Abstract: There is provided herein a multilayer laminate comprised of a layer of a film and a layer of a nonwoven fabric. The film is made from polymers and has as one surface a semi-crystalline/amorphous or "heterophasic" polymer, an optional inner, less expensive, filler type polymer, and as the other surface, a polymer with a lower coefficient of friction. The nonwoven fabric may be a spunbond or meltblown fabric, preferably spunbond and preferably also including a heterophasic polymer. The film and nonwoven components are bonded together using thermal point bonding preferably while the film is stretched at least 5 percent. Such a laminate may be made into a personal care product like a diaper, training pant, absorbent underpants, adult incontinence product, and feminine hygiene product.

Abstract: There is provided a bodily fluid simulant made from red blood cells in an amount between about 10 and about 60 weight percent, egg white in an amount between 20 and 50 weight percent, and plasma.

Abstract: There is provided a surge material for personal care products which is a wettable web of fibers of 30 microns in diameter or less where the web has a permeability between about 250 and 1500 Darcys, a capillary tension between about 1.5 and 5 cm, and which maintains that permeability and capillary tension over the life of the web. Its preferred that the web have a density between about 0.02 g/cc to about 0.07 g/cc.

Abstract: The present invention provides a liquid distribution layer for absorbent articles which exhibits directional liquid distribution properties and has desirable physical integrity. The liquid distribution layer is a nonwoven web of substantially continuous microfibers that has its fibers substantially aligned along one planar dimension of the web, wherein the fibers are hydrophilically modified or hydrophilic. Additionally, the liquid distribution layer may have an increasing fiber alignment gradient as well as a decreasing fiber thickness gradient in the direction of the web thickness. Further provided are suitable processes for producing the liquid distribution layer.

Abstract: The present invention is directed to a pattern-unbonded nonwoven fabric having continuous bonded areas defining a plurality of discrete unbonded areas, which is suitable for use as an improved loop fastening material for hook and loop fastening systems. The fibers or filaments within the discrete unbonded areas of the present invention are dimensionally stabilized by the continuous bonded areas that encircle or surround each unbonded area. The spaces between fibers or filaments within the unbonded areas remain sufficiently open or large to receive and engage hook elements of a complementary hook material. The hook material can be any of a wide variety of commercially available hook components which, as is known in the art, typically include a base material from which a plurality of hook elements project.

Abstract: A composite elastic material is provided having improved hysteresis comprising a layer of an elastic material bonded to a layer of nonelastic material at least one side. The elastic material layer is made from a blend of a narrow polydispersity number polymer and a conventional elastomer, and the blend is essentially free of low molecular weight polyethylene processing aids. The composite elastic material laminate should have a hysteresis at least 15 percent better than a similar laminate made without the narrow polydispersity number elastomer but with the processing aid.

Abstract: A fabric substrate comprising thermoplastic polyolefin fibers is printed with a printing composition comprising a room temperature curable latex polymer, a pigment and a cure promoter, which retains a colorfastness above 3 when exposed to liquids with a pH between about 2 and about 13. The mixture may be applied to the fabric as an aqueous mixture with a pre-cure pH adjusted to above 8 using a fugitive alkali and then cured at room temperature.

Abstract: The present invention is directed to film-nonwoven laminates incorporating stretch-thinned, breathable films onto which a pattern or network of adhesive areas is applied to improve durability and strength of the stretch-thinned film. The present invention has applicability in a wide variety of areas where strength, comfort, liquid impermeability and breathability are needed or desired, including without limitation, personal care absorbent articles, articles of clothing, roll goods and health care-related items.

Abstract: A multifunctional material is provided for use in personal care products. The multifunctional material has a permeability between 100 and 10000 Darcys and a capillary tension between about 2 and 15 cm. Structures containing this multifunctional material can have a runoff rate of less than 25 ml per 100 ml insult, over its life. The multifunctional material should have between about 30 and 75 weight percent of a slow rate superabsorbent, between 25 and 70 weight percent of pulp and from a positive amount up to about 10 percent of a binder component. The material preferably has a density between about 0.05 and 0.5 g/cc. The material has a liquid pass through function which desorbs a surge material across time frames consistent with user conditions and releases the liquid for distribution to remote storage locations. The material, when combined with the intake and distribution materials, defines a composite structure for use in personal care products.

Abstract: Disclosed herein is a film/nonwoven laminate which incorporates a low gauge machine direction oriented film layer laminated to a nonwoven support layer. The individual layers are designed such that the film layer in the laminated state has an elongation at break value in the cross machine direction that is greater the elongation at peak load value for the nonwoven layer in the same direction. Consequently, if the laminate is subjected to severe stretching forces in the cross machine direction, the nonwoven layer will fail before the film layer. In addition, the laminate has a peak load value of at least 300 grams. As a result, the laminate is particularly useful as, for example, an outercover material for personal care absorbent articles.

Abstract: There is provided a surge material for personal care products comprising a layered structure of at least one relatively high permeability layer on a top side toward a wearer and at least one relatively low permeability layer where the structure has a capillary tension range between about 1 and 5 cm with a differential capillary tension of at least about 1 cm from top to bottom. The surge material should have a high permeability layer with a permeability of at least 1000 Darcys and a low permeability layer with a permeability of less than 1000 Darcys. The surge material should also have a said high permeability layer which has a permeability of at least 250 Darcys greater than the low permeability layer. Such a layered structure should have a first insult run-off value of at most 30 ml from a 100 ml insult delivered at 20 ml/second. Such a surge material is useful in personal care products like diapers, training pants, absorbent underpants, adult incontinence products, feminine hygiene products and the like.

Abstract: This invention relates to a fibrous laminated material wherein a first fibrous layer comprising a plurality of staple fibers or continuous filaments of a thermoplastic material and a second fibrous layer comprising a plurality of staple fibers or continuous filaments of two or more thermoplastic or other materials are bonded together in a spaced apart bonding pattern having apertures formed therein to form a fibrous laminate having improved liquid distribution and management properties as well as enhanced comfort and softness when placed in contact with human skin. Also disclosed are a method and apparatus for making such a fibrous laminate, as well as absorbent articles incorporating such fibrous laminate.

Abstract: A breathing mask fabric is provided which has between 50 and 95 weight percent of a through-air bonded, electret treated, nonwoven microfiber first web of fibers where the fibers have an average diameter of between about 10 and 25 microns and where the first web has a Frazier Permeability above about 100 CFM/SF, a density of between about 0.015 and 0.15 gms/cc, and a basis weight between about 67 gsm and about 340 gsm, and between about 5 and 50 weight percent of an electret treated microfiber second web of fibers where the fibers have an average diameter of less than about 10 microns.

Abstract: A method of producing a fabric comprising producing fine denier fibers, using either meltblown or spunbond processes, or a combination of the two, followed by crimping, spotbonding using differential bond roll temperatures, and neck-stretching. Fiber having less than or equal to about 1.5 denier is preferred. The bond temperature differential is about 10.degree.-50.degree. F. The mat produced has the unexpected result of improved strength, conformability and reduced stiffness.

Abstract: The present invention is directed to elastic fibrous nonwoven web laminates which exhibit elastic properties in at least one direction and, if desired, two or more directions due to the use of at least one fibrous nonwoven web facing layer which contains a plurality of slits. The resultant laminates are useful in a wide variety of applications not the least of which include garments, surgical drapes and other supplies as well as personal care absorbent articles including diapers, training pants, sanitary napkins, incontinence garments, bandages and the like. Processes for forming such laminates are also disclosed.

Abstract: Transversely stretchable elastic laminated fabric with cloth-like facings was made by a two-step process. In the first step an inelastic laminate was made by continuously extruding an elastomer sheet between two plies of a fibrous sheet and joining the plies by applying pressure on them between a closed gap niproll assembly. Two longitudinal slits were made into the laminate. Then the rolls of inelastic laminate so made were taken to an oven and the laminate was unwound and pulled through the oven at an elevated temperature, while tension on the web was increased until the slits necked. The necked laminate was wound up on a takeup roll. When samples were unwound, surprisingly they did not grow in width, and they showed good CD-elasticity (elongation and springback). Breathability of the laminate was superior to the laminate formed using an open niproll assembly gap.

Abstract: There is provided a melt extrudable, moisture curable thermoplastic polymer which is produced from a silane modified elastomeric polymer and which has improved hysteresis, reduced stress decay and improved creep properties. The polymer may be processed into a nonwoven web, film or foam which may be laminated to other materials such as spunbond polyolefin layers and may be used in medical, personal care, feminine hygiene and other applications.

Abstract: There is provided a web which has been spun from a mixture of thermoplastic polymer and a softening additive in an amount up to about 3 weight percent, and which has been mechanically treated to increase softness. The web has a final cup crush value which is less than 50 percent of the starting cup crush value and the drop in cup crush value is greater than the sum of the treatments individually. The web may be a single layer or may be a laminate of spunbond and other materials such as meltblown and coform fabrics.

Abstract: A method of producing a fiber is provided where a liquefied polymer is divided into at least two streams. The streams are directed separately to a point of recombination, and extruded through, for example, a spinneret, and fiberized to form a single fiber having portions of each stream. The divided polymer streams are treated substantially identically from the point of division to the point of recombination.

Abstract: There is provided a melt extrudable, moisture curable thermoplastic polymer which is produced from a silane modified elastomeric polymer and which has improved hysteresis, reduced stress decay and improved creep properties. The polymer may be processed into a nonwoven web, film or foam which may be laminated to other materials such as spunbond polyolefin layers and may be used in medical, personal care, feminine hygiene and other applications.