Process for forming improved protective eco-friendly pouch and packaging and products made therefrom

A method of manufacturing a protective padded pouch including:

• providing first, second, third and fourth continuous web substrates, each having a top and bottom side and a length and a width defining a perimeter thereabout;
• forming a sealable adhesive perimeter by applying a layer of sealing adhesive about the perimeter of top side of the first and third web substrates;
• depositing a predetermined pattern of a water-based heat expandable adhesive (WBHEA) comprising a water-based polymer and a plurality of heat-expandable microspheres, on the inner portion of the top side of the first and third web substrates, the WBHEA forming a protective padded area when expanded, wherein the predetermined pattern includes an array of discrete elements formed on the first and third web substrates and spaces between respective discrete elements;
• joining the first and second web substrates and the third and fourth web substrates about the respective perimeters to form a sealed structure enclosing the WBHEA therebetween without substantially compressing the WBHEA;
• sealingly mating the top side of second web substrate to the bottom side of the third web substrate at least along a portion of the perimeter to form an open ended pouch;
• with the second and third web substrate sealingly mated, exposing the WBHEA between the first and second web substrates and third and fourth web substrates to sufficient RF radiation to expand and cure/coalesce the WBHEA;
• and
• evaporatively venting water vapor produced as a by-product of expansion of the WBHEA from between the first and second web substrates and the third and fourth web substrates during manufacturing by forming vents interior to the respective sealed perimeters.