US 7,018,495 B2Granted

Process for making and aging high strength high gas barrier cellular cushioning product

AssigneeSealed Air Corporation (US)

InventorsCharles Kannankeril, Robert O'Dowd

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Abstract

An inflatable cushioning article is made by a process of extruding two multilayer films (or extruding one film which is either annular or folded over) each having (a) a seal layer, (b) a tie layer containing an anhydride modified olefin polymer containing anhydride at a level of at least 150 ppm, based on the weight of the modified olefin polymer, and (c) an oxygen barrier layer comprising crystalline polyamide, crystalline polyester, ethylene/vinyl alcohol copolymer, polyacrylonitrile, and/or crystalline polycycloolefin. Selected portions of the films are heat sealed to one another in a selected area providing a heat seal pattern which leaves inflatable chambers between the films, whereby an inflatable cellular cushioning article is produced. At some point after extrusion, at least one of the multilayer films are aged 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. After aging, the cellular cushioning article is inflated. Preferably, the article is inflated to an internal pressure of at least 1.5 psi.

Claims27

Dependent claims

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.

7 more elements

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 which comprises 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 anhydride modified olefin polymer;
(B) extruding a second multilayer film having an outer heat seal layer, a tie layer, and a gas barrier layer which comprises 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 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 the inflatable cellular cushioning article for a time and at a temperature so that the inflatable cellular cushioning article has a burst strength after aging which is at least 5 percent higher than the burst strength of the article before aging.

1 more element

Dependencies are inferred from the claim text.

Facts

Application: 10/648,015Filed 26 Aug 2003 · continuation in part
Priority: 22 Nov 2002
Published: US 2004/0099986 A127 May 2004
Granted: 28 Mar 2006
Term ends: Not estimatedThe source records don’t support an estimate.

Classification23 codes

B32B 27/08
As the main or only constituent of a layer, which is next to another layer of the same or of a different material: of synthetic resin
B31D 5/0073
For making dunnage or cushion pads: including pillow forming
B32B 3/28
Characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or…
B32B 7/12
Interconnection of layers: using interposed adhesives or interposed materials with bonding properties

Family

Application10/302,004Parent of this continuation-in-part · filed 22 Nov 2002
US 2004/0099986 A1Pre-grant publication · published 27 May 2004
US 2004/0101658 A1Published application
US 6,982,113 B2Related patent
US 7,018,495 B2This patent

From the US filing history. Foreign family members aren’t listed.