CPC B32B 3/08 (2013.01) [B32B 3/30 (2013.01); B32B 7/12 (2013.01); B32B 29/005 (2013.01); B32B 37/0053 (2013.01); B32B 37/10 (2013.01); B65D 27/14 (2013.01); B65D 81/02 (2013.01); B65D 81/03 (2013.01); B32B 2307/558 (2013.01); B32B 2439/40 (2013.01)] | 9 Claims |
1. A method of forming a cushioning sheet comprising:
forming a plurality of first sockets in a first layer;
forming a plurality of second sockets in a second layer, each of the second sockets aligned with a corresponding one of the first sockets;
positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets; and
coupling the first layer to the second layer to retain the plurality of cushioning inserts within the voids;
wherein:
positioning the cushioning insert within the void comprises:
picking up the cushioning insert;
releasing the cushioning insert onto the first layer;
locating the cushioning insert in one of the first sockets; and
covering the first layer with the second layer;
picking up the cushioning insert comprises picking up the cushioning insert with a vacuum roller, the vacuum roller defining an insert indentation and a vacuum port formed in the insert indentation; and
releasing the cushioning insert onto the first layer comprises releasing the cushioning insert from the insert indentation of the vacuum roller.
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