US Patent 9315312 Domed multilayer cushioning article

A cushioning article comprises a flap-cut sheet with a plurality of discrete sets of flaps, with each discrete set of flaps having a plurality of flaps extending outward from the sheet. A plurality of the outwardly extending flaps of each discrete set of flaps are affixed to a discrete cap member, resulting in a composite dome sheet having a plurality of composite domes extending from the flap-cut sheet. A cushioning and thermal protection packaging article for packaging a thermally-sensitive product utilizes a plurality of the layers of the composite dome sheet with each layer separated by a separating sheet. Both the composite dome sheet and the separating sheet can be made of paper.