Abstract: Disclosed herein is a low gauge, multilayer film which may be laminated to other materials such as, for example, fibrous nonwoven webs. The multilayer film may include one or more skin layers which in certain configurations comprise no more than about 15 percent of the overall thickness and in other configurations no more than about 10 percent of the overall thickness of the multilayer film. Such films and laminates have a wide variety of uses including, but not limited to, personal care absorbent products, articles of clothing and health care related items such as surgical drapes and gowns.

Abstract: Process for die extrusion of melted polymers that reduces die lip buildup and its deleterious effects. Direct extrusion of mixed polymer pellets and filler concentrate pellets in one embodiment avoids a precompounding step and reduces the tendency of polymer and filler particles to adhere to the exit portion of the die. In other embodiments a reduced die lip radius and lower melt processing temperatures further enhance the benefits obtained. For co-extruded muitilayer film embodiments elimination of fillers and antiblock additives in skin layers add to the levels of die lip buildup reduction obtained. Hours of continuous operation without excessive die lip buildup in one arrangement have been increased from a level of 4 to 6 hours, for example, to in excess of 20 hours. Reduced product defect levels have also been attained.

Abstract: Breathable barriers, comprising a thermoplastic polymer and at least 30% by weight filler, are stretched in one direction in multiple discrete steps wherein the strain rate of each discrete stretching step is less than about 100,000%/minute and wherein the line speed of the last stretching step is in excess of 500 feet per minute. The resulting films may be stretched, as a result of the cumulative discrete stretching operations, from about 2 to 7 times its original length in order to create a breathable barrier having a WVTR in excess of 800 g/m2/day and a hydrohead of at least 60 cm.