How Bubble Wrap Is Manufactured

A 1959 manufacturing process that creates cushioning material by trapping air between two layers of plastic film.

What it 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.

What it doesn't 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.

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.

Why it matters

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.

Real-world examples

• 1.Bubble Wrap brand packaging material
• 2.Standard protective shipping mailers