How Bubble Wrap Is Manufactured
A 1959 manufacturing process that creates cushioning material by trapping air between two layers of plastic film.
Original patent title: “Method for making laminated cushioning material”
A 1959 manufacturing process that creates cushioning material by trapping air between two layers of plastic film. Granted to Sealed Air Corp in 1964 with 2 claims and 185 forward citations, and it is now in the public domain.
Key facts
Coverage
What does this patent actually cover?
The patent describes a continuous manufacturing process for creating air-filled cushioning material. A thermoplastic film is heated to a specific temperature—soft enough to be shaped but not hot enough to melt—and pressed into a roller with discrete depressions to form bubbles. A second film is then heated and sealed over the first, trapping air within the embossed pockets to create a protective, flexible material.
The gap
What does this patent NOT cover?
- Does not cover the use of non-thermoplastic materials like paper or fabric.
- Does not cover methods that do not use a female molding roller with discrete depressions.
- Does not cover the specific chemical composition of the plastic used, only the mechanical process of forming and sealing.
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
What made this novel
The innovation lies in the precise thermal control: heating the film just enough to allow deformation into the mold without losing structural integrity or melting through the material.
The Patent Drawing
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
Bubble Wrap brand packaging material
Standard protective shipping mailers
Why it matters
The bigger picture
This patent marks the birth of Bubble Wrap. Originally intended as 3D wallpaper, it failed in that market but became the global standard for protective packaging, fundamentally changing how fragile goods are shipped worldwide.
Filed
November 27, 1959
Granted
July 28, 1964
Market context
Who's building on this
Companies in this space
Sealed Air Corporation remains the primary manufacturer and holder of the Bubble Wrap trademarktrademarkA name, logo, or phrase identifying the source of goods or services. Protects brand identity — different from patents (inventions) or copyright (creative works).Read more →. Various global packaging firms continue to refine the material's durability and sustainability by using recycled plastics.
Market impact
This patent enabled the creation of a multi-billion dollar protective packaging industry. It standardized the way fragile items are handled in logistics and e-commerce, effectively becoming a ubiquitous household item.
Claim 1 — Plain English
What this patent covers
The patent describes a continuous manufacturing process for creating air-filled cushioning material. A thermoplastic film is heated to a specific temperature—soft enough to be shaped but not hot enough to melt—and pressed into a roller with discrete depressions to form bubbles. A second film is then heated and sealed over the first, trapping air within the embossed pockets to create a protective, flexible material.
The clever bit
The innovation lies in the precise thermal control: heating the film just enough to allow deformation into the mold without losing structural integrity or melting through the material.
What it does not cover
- Does not cover the use of non-thermoplastic materials like paper or fabric.
- Does not cover methods that do not use a female molding roller with discrete depressions.
- Does not cover the specific chemical composition of the plastic used, only the mechanical process of forming and sealing.
Patent Journey
From filing to expiry
PatentBrief Score
Impact Score
Moderate
Citation count
40/40
Highly cited
Claim breadth
1/20
Narrow claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more →
Recency
0/20
Older than 20 years
Assignee scale
0/20
Independent or smaller assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$32K – $104K
Midpoint $65K · expired or expiring · industry ×0.9
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
The original legal language
Original claims
2 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Chavannes, M. A. (1964). How Bubble Wrap Is Manufactured (U.S. Patent No. 3,142,599). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/3142599/bubble-wrap-cushioning
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
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Common Questions
Frequently Asked Questions
What does How Bubble Wrap Is Manufactured cover?
A 1959 manufacturing process that creates cushioning material by trapping air between two layers of plastic film.
Who owns patent US 3142599?
Sealed Air Corp owns this patent, granted in 1964.
When does this patent expire?
This patent has expired and is now in the public domain — anyone can use the invention freely.
What is patent US 3142599 cited by?
This patent has been cited by 185 later patents that build on its ideas.
What problem does this patent solve?
This patent marks the birth of Bubble Wrap. Originally intended as 3D wallpaper, it failed in that market but became the global standard for protective packaging, fundamentally changing how fragile goods are shipped worldwide.
What does this patent NOT cover?
Does not cover the use of non-thermoplastic materials like paper or fabric.
Patent monitoring