# How Bubble Wrap Is Manufactured

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

- **Patent:** US 3142599
- **Original title:** Method for making laminated cushioning material
- **Owner:** Sealed Air Corp
- **Granted:** 1964
- **Status:** Public domain (expired)
- **Times cited:** 185
- **Field:** mechanical, materials, consumer_electronics

## What it does

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 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.

## 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.

## Real-world examples

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

## 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.

## 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.

**Full plain-English explainer:** https://patentbrief.org/patent/us/3142599/bubble-wrap-cushioning

**Original patent:** https://patents.google.com/patent/US3142599

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_Source: PatentBrief — https://patentbrief.org. Patent facts are from public records; the plain-English explanation is PatentBrief's._


## Related patents

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- [Making Strong, Porous PTFE: The Gore-Tex Process](https://patentbrief.org/patent/us/3953566/gore-tex-expanded-ptfe) — This patent describes a specific process for rapidly stretching a highly crystalline form of PTFE plastic to create a strong, porous material with a unique internal structure, forming the basis for products like Gore-Tex.
- [How Polaroid's Instant Film Pods Work](https://patentbrief.org/patent/us/2543181/polaroid-instant-camera) — A 1951 invention by Edwin Land that enabled instant photography by packaging liquid developer inside a breakable pod attached to the film sheet.
- [How the Modern Waterbed Works](https://patentbrief.org/patent/us/3585356/waterbed-liquid-support) — A 1971 patent describing a liquid-filled, heated furniture support designed to cradle human bodies without letting them touch the bottom of the container.
- [How Disposable Diapers Keep Skin Dry Using Porous Plastic Sheets](https://patentbrief.org/patent/us/3489148/disposable-diaper-topsheet) — A 1970 patent by Procter and Gamble describing a specialized plastic top layer for diapers that allows liquid to pass through while keeping the baby's skin feeling dry.