Composite material having gas cavities and a mechanically bonded protective layer and method of making same

A composite material for protecting or cushioning articles comprising

• first and second layers of plastic film laminated together and defining a multiplicity of spaced apart, gas filled cavities therebetween, and
• a third layer of a material which is incompatible with said first and second layers such that said third layer is incapable of being fusion bonded to either of said first and second layers, said third layer including opposite surfaces having predetermined surface characteristics different from said layers of plastic film, one of said surfaces of said third layer being disposed in contiguous relation to an outer surface of one of said first and second layers of plastic film and having spaced apart projections extending outwardly beyond the remainder of said surface of said third layer, said projections being embedded in the plastic layer contiguous thereto which is otherwise undisturbed, such that said third layer is mechanically bonded to said one of said first and second layers of plastic film to interlock the contiguous surfaces thereof without the plastic of said first or second layer flowing into and through said remainder of said surface of said third layer, whereby a composite material is formed having such predetermined surface characteristics on one side thereof.