Abstract: An elastomeric film includes a first layer co-extruded with a second layer. The first layer includes a single-site catalyzed ethylene-alpha olefin copolymer having a density of about 0.860 to about 0.900 grams per centimeter. The second layer includes a styrene copolymer selected from styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene, or styrene-(ethylene/propylene)-styrene-(ethylene/propylene). The first layer may optionally include filler particles. An extensible laminate including the elastomeric film is also disclosed.

Abstract: A disposable, leakproof, containment garment for a wearer is formed from a liquid-impermeable containment shell in a substantially humanoid shape with elastic marginal seal areas, such as torso and appendage margins. The elastic margins are designed to conformably surround the torso and appendages of the wearer and form tensioned and liquid-tight seals against the skin of the wearer when donned. By forming liquid tight seals against the body of the wearer, the garment is favorably constructed to utilize the full capability of any absorbent structures placed within the shell.

Abstract: Stretchable film laminates including a layer of elastomeric openwork, such as a plurality of elastic strands or an elastomeric mesh structure. The stretchable film laminates may include a film layer bonded to the layer of elastomeric openwork, with the film layer having cross-directional stretch and the laminate having a multi-phase stretchability profile. The stretchable film laminates may be made by extruding a film from a die, stretching the film, forming and stretching a layer of elastomeric openwork, conveying the stretched elastomeric openwork onto the film while the film is stretched, and passing the film and the elastomeric openwork through a nip. The invention also includes a machine capable of producing machine-direction, cross-direction, and biaxial stretch materials. The machine includes at least one extruder, at least one filament die and at least one film die both attached to the extruder(s), and at least one nip downstream of the extruder(s).

Abstract: An extensible laminate having improved set and hysteresis is disclosed. The extensible laminate includes an extensible nonwoven web laminated to an elastomeric sheet that have been mechanically stretched in the cross direction after lamination. A method for making the extensible laminate includes laminating an extensible nonwoven web to an elastomeric sheet to form a laminate and mechanically stretching the laminate in a cross direction by at least about 50 percent.

Abstract: A one-step method of making a necked-bonded laminate, wherein the layers of the laminate are formed and laminated within the same process. The method includes forming a nonwoven web, necking the nonwoven web, and immediately feeding the nonwoven web into a laminator where an elastomeric film is laminated to the nonwoven web. The elastomeric film may also be formed during the process prior to being fed into the laminator. Additionally, more than one nonwoven web may be formed and laminated to the elastomeric film during the process. The invention further includes apparatus for carrying out the one-step method.

Abstract: A breathable laminate having biaxial elastic stretch, cloth-like aesthetics, and a fluid barrier is formed by bonding a breathable elastic film to a nonwoven facing material. The facing material can be inherently machine direction and cross direction stretchable, or can be necked to impart cross direction stretchability, and can be creped or crimped to impart machine direction stretchability. Alternatively, machine direction stretchability of the laminate can be achieved by bonding the elastic film in a pre-stretched condition to the facing material. The breathable laminate is particularly useful as an outer cover for diapers and other personal care products.

Abstract: The present invention provides a method of achieving selectively elasticized zones on nonwoven web substrates, such as may be suitable for the waistbands of disposable absorbent pant garments, cuffs on sleeves of medical garments, or the like. A web, or webs, of nonwoven material which make up the substrate for the elasticized area are provided to be inherently extendable in the transverse, or lateral, direction of the material web at the time the elastic material is affixed to the substrate. If the elastic material is affixed in an untensioned state, a flat waistband without gathering of the substrate may be had for a very efficient seal against the skin of the wearer. If the elastic material is affixed to the substrate in a tensioned state, a waist band with gathering of the substrate may be had to allow for two-stage expansion via the gathers and the expansion of the substrate.

Abstract: The present invention provides a method of achieving low tension, highly conformable elasticized areas in a nonwoven web construction such as may be suitable for the waistbands or leg openings of disposable absorbent pant garments, cuffs on sleeves of medical garments, or the like. A web, or webs, of nonwoven material which make up the substrate for the elasticized area are provided to be very light weight and flexible and provide the minimal amount of substrate to which an elastomeric liquid barrier material is affixed. The absorbent, or liquid retention, section of an absorbent garment article made according to the present invention will have its own barrier layer facing the backsheet, in order that the backsheet may be composed of a light and conformable material.

Abstract: A form-fitting, pant-like, absorbent garment that does not result in bagging and wrinkling of the bodyside liner. The garment has a stretchable outer cover and a non-stretchable bodyside liner with a free-floating absorbent assembly located between the stretchable outer cover and the non-stretchable bodyside liner. A pair of highly stretchable side panels and/or at least one highly stretchable waist member are attached to the non-stretchable bodyside liner. The total transverse stretchability of the side panels is roughly equal to the transverse stretchability of the outer cover, thereby enabling the outer cover to stretch freely without inhibiting the non-stretchable bodyside liner. Alternatively, or additionally, the total longitudinal stretchability of the waist members is roughly equal to the longitudinal stretchability of the outer cover, thereby also enabling the outer cover to stretch freely without inhibiting the non-stretchable bodyside liner.

Abstract: An elastic laminate of a necked, or otherwise inherently stretchable, and perforated nonwoven web layer and an unperforated elastic film layer and methods of making the laminate are disclosed. An elastic laminate according to the present invention may utilize both the stretch gained from the necking, as well as providing increased ability of the necked nonwoven to stretch due to the perforations, cumulatively resulting in high stretch of the elastic laminate in one or more directions.

Abstract: The present invention provides a method of placing elasticized areas in a nonwoven web construction such as may be suitable for the waistbands or leg openings of disposable absorbent pant garments, cuffs on sleeves of medical garments, or the like. A web, or webs, of extendible nonwoven material which make up the substrate for the elasticized area are printed with an elastic adhesive in its fluid or semi-fluid and untensioned state to provide a tensioning force against distension of the web during wearing of the garment for conformable, well fitting, elasticized cuff areas and may further be used to reinforce biaxially extendible web components such as the backsheet web.

Abstract: A breathable, substantially liquid impermeable film and laminate are provided for use in a wide variety of personal care garments and protective garments. The film, and laminate containing the film, are extendible in a cross-direction to a stretched width which is at least 25% greater than an original, unstretched width. The film and laminate have a first water vapor transmission rate of at least about 500 grams/m2-24 hours coinciding with the unstretched width. The film and laminate have a much higher second water vapor transmission rate which is at least about 225% of the first water vapor transmission rate, and not less than about 4000 grams/m2-24 hours, coinciding with a stretched width that is only 25% greater than the stretched width.

Abstract: A breathable, substantially liquid impermeable film and laminate are provided for use in a wide variety of personal care garments and protective garments. The film, and laminate containing the film, are extendible in a cross-direction to a stretched width which is at least 25% greater than an original, unstretched width. The film and laminate have a first water vapor transmission rate of at least about 500 grams/m2-24 hours coinciding with the unstretched width. The film and laminate have a much higher second water vapor transmission rate which is at least about 225% of the first water vapor transmission rate, and not less than about 4000 grams/m2-24 hours, coinciding with a stretched width that is only 25% greater than the stretched width.

Abstract: Stretchable film laminates including a layer of elastomeric openwork, such as a plurality of elastic strands or an elastomeric mesh structure. The stretchable film laminates may include a film layer bonded to the layer of elastomeric openwork, with the film layer having cross-directional stretch and the laminate having a multi-phase stretchability profile. The stretchable film laminates may be made by extruding a film from a die, stretching the film, forming and stretching a layer of elastomeric openwork, conveying the stretched elastomeric openwork onto the film while the film is stretched, and passing the film and the elastomeric openwork through a nip. The invention also includes a machine capable of producing machine-direction, cross-direction, and biaxial stretch materials. The machine includes at least one extruder, at least one filament die and at least one film die both attached to the extruder(s), and at least one nip downstream of the extruder(s).

Abstract: A process for making a plurality of necked nonwoven strips having similar or identical cross-directional profiles includes the steps of slitting a neckable nonwoven web into a plurality of neckable nonwoven strips, passing the neckable nonwoven web between a first pair of nip rollers having a first surface velocity and a second pair of nip rollers having a second surface velocity greater than the first surface velocity, and necking the nonwoven web between the first pair of nip rollers and the second pair of nip rollers.

Abstract: Composite nonwoven webs are provided having two distinct regions extending adjacent one another in the machine direction of the web; the first region is formed from first continuous filaments and the second region is formed from second continuous filaments. The interface of the first and second region is formed from a mixture the first and second continuous filaments in a confluent relationship with one another and such that the two distinct regions form a unitary nonwoven web. The respective first and second regions can have distinct physical attributes as a result of utilizing first and second filaments which are different from one another. The first and second continuous filaments can vary with respect to average fiber denier, cross-sectional shape, cross-sectional configuration, polymer composition, crimp level, and additive composition.

Abstract: A method for producing a nonwoven web material having cross-machine direction extensibility in which a nonwoven web is conveyed through a machine which elongates the nonwoven web in a cross-machine direction (CD). The elongated nonwoven web is then necked, forming a cross-machine direction extensible nonwoven web material. The CD extensible nonwoven web material is highly stretchable and is suitable for use in personal care articles, such as diapers, incontinence garments, and feminine care products, as well as other articles, such as wipes, face masks, tissues, bandages and wound dressings.

Abstract: A liquid reception device is disclosed as a component, for example, of a personal care product such as a disposable diaper, an incontinent garment, or for other applications such as, for example, an industrial soaker pad or the like. The device includes liquid activated means to move a liquid insult from a target zone to a peripheral zone. The liquid activated transport means is operated mechanically by suction created by compression or vacuum or by physical movement of a liquid container from the target zone to the peripheral zone. The disclosed device provides increased use of available liquid handling capacity.

Abstract: An absorbent article comprising a capturing agent and a liquid, wherein the liquid is captured by the capturing agent, for example disposed within or otherwise encapsulated within an encapsualting agent or complexed with a complexing agent is provided.

Abstract: A disposable, leakproof, containment garment for a wearer is formed from a liquid-impermeable containment shell in a substantially humanoid shape with elastic marginal seal areas, such as torso and appendage margins. The elastic margins are designed to conformably surround the torso and appendages of the wearer and form tensioned and liquid-tight seals against the skin of the wearer when donned. By forming liquid tight seals against the body of the wearer, the garment is favorably constructed to utilize the full capability of any absorbent structures placed within the shell.