Laminated plastic packaging material

In a method for the continuous fabrication of laminated cushioning material including the steps of heating a first layer of thermoplastic material above the softening temperature of the thermoplastic;

• passing the softened material over a first forming roller including a plurality of depressions in the outer surface;
• supplying a vacuum to the depressions to draw portions of the softened thermoplastic layer into the depressions;
• passing a second layer of thermoplastic over the roller in contact with the first layer to form air pockets between the first layer and second layer;
• heating the first layer and second layer to a fusing temperature prior to application of the second layer;
• passing the first and second layer past a heated pressure roller adjacent the first roller;
• removing the fused layer from the first roller;
• forming a plurality of air pockets on the side of said first layer remote from said second layer with the additional steps comprising:
• heating a third layer of thermoplastic material above the softening temperature of the thermoplastic;
• passing the softened material over a second forming roller including a plurality of depressions in the outer surface;
• supplying a vacuum to the depressions to draw portions of the softened thermoplastic layer into the depressions;
• passing the fused layers and the third layer between a second pressure roller and the second forming roller;
• said second pressure roller including a plurality of depressions adapted to receive the air pockets on said fused layers;
• supplying a pressure to the depressions of the second roller adjacent the second forming roller to supply a pressure to the fused layer equal to the pressure between the second pressure roller and the second forming roller;
• heating the fused layer and the third layer to a fusing temperature prior to passing between the second pressure roller and the second forming roller;
• removing the three fused layers from the second forming roller.