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

A process for making an inflated cellular cushion article, comprising: (A) extruding a first multilayer film having an outer layer of heat seal, a bonding layer and a sealing layer gas comprising at least one member selected from group consisting of crystalline polyamide, crystalline polyester, ethylene / vinyl alcohol, 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 layer of heat seal, a bonding layer and a sealing layer gas comprising at least one member selected from the group consisting of crystalline polyamide, crystalline polyester, ethylene / vinyl alcohol, polyacrylonitrile and crystalline polycycloolefin, wherein the tie layer comprises an anhydride modified olefin polymer containing anhydride at a that 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 melting temperature, so that films of various first and second layers are termosellen together in a selected area, providing the selected heat seal design which leaves inflatable chambers between the first film and the second film area; whereby an inflatable cellular cushion article occurs; (D) aging at least one member selected from the group consisting of the first multilayer film and the second multilayer film, carrying out aging before inflating Article inflatable cell cushion, and for a time and at a temperature of according to at least one member selected from the group consisting of: (i) 60, 6 ° C at 121, 1 ° C (141 ° F to 250 ° F in) for a period of at least 1 second; (Ii) from 38 to 60 3ºC (101ºF to 140) for a period of at least 10 minutes; (Iii) from 16 to 37 1 ° C, 8 ° C (61 ° F to 100 ° F in) for a period of at least 1 hour; and (iv) -1, 1 ° to 15 6 ° C (30 ° F to 60 ° F in) for a period of at least 1 day; (E) inflating the cellular cushion article after aging.