Cushioning Assembly

Abstract

A cushioning assembly includes a first sheet and a second sheet opposing the first sheet. A plurality of foam elements are between the first and second sheets and adhered to at least one of the first sheet interior surface and the second sheet interior surface. The aspect ratio of the plurality of foam elements is at least 1.2.

What is claimed is: 
     
         1 . A cushioning assembly comprising:
 a first sheet and a second sheet opposing the first sheet, wherein the first sheet has an interior surface and the second sheet has an interior surface facing the first sheet interior surface;   a plurality of foam elements between the first and second sheets and adjacent both the first sheet interior surface and the second sheet interior surface, wherein:   the plurality of foam elements is adhered to at least one of the first sheet interior surface and the second sheet interior surface; and   the aspect ratio of the plurality of foam elements is at least 1.2.   
     
     
         2 . The cushioning assembly of  claim 1  wherein the plurality of foam elements has an average length of at least 5 mm and at most 100 mm. 
     
     
         3 . The cushioning assembly of  claim 1  wherein the first sheet is attached to the second sheet to encase the plurality of foam elements. 
     
     
         4 . The cushioning assembly of  claim 1  wherein the plurality of foam elements comprises starch. 
     
     
         5 . The cushioning assembly of  claim 4  wherein the starch is derived from sorghum. 
     
     
         6 . The cushioning assembly of  claim 1  wherein the first and second sheets comprise cellulosic material. 
     
     
         7 . The cushioning assembly of  claim 1  further comprising a non-water based adhesive adhering the plurality of foam elements to at least one of the first sheet interior surface and the second sheet interior surface. 
     
     
         8 . The cushioning assembly of  claim 1  wherein the plurality of foam elements comprise a hydrophobic coating on or additive in the foam elements. 
     
     
         9 . The cushioning assembly of  claim 1  further comprising a water-based adhesive adhering the plurality of foam elements to at least one of the first sheet interior surface and the second sheet interior surface. 
     
     
         10 . The cushioning assembly of  claim 1  wherein the interior surface of the first sheet is adhered directly to the interior surface of the second sheet in selected regions. 
     
     
         11 . The cushioning assembly of  claim 10  wherein the selected regions enclose the plurality of foam elements. 
     
     
         12 . The cushioning assembly of  claim 1  wherein the foam elements of the plurality of foam elements have a curved longitudinal extent. 
     
     
         13 . The cushioning assembly of  claim 1  wherein the cross-section profile of the foam elements of the plurality of foam elements comprises one or more of the following shapes:
 circular shape, star shape, rectangular shape, “C” shape, cross shape, triangular shape, ellipse shape, peanut shape, “I” shape, “S” shape, and “T” shape. 
 
     
     
         14 . The cushioning assembly of  claim 1  wherein the cushioning assembly is repulpable. 
     
     
         15 . A mailer comprising the cushioning assembly of  claim 1 .