Abstract: Process for die extrusion of melted polymers that reduces die lip buildup and its deleterious effects. Direct extrusion of mixed polymer pellets and filler concentrate pellets in one embodiment avoids a precompounding step and reduces the tendency of polymer and filler particles to adhere to the exit portion of the die. In other embodiments a reduced die lip radius and lower melt processing temperatures further enhance the benefits obtained. For co-extruded muitilayer film embodiments elimination of fillers and antiblock additives in skin layers add to the levels of die lip buildup reduction obtained. Hours of continuous operation without excessive die lip buildup in one arrangement have been increased from a level of 4 to 6 hours, for example, to in excess of 20 hours. Reduced product defect levels have also been attained.

Abstract: Breathable barriers, comprising a thermoplastic polymer and at least 30% by weight filler, are stretched in one direction in multiple discrete steps wherein the strain rate of each discrete stretching step is less than about 100,000%/minute and wherein the line speed of the last stretching step is in excess of 500 feet per minute. The resulting films may be stretched, as a result of the cumulative discrete stretching operations, from about 2 to 7 times its original length in order to create a breathable barrier having a WVTR in excess of 800 g/m2/day and a hydrohead of at least 60 cm.

Abstract: A method of producing a fabric comprising producing fine denier fibers, using either meltblown or spunbond processes, or a combination of the two, followed by crimping, spotbonding using differential bond roll temperatures, and neck-stretching. Fiber having less than or equal to about 1.5 denier is preferred. The bond temperature differential is about 10.degree.-50.degree. F. The mat produced has the unexpected result of improved strength, conformability and reduced stiffness.

Abstract: A pull-activated container adapted to hold a fluid, volatile solid, or absorbent for a fluid wherein at least a portion of the container includes a laminate which, in turn, includes a first layer, a second layer, a third layer, and a grasping means. The first layer is a fibrous sheet, the second layer is a film having a first side and a second side, and the third layer is a porous fibrous sheet. The third layer is inside the container. The first layer is bonded to the first side of the second layer and has a first bonding strength and the third layer is bonded to the second side of the second layer and has a second bonding strength. For example, the first bonding strength may be greater than the second bonding strength to an extent sufficient to permit selectively removing the first and second layers from the third layer without tearing the third layer. The grasping means is affixed to the first layer and has a third bonding strength which is greater than the second bonding strength.