Abstract: Disclosed herein are methods of preparing a composite sheet material having strength and barrier properties suitable for use as a housewrap, the methods comprising extrusion coating a polyolefin film layer onto a surface of an area-bonded, spunbond nonwoven substrate to form a composite sheet material, the composite sheet material having a grab tensile strength of at least 178 Newtons in at least one of the machine direction (MD) or the cross-machine direction (CD), and stretching the composite sheet material to impart to the composite sheet material a hydrostatic head of at least 100 cm, and a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr at 50% relative humidity and 23° C.

Abstract: Disclosed herein are methods of preparing a composite sheet material having strength and barrier properties suitable for use as a housewrap, the methods comprising extrusion coating a polyolefin film layer onto a surface of an area-bonded, spunbond nonwoven substrate to form a composite sheet material, the composite sheet material having a grab tensile strength of at least 178 Newtons in at least one of the machine direction (MD) or the cross-machine direction (CD), and stretching the composite sheet material to impart to the composite sheet material a hydrostatic head of at least 100 cm, and a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr at 50% relative humidity and 23° C.

Abstract: A moisture vapor permeable, water impermeable composite sheet material is provided which is suitable for use as a housewrap material, and is also useful for other applications such as tarpaulins, or as covers for automobile, boats, patio furniture or the like. The composite sheet material includes a nonwoven substrate and an extrusion-coated polyolefin film layer overlying one surface of the substrate. The nonwoven substrate is comprised of polymeric fibers randomly disposed and bonded to one another to form a high tenacity nonwoven web. The nonwoven substrate has a grab tensile strength of at least 178 Newtons (40 pounds) in at least one of the machine direction (MD) or the cross-machine direction (CD). The extrusion coated polyolefin film layer is intimately bonded to the nonwoven substrate. The film layer has micropores formed therein to impart to the composite sheet material a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr. at 50% relative humidity and 23° C.

Abstract: The present invention provides a composite sheet material (10) that is particularly useful as an underlayment material in roofing applications. In particular, the present invention provides a composite sheet material (10) that is flexible, relatively lightweight, resistant to water as well as being water vapor permeable and resistant to tearing. In addition, the composite sheet material (10) includes an outer non-skid surface (18) that can help prevent slippage of workers during installation of the roofing system. Embodiments of the composite sheet material can help provide a roofing\structure, such as a shingled roof, with fire resistance so that the roof can meet the Fire Resistance requirements of ASTM E 108-07a, Class A.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: The present invention provides an impact resistant sheet material that helps provide exterior walls of a building with resistance to impacts so that the building structure can meet building standards, such as the Miami-Dade County Large Missile Impact Test, for resisting impacts in high wind areas. In one embodiment, sheet material comprises an impact resistant layer that attached to fibrous substrate. The impact resistant layer provides impact resistance to the sheet material so that a wall structure employing the sheet material is able to successfully withstand an impact from a projectile comprising a 9 pound, 7 foot two-by-four (“2×4”) traveling at a speed of at least 34 miles per hour. The impact resistant sheet material may comprise a moisture vapor permeable, water-impermeable barrier layer having a hydrohead of at least 55 cm and a moisture vapor transmission rate of at least 35 g/m2/day. Such a sheet material is particularly useful in barrier applications, such as a house wrap.

Abstract: A moisture vapor permeable, water impermeable composite sheet material is provided which is suitable for use as a housewrap material, and is also useful for other applications such as tarpaulins, or as covers for automobile, boats, patio furniture or the like. The composite sheet material includes a nonwoven substrate and an extrusion-coated polyolefin film layer overlying one surface of the substrate. The nonwoven substrate is comprised of polymeric fibers randomly disposed and bonded to one another to form a high tenacity nonwoven web. The nonwoven substrate has a grab tensile strength of at least 178 Newtons (40 pounds) in at least one of the machine direction (MD) or the cross-machine direction (CD). The extrusion coated polyolefin film layer is intimately bonded to the nonwoven substrate. The film layer has micropores formed therein to impart to the composite sheet material a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr. at 50% relative humidity and 23° C.

Abstract: The invention provides a sheet material comprising bicomponent filaments having first and second polymer components that are arranged in substantially distinct zones within the filaments, with the first polymer component formed of a relatively lower melting polymer and the second component formed of a relatively higher melting polymer. The filaments of the nonwoven fabric layer are densely arranged and compacted against one another to form smooth, substantially nonporous opposite outer surfaces, and the nonwoven fabric layer are calendered such that the lower melting sheath polymer is fused to the contacting surface portions of adjacent filaments to impart strength and coherency to the nonwoven fabric layer. The sheet material has excellent breathability and liquid barrier properties and may be useful in house wrap, medical garments, and envelope applications.

Abstract: Nonwoven fabric laminates suitable for use as semipermeable membrane supports are produced by forming a spunbond nonwoven fabric first layer of continuous thermoplastic polymer filaments; forming a wet-laid nonwoven fabric second layer of discrete length thermoplastic polymer fibers; and bonding the first and second layers in opposing face-to-face relationship to form a composite support, where the first and second layers define first and second outer surfaces of the composite support. The resulting semipermeable membrane supports provide an advantageous balance of properties, including smoothness, porosity, interlaminar adhesion, and flux properties.