The disclosed embodiments relate to an insulative protective packaging material constructed using recyclable paper materials. The packaging material includes one or more plies of paper adhered to each other. The one or more plies can have protrusions that form gas pockets. The gas pockets can be sealed by another ply to provide shock absorbency and insulation. Further, the plies can be used in multiple ways such as by nesting the protrusions of one ply into the recessed of another ply, layering multiple plies on top of each other, or individually. Each ply can be substantially flat or have protrusions. The protrusions can be made in various ways such as alternating the directions that they extend and varying the shapes of the protrusions. The resulting packaging material can be used as a shipping container or as liners within shipping containers.
Claim CLM-00001. 1. A packaging material comprising:
a first ply made of paper and having a surface and a plurality of protrusions from the surface that form a corresponding plurality of volumes.
Claim CLM-00014. 14. A recyclable multiple-ply packaging comprising:
a plurality of two-ply materials, wherein each two-ply material comprises:
a first ply having a top side and a bottom side opposite the top side, wherein the bottom side comprises flat portions and recessed portions, and the top side comprises protrusions; anda second ply being substantially flat and being coupled to the flat portions of the bottom side of the first ply to seal the recessed portions;
wherein the top side of each two-ply material are coupled together such that the protrusions of each two-ply material are not aligned.
Claim CLM-00017. 17. A method of forming an insulative and recyclable packaging material, the method comprising:
receiving, at a forming tool, a first ply of paper, wherein the first ply has a top side and a bottom side opposite the top side, wherein the forming tool includes a female component and a male component, and wherein the first ply is positioned between the male component and female component; forming, by the forming tool, a plurality of protrusions on the first ply such that the bottom side is caused to have flat portions and recessed portions, and the top side is caused to have the protrusions, wherein forming the plurality of protrusions includes:
forcing at least a portion of the top side against the female component by using the male component; and
adhering a second ply of paper to the flat portions of the bottom side.
