Apparatuses and methods for manufacturing packaging receptacles and receptacles thereof

A multipurpose modular apparatus for manufacturing packaging receptacles, the multipurpose modular apparatus comprising:

• a first feeder module;
• a polymer cushion feeder module;
• and
• a heat-sealing module;
• wherein the first feeder module comprises a plurality of first feeder rollers configured to feed one or more layers of a polymer-based material to the heat-sealing module, wherein the polymer cushion feeder module comprises at least one polymer cushion material roller configured to feed a layer of a polymer cushion material to the heat-sealing module, and
• wherein the heat-sealing module comprises a heated-sealing roller set configured to thermally seal the one or more layers of the polymer-based material with the layer of the polymer cushion material by fusing an outermost surface of the one or more layers of the polymer-based material with an inner surface of the layer of the polymer cushion material.

A multipurpose modular apparatus for manufacturing packaging receptacles, the multipurpose modular apparatus comprising:

• a first feeder module;
• a polymer cushion feeder module;
• a heat-sealing module;
• a paper feeder module;
• an embossing module;
• an adhesive coating module;
• a layer-sealing module;
• a folding module;
• a heated compression module;
• and
• a cutting module;
• wherein the first feeder module comprises a plurality of first feeder rollers configured to feed one or more layers of a polymer-based material to the heat-sealing module,
• wherein the polymer cushion feeder module comprises at least one polymer cushion material roller configured to feed a layer of a polymer cushion material to the heat-sealing module, po1 wherein the heat-sealing module comprises a heated-sealing roller set configured to thermally seal the one or more layers of the polymer-based material with the layer of the polymer cushion material by fusing an outermost surface of the one or more layers of the polymer-based material with an inner surface of the layer of the polymer cushion material,
• wherein the paper feeder module comprises a plurality of paper feeder rollers, the plurality of paper feeder rollers configured to feed one or more first layers of a paper to the embossing module, and a second layer of the paper to the adhesive coating module,
• wherein the embossing module comprises a first embossing roller and a second embossing roller, the embossing module configured to emboss a plurality of impressions onto the one or more first layers by passing the one or more first layers between the first embossing roller and the second embossing roller, and feed the embossed one or more first layers to the adhesive coating module,
• wherein the adhesive coating module is configured to apply an adhesive to an outermost surface of the embossed one or more first layers and an inner surface of the second layer,
• wherein the layer-sealing module comprises a plurality of sealing implements configured to seal the embossed one or more first layers with the second layer, thereby generating a layer of a first packaging material, and to seal the one or more layers of polymer-based material with the layer of the polymer cushion material, thereby generating a layer of a second packaging material,
• wherein the folding module comprises a plurality of folding implements configured to fold the layer of the first packaging material and the layer of the second packaging material into a plurality of continuous predefined receptacles,
• wherein the heated compression module comprises a plurality of heated bars configured to thermally seal a plurality of folded surfaces of the plurality of continuous predefined receptacles, and
• wherein the cutting module is configured to cut the plurality of continuous predefined receptacles into a plurality of respective individual predefined receptacles of a plurality of respective predefined sizes.

A method of manufacturing packaging receptacles, the method comprising:

• feeding, by a plurality of paper feeder rollers of a paper feeder module, one or more first layers of a paper to an embossing module, and a second layer of the paper to an adhesive coating module;
• embossing, by a first embossing roller and a second embossing roller of the embossing module, a plurality of impressions onto the one or more first layers, by passing the one or more first layers between the first embossing roller and the second embossing roller, and feeding the embossed one or more first layer to the adhesive coating module;
• and
• applying, by the adhesive coating module, an adhesive to an outermost surface of the embossed one or more first layers, and an inner surface of the second layer.

A method for manufacturing packaging receptacles, the method comprising:

• feeding, by a plurality of first feeder rollers of a first feeder module, one or more layers of a polymer-based material to a heat-sealing module;
• feeding, by at least one polymer cushion material roller of a polymer cushion feeder module, a layer of a polymer cushion material to the heat-sealing module;
• and
• sealing, by a heated-sealing roller set of the heat-sealing module, the one or more layers of the polymer-based material with the layer of the polymer cushion material, by fusing an outermost surface of the one or more layers of the polymer-based material with an inner surface of the layer of the polymer cushion material.

A layer of a packaging material, the layer comprising:

• one or more first layers of paper with a plurality of impressions embossed thereupon;
• and
• a second layer of paper,
• wherein an outermost surface of the embossed one or more first layers is sealed with an inner surface of the second layer, through thermal curing of an adhesive applied between the outermost surface of the embossed one or more first layers, and the inner surface of the second layer.