Abstract: A latent elastic laminate material, and methods of making latent elastic laminate materials. The laminate includes a latent polymer, which itself may or may not possess latent elasticity, that is applied to at least one elastic member while the elastic member is in a stretched configuration. The elastic member, at least partially covered with the latent polymer, is attached to at least one substrate. The amount of latent polymer applied to the elastic member may provide enough force to overcome a retractive force of the elastic member when the latent polymer is at a temperature below a softening point of the latent polymer, yet the amount of latent polymer may be small enough to allow the laminate to retract into an elastic, gathered structure when the laminate is heated to a softening point of the latent polymer. The laminate may be incorporated into a variety of articles including personal care garments and cleaning cloths.

Abstract: An elastic laminate that contains a nonwoven web bonded to an elastic layer is provided. The elastic layer contains one or more elastomeric polymers that are generally polar in nature, such as polyurethanes. To the contrary, the nonwoven web is formed from a material that is non-polar in nature. Nevertheless, one or more surfaces of the nonwoven web are fluorinated so that the resulting surface tension is increased. In this manner, the present inventors have discovered that, despite the difference in polarity between the layers, good attachment may be achieved without necessarily requiring an adhesive. Not only will such layers remained attached, but the functionality of the resulting laminate is also not adversely affected.

Abstract: A polymer-coated protective garment is disclosed. The garment may be configured to fit around the arm, leg, foot or hand of a wearer. For example, in one embodiment, the protective garment comprises a glove. The glove includes a hollow member defining an opening for receiving a hand. The hollow member is made from an elastic laminate. The elastic laminate may comprise at least one nonwoven web. The hollow member further includes an elastomeric coating that covers at least a portion of the hollow member. In one embodiment, for instance, the elastomeric coating covers a palm portion and finger portions of the glove.

Abstract: An apparatus for making an elastic laminate including a crosslinked elastic layer formed of an elastic copolymer includes a die for extruding a layer of crosslinkable elastic copolymer, at least one roll for conveying the elastic layer, a supply source for providing at least one nonwoven web, a lamination nip for laminating at least one nonwoven web to the elastic layer, a processing unit for crosslinking the elastic layer and a winder for collecting the elastic laminate. The crosslinkable elastic copolymer may be a crosslinkable elastic styrenic block copolymer, a crosslinkable semi-crystalline polyolefin plastomer, or a crosslinkable propylene-ethylene copolymer. The crosslinkable elastic layer may be extruded in the form of a plurality of parallel filaments such as by a filament die. The processing unit may be positioned between the at least one roll and the lamination nip or may be positioned between the lamination nip and the winder.

Abstract: A protective glove is provided made substantially from a laminate material. The laminate material includes a plurality of elastic strands. A first nonwoven web is attached to the plurality of elastic strands so that in a relaxed state of the elastic strands and the first nonwoven web at least one wrinkle is formed in the first nonwoven web. A second nonwoven web is also provided and is attached to the plurality of elastic strands so that in a relaxed state of the elastic strands and the second nonwoven web at least one wrinkle is formed in the second nonwoven web. The elastic strands, first nonwoven web and second nonwoven web form a laminate that is stretchable and permeable to liquid. A method of manufacture of a protective glove is also provided.

Abstract: An elastic, breathable barrier sheet material and laminates thereof are disclosed that include a first layer including an apertured elastic film and a second layer including an extensible, breathable, non-elastic film, wherein the first layer is bonded to the second layer. Desirably, the second layer is unapertured. The elastic materials are useful, for example, in personal care products. Also disclosed is a process for making an elastic, breathable barrier laminate structure that includes the steps of: forming an elastic film; aperturing the elastic film; forming an extensible, breathable, non-elastic film; and bonding the apertured elastic film to the extensible, breathable, non-elastic film to form an elastic, breathable barrier film laminate.

Abstract: The present invention is directed to elastic webs, such as elastic films and elastomeric fibrous meltblown or spunbond webs which may include elastomeric fibers and/or elastomeric continuous filaments. The elastic webs include an elastomeric block copolymer and an amorphous polyolefin plastomer wax. The elastic webs may include a tackifier, but desirably they do not. The elastic webs of the present invention may display hysteresis values and/or immediate set values upon elongation and retraction less than the hysteresis values and immediate set values of previously known elastic webs of similar basis weight. The elastic webs may display tension values upon elongation less than tension values displayed by previously known elastic webs of similar basis weight. The present invention is also directed to elastic laminate structures comprising at least one layer of an elastic web adhesively bonded to one or more other webs, such as, for instance a woven or nonwoven web.

Abstract: A protective article formed of a laminate between at least a layer of a liquid-impermeable, vapor-permeable barrier, and at least a layer of a stretchable or elastomeric, nonwoven fiber web is described. The barrier is reinforced at least on one side by the nonwoven fiber web, which remains elastic after being bonded to the barrier layer. The elasticity of both barrier and bonded fiber layers simulate the flexibility of natural or synthetic latex or other polymer films. The nonwoven fiber web includes at least about 75% of individual fibers with a length of over about 1 mm, and the fibers are substantially continuous. A second nonwoven web, a second barrier layer, or both may be attached to the exterior side of the breathable barrier. An elastomeric material coating, such as either a nature or synthetic latex or other polymers, may be applied over at least a portion of the article to provide for additional protection.

Abstract: A thermoplastic elastomer film demonstrates reduced roll blocking capabilities. The film can either be breathable or nonbreathable. The breathable elastic film includes a core layer of a thermoplastic elastomer and a filled semi crystalline predominantly linear polymer and at least one skin layer of a polyethylene or filled polyethylene. The film core layer includes between about 25 and 70 weight percent filler, between about 5 and 30 by weight percent semi-crystalline linear polymer, and between about 15 and 60 by weight elastomer. The nonbreathable film desirable includes a core of 80-98 percent film volume and a skin of 20-2 percent film volume, with the core including both styrenic block copolymers and single site catalyzed polyethylenes and the skin including single site catalyzed polyethylenes and additional amounts of roll blocking prevention agents (antiblock agents).

Abstract: An elastic laminate having improved elastomeric properties is prepared by forming an elastic layer from a thermoplastic styrene block copolymer elastomer, crosslinking the elastic layer, and bonding the elastic layer to at least one nonwoven web. The elastic layer may be crosslinked before or after it is bonded to the nonwoven web. The elastic laminate combines the advantages of relatively low cost starting materials with the performance advantages typically associated with more expensive elastomers.

Abstract: A soft, flexible, low-density, open-cell, thermoplastic, absorbent foam formed from a foam polymer formula including a balanced amount of a plasticizing agent and a surfactant in combination with a base resin. Thermoplastic elastomers can be added to the foam polymer formula to improve softness, flexibility, elasticity, and resiliency of the resulting foam. The surfactant may be either a single surfactant or a multi-surfactant system. The foam possesses a number of qualities, such as softness and strength, which render the foam particularly suitable for use in a variety of personal care products, medical products, and the like.

Abstract: An extensible fluid permeable substrate having at least one direction of extensibility in an X-Y plane is provided with improved retraction to make the composite material suitable for disposable garment applications with minimal application of coalesced elastomeric materials. A pattern of untensioned coalesced elastomeric stripes is applied on an X-Y plane surface of the substrate in low add-on amounts of between about 20% to about 100% of the substrate basis weight to make the composite material. The longitudinal axes of the coalesced elastomeric stripes are oriented substantially along the direction of substrate extensibility and desired retraction of the composite material. By applying the minimal amount of elastomer necessary in an open pattern, the economical composite material also avoids negative by-products of elastic coatings or films such as bad hand, bad drape, loss of fluid transfer or intake ability and lack of breathability.

Abstract: Compositions of high and low performance elastomer are formed using a process that chemically reacts some of the high and low performance elastomers together to form a graft copolymer. The elastomeric compositions provide intimately mixed elastomeric compositions which are thermodynamically stable and do not phase separate. The elastomeric compositions exhibit a variety of improved properties compared to simple blends of the same high and low performance elastomers in the same weight proportions. The elastomeric compositions are useful for producing films, fabrics, and laminates for use in a wide variety of personal care and medical articles.

Abstract: A soft, flexible, low-density, open-cell, thermoplastic, absorbent foam formed from a foam polymer formula including a balanced amount of a plasticizing agent and a surfactant in combination with a base resin. Thermoplastic elastomers can be added to the foam polymer formula to improve softness, flexibility, elasticity, and resiliency of the resulting foam. The surfactant may be either a single surfactant or a multi-surfactant system. The foam possesses a number of qualities, such as softness and strength, which render the foam particularly suitable for use in a variety of personal care products, medical products, and the like.

Abstract: A targeted elastic laminate material includes a plurality of elastomeric strands positioned attached to a first facing layer. A carrier layer having a width narrower than a width of the first facing layer is attached to the first facing layer. At least one of the elastomeric strands is directly attached to the first facing layer adjacent to the carrier layer. At least another of the elastomeric strands may be directly attached to the carrier layer. A second facing layer may also be attached to the first facing layer with at least a portion of the carrier layer positioned between the two facing layers, and at least one elastomeric strand directly attached to both facing layers. Additionally, multiple elastomeric strands may be directly attached to the first facing layer adjacent to opposite longitudinal edges of the carrier layer. A disposable garment may utilize the targeted elastic laminate material to include an area of elasticized gathering under tension to better conform to the body of the wearer.