Patent ID: 7018495

Claim:
A process for making an inflated cellular cushioning article, comprising: (A) extruding a first multilayer film having an outer heat seal layer, a tie layer, and a gas barrier layer comprising at least one member selected from the group consisting of crystalline polyamide, crystalline polyester, ethylene/vinyl alcohol copolymer, polyacrylonitrile, and crystalline polycycloolefin, wherein the tie layer comprises an anhydride modified olefin polymer containing anhydride at a level of at least 150 ppm, based on the weight of the modified olefin polymer; (B) extruding a second multilayer film having an outer heat seal layer, a tie layer, and a gas barrier layer comprising at least one member selected from the group consisting of crystalline polyamide, crystalline polyester, ethylene/vinyl alcohol copolymer, polyacrylonitrile, and crystalline polycycloolefin, wherein the tie layer comprises an anhydride modified olefin polymer containing anhydride at a level of at least 150 ppm, based on the weight of the modified olefin polymer; (C) heating selected portions of at least one of the first multilayer film and the second multilayer film to a temperature above a fusion temperature, so that the first and second multilayer films are heat sealed to one another at a selected area, with the selected area providing a heat seal pattern which leaves inflatable chambers between the first film and the second film, whereby an inflatable cellular cushioning article is produced; (D) aging at least one member selected from the group consisting of the first multilayer film and the second multilayer film, the aging being carried out before inflating the inflatable cellular cushioning article, and for a time and at a temperature in accordance with at least one member selected from the group consisting of: (i) 141° F. to 250° F. for a period of at least 1 second; (ii) 101° F. to 140° F. for a period of at least 10 minutes; (iii) 61° F. to 100° F. for a period of at least 1 hour; and (iv) 30° F. to 60° F. for a period of at least 1 day; (E) inflating the cellular cushioning article after aging.