Integrated Process For Making Inflatable Article

Abstract

An integrated process for making an inflatable laminated article comprises extruding a first film and a second film, followed by cooling the first film and the second film so that the films will not fuse to one another upon contact with each other. The films are then brought into contact with one another, and selected portions of one or both films are heated so that the films are heat sealed to one another in a selected area having a desired pattern. The unsealed area between the film provides inflatable chambers between the first film and the second film. An alternative process utilizes a film tubing in lay-flat configuration to produce a laminated inflatable article.

1 - 20 . (canceled) 
     
     
         21 . An integrated process for making an inflatable laminated article, comprising the steps of:
 (A) extruding a first flat film and a second flat film;   (B) cooling the first flat film and the second flat film so that the first and second flat films will not fuse to one another upon contact with each other;   (C) contacting the first flat film with the second flat film;   (D) bringing the first flat film into contact with a heated raised surface roller, with the first flat film contacting the heated raised surface roller while the first and second flat films remain in contact with one another, with the heated raised surface roller heating selected portions of the first and second flat films to a temperature above the fusion temperature by passing the first and second flat films together in a partial wrap around the heated raised surface roller, so that the first flat film and the second flat film are heat sealed to one another at a selected area to make the inflatable laminated article, with the selected area providing a heat seal pattern which provides inflatable chambers between the first flat film and the second flat film; and   (E) winding up or transporting the inflatable laminated article, with the inflatable chambers uninflated.   
     
     
         22 . The process according to  claim 21 , wherein the selected portions of the first and second flat films are heat sealed to one another using a combination of heat and pressure. 
     
     
         23 . The process according to  claim 21 , wherein the cooling step comprises contacting at least one of the first and second flat films with at least one cooling roller. 
     
     
         24 . The process according to  claim 21 , wherein the heated raised surface roller has a continuous raised surface therearound. 
     
     
         25 . The process according to  claim 21 , wherein the first and second flat films are heat sealed to one another to provide a repeating pattern consisting of sealed areas and unsealed areas. 
     
     
         26 . The process according to  claim 21 , wherein the heated raised surface roller has a release coating thereon. 
     
     
         27 . The process according to  claim 26 , wherein the release coating has a surface roughness of from 50 to 500 RMS. 
     
     
         28 . The process according to  claim 27 , wherein the release coating comprises a polyinfused coating. 
     
     
         29 . The process according to  claim 28 , wherein the polyinfused coating comprises polyinfused polytetrafluoroethylene. 
     
     
         30 . The process according to  claim 29 , wherein the release coating on the heated raised surface roller has a surface roughness of from 50 to 500 rms. 
     
     
         31 . The process according to  claim 21 , further comprising cooling the first and second flat films after heating the selected portions of the first and second flat films, the cooling being carried out by passing the first and second flat films together in a partial wrap around a cooling roller. 
     
     
         32 . The process according to  claim 31 , wherein the cooling roller has a release coating thereon. 
     
     
         33 . The process according to  claim 32 , wherein the release coating on the cooling roller has a Shore A hardness of from 40 to 100. 
     
     
         34 . The process according to  claim 21 , wherein the first flat film and the second flat film are forwarded at a speed of at least 120 feet per minute, and the heated raised surface roller has a release coating thereon and raised surface edges rounded off to a radius of from 1/256 inch to ⅜ inch, and further comprising a cooling roller downstream of and in nip relationship with the heated roller, the cooling roller also having a release coating thereon. 
     
     
         35 . The process according to  claim 34 , wherein the first and second flat films are forwarded at a speed of from 120 to 500 feet per minute, and the release coating on the cooling roller having a Shore A hardness of from 40 to 100. 
     
     
         36 . The process according to  claim 21 , wherein after cooling, the first flat film and the second flat film make a partial wrap around a roller which is upstream of the heated raised surface roller. 
     
     
         37 . The process according to  claim 36 , wherein the roller which is upstream of the heated raised surface roller is in nip relation with the heated roller having the raised surface. 
     
     
         38 . The process according to  claim 21 , further comprising passing a contact roller in nip relationship with the heated raised surface roller, with the first and second flat films passing through the nip between the contact roller and the heated raised surface roller, with the contact roller applying pressure to the first and second flat films as the first and second flat films pass through the nip between the contact roller and the heated raised surface roller. 
     
     
         39 . The process according to  claim 38 , wherein the contact roller has an elastic outer layer.