Abstract: A sustainable thermoplastic composition made by forming a mixture of virgin polypropylene and post-industrial-recycled material (PIR). The PIR may include a thermoplastic, elastomeric-polymer and a spunbond component. The mixture is melt-blended in an extruder. Extruded materials made from the mixture demonstrate little variance in the results of the IZOD Impact Test of materials containing 30 to 70 percent PIR, and a material containing 100 percent virgin polypropylene. In addition, the extruded materials containing 30 to 70 percent PIR demonstrate a substantially constant strain at yield, that strain at yield being substantially equal to that demonstrated by a material containing 100 percent virgin polypropylene.

Abstract: A sustainable thermoplastic composition made by forming a mixture of virgin polypropylene and post-industrial-recycled material (PIR). The PIR may include a thermoplastic, elastomeric-polymer and a spunbond component. The mixture is melt-blended in an extruder. Extruded materials made from the mixture demonstrate little variance in the results of the IZOD Impact Test of materials containing 30 to 70 percent PIR, and a material containing 100 percent virgin polypropylene. In addition, the extruded materials containing 30 to 70 percent PIR demonstrate a substantially constant strain at yield, that strain at yield being substantially equal to that demonstrated by a material containing 100 percent virgin polypropylene.

Abstract: A composite film includes a composite blend layer including a water-soluble synthetic thermoplastic polymer and blocking particles, wherein the blocking particles are nanoclay particles or talc particles, and wherein the composite film is free of compatibilizers. In addition, a laminate film consists of two layers, wherein the first layer is a composite blend layer including polyvinyl alcohol (PVOH) and blocking particles, wherein the blocking particles are nanoclay particles or talc particles, and wherein the second layer is a polyolefin film layer in facing relationship with the composite blend layer, wherein the laminate is free of compatibilizers. These films can be used to manufacture a glove or other article for solvent resistance.

Abstract: A continuous process for manufacturing a blended polymer includes mixing a native starch, a polyolefin, and a compatibilizer; and forming the blended polymer from the resulting mixture using an extruder. The process can also include mixing the native starch, the polyolefin, and the compatibilizer in the extruder. The polyolefin can be a petroleum- or bio-based polyethylene, and the compatibilizer can be a maleic anhydride grafted polyolefin. The process can further include mixing a processing aid such as glycerin, and forming the blended polymer into a film.

Abstract: A continuous process for manufacturing a blended polymer includes mixing a native starch, a polyolefin, and a compatibilizer; and forming the blended polymer from the resulting mixture using an extruder. The process can also include mixing the native starch, the polyolefin, and the compatibilizer in the extruder. The polyolefin can be a petroleum- or bio-based polyethylene, and the compatibilizer can be a maleic anhydride grafted polyolefin. The process can further include mixing a processing aid such as glycerin, and forming the blended polymer into a film.

Abstract: Sustainable film compositions and articles including recycled elastomer. The compositions comprise one or more virgin polymers. Optionally, the films may also include one or more compatibilizers having compatibility with the polymers and a thermoplastic elastomer (TPE) such as a block copolymer with a hard block and a soft block. Multi- or mono-layer films are possible. The films are useful for packaging films or component films for consumer products.

Abstract: A sustainable thermoplastic composition made by forming a mixture of virgin polypropylene and post-industrial-recycled material (PIR). The PIR may include a thermoplastic, elastomeric-polymer and a spunbond component. The mixture is melt-blended in an extruder. Extruded materials made from the mixture demonstrate little variance in the results of the IZOD Impact Test of materials containing 30 to 70 percent PIR, and a material containing 100 percent virgin polypropylene. In addition, the extruded materials containing 30 to 70 percent PIR demonstrate a substantially constant strain at yield, that strain at yield being substantially equal to that demonstrated by a material containing 100 percent virgin polypropylene.

Abstract: A biodegradable and flushable film is generally provided. The film can be a multi-layer film including a water-dispersible core layer that comprises a water-soluble polymer; and a water-barrier skin layer positioned adjacent to the water-dispersible core layer. The water-dispersible core layer constitutes from about 50 wt. % to about 99 wt. % of the film, while the water-barrier skin layer constitutes from about 1 wt. % to about 50 wt. % of the film. The biodegradable polymers of the water-barrier skin layer can constitute from about 80 wt. % to 100 wt. % of the polymer content in the water-barrier skin layer, with from about 10 wt. % to about 90 wt. % of the biodegradable polymers being polyalkylene carbonate and from about 10 wt. % to about 90 wt. % of the biodegradable polymers being biodegradable polyesters. The film may be used as a packaging film or as a backsheet of an absorbent article.

Abstract: A film is provided including from about 10 wt. % to about 90 wt. % of at least one polyalkylene carbonate and from about 10 wt. % to about 90 wt. % of at least one polyolefin. The film can be utilized as a packaging film, or as in the construction of an absorbent article (e.g., as the outer cover/backsheet of the article). The film can be a multi-layered film including a core layer that constitutes from about 20% to about 90% of the thickness of the film and an outer layer positioned adjacent to the core layer, with the core layer including from about 10 wt. % to about 90 wt. % of at least one polyalkylene carbonate and from about 10 wt. % to about 90 wt. % of at least one polyolefin. The outer layer can contain about 50 wt. % or more of at least one polyolefin.

Abstract: An absorbent article comprising a laminated outer cover is disclosed. The laminated outer cover comprises an aliphatic-aromatic copolyester film including a filler material. The aliphatic-aromatic copolyester films have suitable breathability, vapor transfer and tensile strength properties while being substantially biodegradable.

Abstract: Biodegradable aliphatic-aromatic films are disclosed. The films comprise filler particles and a copolyester. The films have high vapor permeability and tensile strength and are suitable for use in absorbent and non-absorbent products.

Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The plurality of molten fibers is then routed through a quenching chamber to form a plurality of continuous cooled fibers. The plurality of continuous cooled fibers is then routed through a drawing unit to form a plurality of continuous, solid linear fibers. The linear fibers are then deposited onto a moving support, such ass a forming wire, to form an accumulation or fibers. The accumulation of fibers are stabilized and bonded to form a web. The web is then stretched by at least 50 percent in at least one direction before being allowed to relax.

Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The molten fibers are then muted through a quenching chamber to form a plurality of continuous cooled fibers. The coiled fibers are then routed through a drawing unit to form a plurality of continuous, solid linear fibers. Each of the solid fibers is then stretched by at least 50 percent before it is allowed to relax. The relaxation step forms the linear fibers into a plurality of continuous 3-dimensional fibers each having a coiled configuration over at least a portion of its length. The continuous 3-dimensional, coiled fibers are then deposited onto a moving support to form a web.

Abstract: A method of forming bicomponent fibers into a web is disclosed. The method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2 The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The plurality of molten fibers is then routed through a quenching chamber to form a plurality of continuous cooled fibers. The plurality of continuous cooled fibers is then routed through a drawing unit to form a plurality of continuous, solid linear fibers. The linear fibers are then deposited onto a moving support, such as a forming wire, to form an accumulation of fibers. The accumulation of fibers are stabilized and bonded to form a web. The web is then stretched by at least 50 percent in at least one direction before being allowed to relax.

Abstract: A method of forming 3-dimensional fibers is disclosed along with a web formed from such fibers. The method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous molten fibers. The molten fibers are then routed through a quenching chamber to form a plurality of continuous cooled fibers. The cooled fibers are then routed through a draw unit to form a plurality of continuous, solid linear fibers. The solid fibers are then accumulated and stretched by at least about 50 percent. The plurality of stretched fibers are then cut and allowed to relax such that a plurality of 3-dimensional, coiled fibers is formed.

Abstract: A method of forming 3-dimensional fibers into a web is disclosed. The method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2 The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The molten fibers are then routed through a quenching chamber to form a plurality of continuous cooled fibers. The cooled fibers are then routed through a drawing unit to form a plurality of continuous, solid linear fibers. Each of the solid fibers is then stretched by at least 50 percent before it is allowed to relax. The relaxation step forms the linear fibers into a plurality of continuous 3-dimensional fibers each having a coiled configuration over at least a portion of its length. The continuous 3-dimensional, coiled fibers are then deposited onto a moving support to form a web.

Abstract: A 3-dimensional fiber is disclosed that is constructed from first and second components. The first component is capable of being stretched and has a recovery percentage R1. The second component is also capable of being stretched and has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are combined to form a linear fiber having an initial length that can be stretched at least 50%. The stretched fiber has the ability to retract to a length of from about 5% to about 90% of the stretched length to form a 3-dimensional fiber that exhibits elongation properties of at least 250% in at least one direction from the retracted length before the fiber becomes linear. A web formed from a plurality of 3-dimensional fibers is also disclosed.