Abstract: A soft, fibrous material having excellent abrasion resistance and superior softness is made by relatively highly consolidating and then incrementally stretching a nonwoven material. The finished material is a nonwoven web having a plurality of discrete, spaced apart relatively high basis weight regions which are at least partially surrounded by at least one relatively low basis weight region. In one embodiment the soft, fibrous material is made from a nonwoven web having a consolidation area of at least about 30%, and the material has a bending rigidity (which correlates to softness) in a machine direction axis of bending of less than about 0.018 gcm2/cm. In another embodiment, the soft, fibrous material is made from a nonwoven web having a consolidation area of at least about 30%, and the material has a fuzz removal value (which correlates to abrasion resistance) of less than about 0.30 mg/cm2.

Abstract: An economical method is disclosed for modifying the physical characteristics of a nonwoven fibrous web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has advantageous elongation, extensibility and strength properties, as well as other desirable characteristics. In another aspect, a method is disclosed for forming a composite material by combining a modified nonwoven web with a polymeric film, or an elastic member, which may be liquid impervious yet breathable. In yet other aspect, a method is disclosed for forming a composite material by combining a modified web with a polymeric film which is rendered liquid-impervious yet breathable while the method is performed.

Abstract: An electrical cable of the present invention comprises a plurality of spaced, parallel flat conductors. Each of the plurality of flat conductors was previously integral with each immediately adjacent flat conductor. A dielectric material is holds the conductors in the spaced, parallel relationship. The dielectric material can be a polymer film, a nonwoven, or other polymer materials such as PTFE, or expanded PTFE. The cable of the present invention is made by providing first and second webs of dielectric materials and a third sheet of conductive material. The first and second web materials are bonded to the third sheet of conductive material in a face-to-face layered relationship thereby forming a bonded laminate. The bonded laminate is then incrementally stretched to separate the sheet of conductive material in to spaced, parallel flat conductors.

Abstract: An economical method is disclosed for modifying the physical characteristics of a nonwoven fibrous web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has advantageous elongation, extensibility and strength properties, as well as other desirable characteristics. In another aspect, a method is disclosed for forming a composite material by combining a modified nonwoven web with a polymeric film, or an elastic member, which may be liquid impervious yet breathable. In yet other aspect, a method is disclosed for forming a composite material by combining a modified web with a polymeric film which is rendered liquid-impervious yet breathable while the method is performed.

Abstract: A substance encapsulation system capable of being apertured under a tensioning force comprises a first web and a second web. A powdered, granular, particulate, or gel substance can be disposed between the first and second webs. Upon application of a sufficient force having a vector component parallel to the transverse axis, the bond site fractures to form a corresponding aperture to facilitate exposure of the substance. Alternatively, a central layer may be disposed between at least a portion of the first and second webs. The central layer may carry a substance to be exposed or the central layer may be a dissimilar material from the first and second webs. In a preferred embodiment, the system has a plurality of bond sites.

Abstract: A laminate web and several uses of the laminate web are disclosed. The laminate web comprises a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second webs. The laminate webs of the present invention are suitable for a variety of uses. Such uses include flexible carrying implement, medical applications, kitchen or bathroom implements, decorative coverings, home accent items, pet industry articles, fabric, fabric backings, edible materials, bedding applications, absorbent food pads, clean room wipes, tack cloths, and many other uses.

Abstract: A user-activatible substance delivery system of the present invention comprises a first web and a second web, the first and second webs having a periphery and being enclosed about their respective peripheries and defining a void space therein. A substance for delivery upon user activation is disposed in the void space. At least one of the first or second webs has at least one bond site. The bond site(s) define(s) a melt weakened region such that upon application of a force having a vector component parallel to the transverse axis, the bond site(s) fracture(s) to form a corresponding aperture in the respective web. The apertures provide a fluid communication path to facilitate delivery of the substance from the void space.

Abstract: An elastic laminate web is disclosed. The elastic laminate web can be non-apertured or apertured, and comprises a first web, and a second web joined to the first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2. The first and second webs form an interior region therebetween. An elastic material is disposed between the first and second webs. The elastic material is apertured in regions coincident the bond sites, such that the first and second webs are joined through the apertures. The laminate so produced can be stretched in a predetermined direction, such as by incremental stretching, to produce an apertured elastic laminate.

Abstract: Described herein is a multiple layer absorbent core having a front ear section, a crotch section and a back ear section, wherein the machine direction length of the crotch section equals the combined machine direction length of the front ear section and the back ear section, the angle and radii forming the transition from the crotch width to the ear width being equal, the core being suitable for use in an absorbent article, and a method for manufacturing such multiple layer absorbent core.