Abstract: An absorbent structure and method for making the absorbent structure including an absorbent core made from a matrix of fibers, wherein the matrix is reinforced with a stretchable reinforcing member, such as scrim. The absorbent matrix may be secured to the web of scrim with the scrim in a stretched condition. When the web of scrim is in an unstretched condition, the web of scrim partially gathers the absorbent core to form rugosities on the core. The reinforcing member can have a non-uniform transverse width to conform to the shape of the absorbent core. The absorbent structure can have multiple layers of reinforcing members. The reinforcing member has strands arranged in a pattern to facilitate stretching. A first set of strands can cross a second set of strands at junction in a non-orthogonal relationship.

Abstract: An elastomeric, breathable laminate having enhanced breathability is formed by bonding a breathable, microporous, extendible/elastic film to a nonwoven facing material. The facing material can be necked to impart cross-directional stretchability. Once the film and the facing material are bonded together, the resulting laminate is stretched in one or more areas to impart higher breathability to selected areas of the laminate. The breathable laminate with enhanced breathability is particularly useful as an outer cover for diapers and other personal care products.

Abstract: A thermally stable microporous breathable film is provided comprising at least 35% filler, by weight of the filled-film, and a thermoplastic polymer blend of a first polyethylene polymer and a second polyethylene polymer. The first polyethylene polymer comprises 30%-70% by weight of the polymer blend and can have a density between about 0.86 g/cm3 and 0.89 g/cm3 and the second polyethylene polymer can have a density between about 0.90 g/cm3 and 0.92 g/cm3. The filled-film can be uniaxially or biaxially oriented to form a microporous film and/or film laminate having good body conformance and which retains a high WVTR at 37° C. and above.

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 method of forming fibers into a web includes the steps of co-extruding a first elastomeric component and a second thermoplastic component; directing the first and second components through a fiber spin pack to form a plurality of continuous molten fiber spinlines, where the first elastomeric component is present in an amount greater than about 70 percent by weight of the molten fibers and the second thermoplastic component is present in an amount of between about 10 and 30 percent by weight of the molten fibers; attenuating the spinlines and routing the plurality of molten fibers through a quench chamber to form a plurality of cooled fibers; routing the plurality of cooled fibers through a fiber draw unit, whereby the fibers are pulled downward; allowing the pulled fibers to be deposited onto a forming surface thereby forming a web wherein the fibers are relaxed; stabilizing the web; and bonding the web to produce a web demonstrating greater than about 25 percent machine direction stretch recovery.

Abstract: A dynamic-fitting absorbent article that includes a liquid impermeable outer cover (42), a liquid permeable bodyside liner (44) in superimposed relation to the outer cover (42) and a continuous elastic absorbent core (28) disposed between the outer cover (42) and the bodyside liner (44). The continuous elastic absorbent core (28) can extend from about 80 to about 400 percent upon application of a force of from about 60 to about 325 grams. The continuous elastic absorbent core (28) can have a tension reducing geometry in the crotch section of the article. Additionally, the continuous elastic absorbent core can have a dry tensile strength and a wet tensile strength that is at least 95% of the dry tensile strength.

Abstract: A dynamic-fitting absorbent article that includes a liquid impermeable outer cover (42), a liquid permeable bodyside liner (44) in superimposed relation to the outer cover (42) and a continuous elastic absorbent core (28) disposed between the outer cover (42) and the bodyside liner (44). The continuous elastic absorbent core (28) can extend from about 80 to about 400 percent upon application of a force of from about 60 to about 325 grams. The continuous elastic absorbent core (28) can have a tension reducing geometry in the crotch section of the article. Additionally, the continuous elastic absorbent core can have a dry tensile strength and a wet tensile strength that is at least 95% of the dry tensile strength.

Abstract: A nonwoven composite web contains coated superabsorbent and binder, such as thermoplastic staple fibers. The nonwoven composite web is easily made, economical, and has good distribution of materials, high absorbent particle loading, saturation capacity and flexibility.

Abstract: A wrapped absorbent structure that includes two or more absorbent materials to maximize the absorbent functionality of the structure without sacrificing integrity. The structure includes an absorbent core surrounded by an absorbent wrap. The absorbent core is primarily intended to provide absorbent capacity while the absorbent wrap is used to maintain wetness integrity, although the absorbent wrap also provides a considerable amount of absorbent capacity. The absorbent structure is particularly suitable for use in absorbent swimwear.

Abstract: A method for stretching nonwoven sheet material in the cross-machine direction includes coursing a nonwoven sheet material through a deformable nip, the nip being formed between two rotating stretch surfaces having intermeshing peaks and troughs, the surfaces of the peaks and troughs being covered with a deformable material, and contemporaneously pressing the stretch surfaces together while rotating them, such that as the nonwoven material travels through the nip, the nip deforms from an initial flat formation into a convoluted formation.

Abstract: There is provided a laminate having at least one layer of meltblown elastic fibers bonded on either side with a layer of soft non-elastic fibers of greater than 7 microns in average diameter. The laminate has a drape stiffness less than half of a similar fabric having a layer of meltblown non-elastic fibers in place of the layer of meltblown elastic fibers.

Abstract: There is provided a fully elastic, breathable, barrier fabric comprising a nonwoven web layer of fibers of less than 40 microns in average diameter, where the web has a hydrohead of at least 10 mbar, a Frazier Permeability of at least 100 CFM, a basis weight of less than 68 gsm and which is made from an elastic polymer. If the fabric is a laminate it may be an SMS, SBL or NBL laminate. This fabric is particularly well suited to use as a containment flap for personal care products such as diapers, incontinence products and feminine hygiene products and in infection control products.

Abstract: Disclosed herein are multicomponent fibers wherein at least one component will permit bonding of the fibers to themselves and other types of fibers and wherein the same first component is also degradable in an aqueous medium. Such fibers can be used to form fibrous nonwoven webs which can be used as components in such end-use products as medical and health care related items, wipes and personal care absorbent articles.

Abstract: A composite elastic material is provided having improved hysteresis comprising a layer of an elastic material bonded to a layer of nonelastic material at least one side. The elastic material layer is made from a blend of a narrow polydispersity number polymer and a conventional elastomer, and the blend is essentially free of low molecular weight polyethylene processing aids. The composite elastic material laminate should have a hysteresis at least 15 percent better than a similar laminate made without the narrow polydispersity number elastomer but with the processing aid.

Abstract: There is provided a fully elastic, breathable, barrier fabric comprising a nonwoven web layer of fibers, where the web has a hydrohead of at least 4 mbar, a basis weight of less than 68 gsm and which is made from an elastic polyolefin. If the fabric is a laminate it may be an SMS, SBL or NBL laminate. This fabric is particularly well suited to use as a containment flap for personal care products such as diapers, incontinence products and feminine hygiene products and in infection control products. The fabric may also be used as a liner in personal care products.

Abstract: There is disclosed fibers and fabrics formed from a polymer which is a "hand enhancing" polymer. The "hand enhancing" polymer is a copolymer of polypropylene which contains ethylene, 1-butene, or 1-hexene or a terpolymer of propylene, ethylene and butene. If the polymer is an ethylene copolymer, the copolymer may be random or random and block and the ethylene must be present in an amount between greater than 5 and 7.5 weight percent of the copolymer. If the copolymer contains 1-butene, it must be present in an amount between 1 and 15.4 weight percent of the copolymer. If the copolymer contains 1-hexene, it must be present in an amount between 2 and 5 weight percent of the copolymer. If the polymer is a terpolymer of propylene, ethylene and butylene, the polypropylene is present in an amount between 90 and 98 weight percent, the ethylene is present in an amount between 1 and 6 weight percent and the butylene is present in an amount between 1 and 6 weight percent.