PAPER-BASED CUSHION PACKAGE
An example disclosed article may include a first layer and a second layer, where the first layer and the second layer may be bonded together within a peripheral region, the first layer and the second layer may be spaced apart within a cushion portion, the peripheral region may extend at least partially around the cushion portion, and the first layer may include cellulose fibers. The article may be used as a component of a packaging arrangement that may be entirely recycled using a paper recycling process. Examples also include, for example, related methods, systems, and assemblies.
1 . An article, comprising:
a first layer having a first layer thickness between 0.5 mm and 2 mm, the first layer being a semi-rigid layer comprising a paper-based material; and
a second layer having a second layer thickness between 0.1 mm and 2 mm,
wherein:
the article comprises a cushion portion;
the cushion portion comprises a gas-filled enclosure located between the first layer and the second layer;
the second layer is bonded to the first layer within a peripheral region that extends around the cushion portion; and
the article is conformable to a curved surface.
2 . The article of claim 1 , wherein the first layer and the second layer each comprise cellulose fibers.
3 . The article of claim 1 , wherein:
the first layer and the second layer are spaced apart by a gap thickness within the cushion portion;
the gap thickness is between approximately 0.1 mm and approximately 5 mm; and
the gap thickness is generally uniform within the cushion portion.
4 . The article of claim 1 , wherein the gas-filled enclosure is a sealed enclosure.
5 . The article of claim 1 , wherein the cushion portion comprises an embossed portion of the second layer spaced apart from the first layer.
6 . The article of claim 1 , wherein the article is sized to cover a light-receiving surface of a head-mounted apparatus.
7 . The article of claim 1 , wherein the first layer thickness is approximately equal to the second layer thickness.
8 . The article of claim 1 , wherein the second layer thickness is less than approximately half the first layer thickness.
9 . The article of claim 1 , wherein the article is recyclable within a paper recycling process.
10 . The article of claim 1 , wherein the article comprises less than 1% by weight of synthetic polymers.
11 . The article of claim 1 , wherein:
the first layer has an exterior surface and an inner surface;
the inner surface of the first layer is bonded to the second layer within the peripheral region; and
the article further comprises a coating extending over at least a portion of the exterior surface of the first layer.
12 . The article of claim 11 , wherein the coating comprises a polyolefin.
13 . The article of claim 11 , wherein the coating comprises polypropylene.
14 . The article of claim 11 , wherein the coating comprises cellulose.
15 . The article of claim 11 , wherein the coating has a grooved external surface profile.
16 . The article of claim 11 , wherein the coating has a coating thickness of less than 100 microns.
17 . The article of claim 11 , wherein the article further comprises a second coating extending over at least a part of the second layer.
18 . A method comprising:
embossing a layer to form an embossed portion of the layer within an non-embossed portion of the layer;
bonding the non-embossed portion of the layer to an additional layer to form a peripheral region, the peripheral region surrounding an enclosure formed between the embossed portion of the layer and the additional layer; and
trimming the peripheral region to match a surface portion of an electronic device,
wherein the layer and the additional layer each comprise cellulose fibers and are recyclable within a paper recycling process.
19 . The method of claim 18 , further comprising forming a polypropylene layer on at least a portion of the layer.
20 . A method comprising:
packaging an electronic device within a package assembly comprising a box, a device receptacle, and a cushion package,
wherein:
the cushion package protects a surface portion of the electronic device; and
the package assembly is entirely recyclable using a paper recycle process.