412  and the second laminating roller  414  have a plurality of recesses  416  formed in their exterior surface. Between the recesses  416  is a land  418 . The first laminating roller  412  and the second laminating roller  414  are posited to form a bonding nip therebetween in which the recesses  416  of each laminating roller oppose each other in the bonding nip and the lands  418  of each laminating roller oppose each other in the bonding nip. 
     The adhesive  136  is applied to at least one of the upper tape  132  and the lower tape  134 . In this embodiment, the adhesive  136  is applied to the upper tape  132  by an adhesive application unit  420 . Alternatively, another adhesive application unit  420  may be used to also apply adhesive  136  to the lower tape  134 . The adhesive application unit  420  includes a reservoir  422  holding the adhesive  136 . The adhesive  136  is transferred from the reservoir  422  to an outer surface of applicating roller  424 . The adhesive application unit  420  also includes a backing roller  426 , which forms an adhesive application nip with the applicating roller  424 . The upper tape  132  passes through the adhesive application nip and the adhesive  136  is applied by the applicating roller  424  to a surface (which will become an inner surface) of the upper tape  132 . Other suitable adhesive application units  420  may be used including, for example, spray adhesive applicators. 
     After the cellulosic cushioning element  110  is formed and discharged from the form  230 , the cellulosic cushioning element  110  is guided to the entrance of the nip by, for example, a chute  406 . The cellulosic cushioning element  110  is then located in a cavity formed by two opposing recesses  416  and separated from adjacent cellulosic cushioning element  110  by opposing lands  418 . The upper tape  132  is sandwiched between the first roll  402  and the cellulosic cushioning element  110 , and the lower tape  134  is sandwiched between the second roll  404  and the cellulosic cushioning element  110 . As the upper tape  132  and the lower tape  134  pass through the bonding nip without a cellulosic cushioning element  110  between them, the upper tape  132  and the lower tape  134  are bonded to each other to form the first gap  122 . 
     Another packing material is shown in  FIG. 13 . For clarity with the other packing materials discussed herein, the packing material of this embodiment is referred to as a sandwich wrap  150 . The sandwich wrap  150  includes a top sheet  152  and a bottom sheet  154 . Although any suitable sheet may be used, the top sheet  152  and the bottom sheet  154  are preferably paper (cellulosic) sheets. The top sheet  152  is connected to the bottom sheet  154  with a plurality of discrete cushioning elements  100  positioned therebetween. As shown in  FIG. 13 , the discrete cushioning elements  100  of this embodiment are cellulosic cushioning elements  110 . In this embodiment, the cellulosic cushioning element  110  are arrayed in the length direction A and in the width direction B. Although gaps may be present between adjacent cellulosic cushioning elements  110 . The adjacent cellulosic cushioning elements  110  of this embodiment contact each other. Each of the top sheet  152  and the bottom sheet  154  include an inner surface  156 . An adhesive  136  is applied to the inner surface  156  of each of the top sheet  152  and the bottom sheet  154  to attach the cellulosic cushioning element  110  to the top sheet  152  and the bottom sheet  154  and connect the top sheet  152  and the bottom sheet  154  to each other. 
     As noted above, the cushioning elements  100  may be positioned between the top sheet  152  and the bottom sheet  154  with the cushioning elements  100  spaced apart from each other. One such packing material is shown in  FIGS. 14 and 15 . For clarity with the other packing materials discussed herein, the packing material of this embodiment is referred to as a wrap-like packing material  160 .  FIG. 15  is a cross-sectional view of the wrap-like packing material  160  taken along line  15 - 15  in  FIG. 14 . The wrap-like packing material  160  of this embodiment has similarities to the sandwich wrap  150 . For example, the wrap-like packing material  160  includes a top sheet  152  connected to a bottom sheet  154  with cellulosic cushioning elements  110  positioned therebetween. At least one of the top sheet  152  and the bottom sheet  154  includes a plurality of pockets  162 . In this embodiment, both the top sheet  152  and the bottom sheet  154  include a plurality of pockets  162 . Each of the pockets  162  includes an opening  164 . In the wrap-like packing material  160  shown in  FIG. 15 , each opening  164  of the top sheet  152  opposes a corresponding opening  164  of the bottom sheet  154 , forming a combined pocket. An area sounding each pocket  162  or combined pocket is referred to herein as webbing area  166 . The top sheet  152  and bottom sheet  154  are adhered to each other using, for example, the adhesive  136  discussed above in the webbing area  166 . 
     At least one cellulosic cushioning element  110  is located in each combined pocket. In this embodiment, each pocket  162  includes a plurality of cellulosic cushioning elements  110 . The plurality of cellulosic cushioning elements  110  in each pocket  162  or combined pocket may be bonded to each other with bonds comprising adhesive and cellulosic fibers, as will be described further below. Instead of both the top sheet  152  and the bottom sheet  154  having a plurality of pockets  162 , pockets  162  may be formed in one of the top sheet  152  and the bottom sheet  154 .  FIG. 16  is a cross-sectional view of the wrap-like packing material  160  taken along line  15 - 15  in  FIG. 14 , where a plurality of pockets  162  are formed in the bottom sheet  154  but not the top sheet  152 . In this embodiment, the top sheet  152  is bonded to the bottom sheet  154  such that the top sheet  152  covers the openings  164  of the plurality of pockets  162  in the bottom sheet  154 . 
     To increase the flexibility of the wrap-like packing material  160 , a plurality of holes  168  may be formed through both the top sheet  152  and the bottom sheet  154 , as shown in  FIGS. 17 and 18 . The wrap-like packing material  160  shown in  FIG. 17  has the holes  168  located between each pocket  162  in the length direction A and in the width direction B. Another configuration for the wrap-like packing material  160  with holes  168  is shown in  FIG. 18  in which the holes  168  are formed in interstitial potions between the pockets  162 . 
     When a single cellulosic cushioning element  110  is located in each combined pocket of the wrap-like packing material  160 , a modified method and machine assembly  400  shown and discussed above with reference to  FIG. 12  may be used. The first laminating roller  412  and the second laminating roller  414  may be longer and the machine assembly  200  is configured to place a plurality of cellulosic cushioning elements  110  along the length of the first laminating roller  412  and the second laminating roller  414 . Instead of the first roll  402  and the second roll  404  being tape, they may be rolls of paper used to form the top sheet  152  and the bottom sheet  154 . 
     A method of forming the wrap-like packing material  160  shown in  FIG. 16  and a machine assembly  500  used in this method will be described with reference to  FIG. 19 . The bottom sheet  154  is provided with the plurality of pockets  162  formed therein. At a first station  502 , the plurality of cellulosic cushioning elements  110  are filled in each pocket  162 . Optionally, at a second station  504 , the cellulosic cushioning elements  110  in each pocket  162  may be bonded together. The cellulosic cushioning elements  110  may be bonded together by an adhesive, which is preferably a biodegradable adhesive. Even more preferably, an emulsion of water, adhesive, and cellulosic (paper) fibers are sprayed into each pocket  162  at the second station  504 . Each pocket  162  is conveyed and supported by a backing member, such as by the first laminating roller  412  discussed above, through a bonding nip formed between the first laminating roller  412  and a press roller  512 . The top sheet  152  may be conveyed by the press roller  512  into the bonding nip and the top sheet  152  is bonded to the bottom sheet  154 . Where the emulsion is used, the emulsion may then be dried resulting in a plurality of cellulosic cushioning elements  110  that are bonded by bonds comprising cellulosic fibers and the adhesive and/or a matrix of cellulosic fibers and the adhesive, as discussed further below in connection with the molded packing material  170 . 
     Instead of using a sheet of paper alone as top sheet  152 , a top sheet  152  with pockets  162  filled with cellulosic cushioning elements  110  and optionally bonded may formed in a manner similar to the bottom sheet  154 , as discussed above. This top sheet  152  with pockets may then be brought together with the bottom sheet  154  in the bonding nip to form the wrap like packing material shown in  FIG. 15 . Alternatively, two of the wrap-like packing materials  160  shown in  FIG. 16  may be brought together to form the wrap-like packing material  160  shown in  FIG. 15 . In any of these cases, the top sheet  152  and the bottom sheet  154  may be bonded together with an adhesive, which is preferably a biodegradable adhesive. 
     The cellulosic cushioning elements  110  discussed herein may also be suitable to make a polystyrene foam (or other plastic foam) replacement.  FIGS. 20 and 21  show such a packing material according to a preferred embodiment of the invention. For clarity with the other packing materials discussed herein, the packing material of this embodiment is referred to as a molded packing material  170 . The molded packing material  170  is shown in  FIG. 20 , and  FIG. 21  is a cross section of the molded packing material  170  shown in  FIG. 20  taken along line  21 - 21  in  FIG. 20 . 
     The molded packing material  170  will be formed into a shape in order to pack the item-to-be-shipped  104 . Such molded shape may include recesses and protrusions. For example, the molded packing material  170  shown in  FIG. 20  includes a hemispherical cavity  172  in which a portion of the item-to-be-shipped  104  can be placed. The molded packing material  170  of this embodiment includes a plurality of cellulosic cushioning elements  110  that are formed into the desired shape and then joined together. The plurality of cellulosic cushioning elements  110  may be joined together by bonds comprising adhesive and cellulosic (paper) fibers. In some embodiments, the plurality of cellulosic cushioning elements  110  may be joined together by a matrix of cellulosic fibers, and in a preferred embodiment, a matrix of cellulosic (paper) fibers and an adhesive. Additional features of the bonds and matrix will be discussed below in connection with the method of manufacturing the molded packing material  170 . Optionally, the outer surfaces of the molded packing material  170  may be covered with an outer sheet  174 . The outer sheet  174  is preferably a cellulosic (paper) sheet. 
     A method of manufacturing the molded packing material  170  shown in  FIG. 20  will be described with reference to  FIG. 22 . First, a mold  520  having the desired shape is provided. The mold  520  may preferably be silicon. If an outer sheet  174  is used, the outer sheet  174  is placed into the mold. The mold  520  is then filled with the cellulosic cushioning elements  110 . Next, an emulsion of water, cellulosic (paper) fibers, and preferably adhesive is sprayed into the mold  520  with the cellulosic cushioning elements  110 . The emulsion flows around and between the cellulosic cushioning elements  110 . In addition, the emulsion may also flow at least a portion of the way into crevices exposed on the outer surfaces of the plurality of cellulosic cushioning elements  110 . If the outer sheet  174  is used, the outer sheet  174  may be placed on top of an exposed surface  176  of the cellulosic cushioning elements  110 . The cellulosic cushioning elements  110  with the emulsion is then removed from the mold  520 , such as by turning the mold  520  upside down, and then dried to form the molded packing material  170 . The drying step may also take place before removing the cellulosic cushioning elements  110  from the mold  520 . 
     As the cellulosic cushioning elements  110  with the emulsion is dried bonds form between the folds of each of the cellulosic cushioning elements  110  and also between the cellulosic cushioning elements  110 . The emulsion may also form, as it is dried, a matrix around the cellulosic cushioning elements  110 , and the cellulosic cushioning elements  110  may be connected to each other by the cellulosic fibers and, when used, the adhesive of the matrix. The molded packing material  170  may thus include a plurality of cellulosic cushioning elements  110  that are interconnected to each other by cellulosic fibers. The cellulosic cushioning elements  110  may retain some of the air pockets therein, and the molded packing material  170  may also be described as having discrete groupings of air (gas) pockets interspersed within a cellulosic (paper) mass. 
     As discussed above, factors impacting the amount of energy absorbed include the weight of the paper, the volume or size (e.g., diameter) of the cellulosic cushioning element  110 , and the density of the cellulosic cushioning element  110 . In this embodiment, the amount of emulsion and the amount of the cellulosic fibers and the amount of adhesive in the emulsion may also be modified to create a packing material with the desired strength and energy absorbing properties. The emulsions discussed herein may be referred to herein as an aqueous slurry of cellulosic fibers and adhesive. In the emulsions discussed herein the cellulosic fibers are preferably the same fibers as are used in the paper for the cellulosic cushioning element  110 . In addition, the adhesive of the emulsion is preferably a biodegradable emulsion. 
     Although this invention has been described with respect to certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art, in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive, and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description.