Sheet with cushioning inserts

A cushioned mailer comprising:

• a first layer defining a plurality of first sockets;
• a second layer defining a plurality of second sockets, each of the first sockets aligned with a corresponding one of the second sockets to define a void therebetween;
• and
• a cushioning insert received within each of the voids, wherein each void has a diameter that is larger than a diameter of the cushioning insert disposed therein so that each void is configured to allow unrestricted movement of the cushioning insert disposed therein about the corresponding void;
• wherein:
• the first layer is coupled to the second layer by a first adhesive to define a cushioning sheet;
• the cushioning sheet defines an inner cavity configured to receive contents;
• the inner cavity is at least partially surrounded by the second layer;
• the first layer faces away from the inner cavity;
• the cushioned mailer further comprises an outer sheet defining an outer cavity;
• the cushioning sheet is received within the outer cavity;
• each of the first sockets are arranged in a plurality of linear rows extending in a lateral direction and linear columns extending in a longitudinal direction perpendicular to the lateral direction;
• in each of the linear rows, none of the first sockets are longitudinally aligned with any of the first sockets in adjacent linear rows;
• in each of the linear columns, none of the first sockets are laterally aligned with any of the first sockets in adjacent linear columns;
• and
• each of the first layer and the second layer comprise a coating configured to limit the passage of air therethrough.

A cushioning sheet comprising:

• a first layer comprising a first base and a plurality of first sockets extending from the first base, each of the first sockets spaced apart from adjacent ones of the first sockets;
• a second layer coupled to the first layer, the second layer comprising a second base and a plurality of second sockets extending from the second base, the second base coupled to the first base by an adhesive to form the cushioning sheet, each of the second sockets aligned with a corresponding one of the first sockets to define a void therebetween;
• and
• a plurality of cushioning inserts, each of the plurality of cushioning inserts substantially spherical in shape and received in a corresponding one of the voids;
• wherein each void has a diameter that is larger than a diameter of the cushioning insert disposed therein so that each void is configured to allow unrestricted movement of the cushioning insert disposed therein about the corresponding void.