Abstract: A method is presented for forming a collapsed foam film-like structure, the method including positioning a composition applicator adjacent to a hot non-permeable dryer surface, producing a first frothed dispersion or frothed solution from a first dispersion or solution, applying the first frothed dispersion or frothed solution to the dryer surface, allowing the first frothed dispersion or frothed solution to convert to a collapsed foam film-like structure, and scraping the collapsed foam film-like structure from the dryer surface. The method can further include producing a second dispersion or solution, blending the first dispersion or solution and the second dispersion or solution, frothing the blended dispersion or solution, applying the blended frothed dispersion or frothed solution to the dryer surface, and allowing the frothed dispersion or frothed solution to convert to a collapsed foam film-like structure.

Abstract: Elastomeric articles, such as gloves, are made by welding together two plies of a multi-layer film. The film plies are welded together through ultrasonic bonding, thermal bonding, or mixtures thereof. The multi-layer film includes at least three layers that, in one embodiment, are coextruded. Each layer of the multi-layer film is made from a different composition that produces layers having different properties.

Abstract: A method is presented for forming a collapsed foam film-like structure, the method including positioning a composition applicator adjacent to a hot non-permeable dryer surface, producing a first frothed dispersion or frothed solution from a first dispersion or solution, applying the first frothed dispersion or frothed solution to the dryer surface, allowing the first frothed dispersion or frothed solution to convert to a collapsed foam film-like structure, and scraping the collapsed foam film-like structure from the dryer surface. The method can further include producing a second dispersion or solution, blending the first dispersion or solution and the second dispersion or solution, frothing the blended dispersion or solution, applying the blended frothed dispersion or frothed solution to the dryer surface, and allowing the frothed dispersion or frothed solution to convert to a collapsed foam film-like structure.

Abstract: Elastomeric articles, such as gloves, are described that are made by welding two polymer films together. Polymer films are selected that have excellent elastic properties in combination with tensile strength properties. For instance, the polymer films can be made from a thermoplastic elastomer that has a tensile strength of greater than 40 MPa and has a modulus of from about 2 MPA to about 20 MPa.

Abstract: Elastomeric articles, such as gloves, are made by welding together two plies of a multi-layer film. The film plies are welded together through ultrasonic bonding, thermal bonding, or mixtures thereof. The multi-layer film includes at least three layers that, in one embodiment, are coextruded. Each layer of the multi-layer film is made from a different composition that produces layers having different properties.

Abstract: Elastomeric articles, such as gloves, are described that are made by welding two polymer films together. Polymer films are selected that have excellent elastic properties in combination with tensile strength properties. For instance, the polymer films can be made from a thermoplastic elastomer that has a tensile strength of greater than 40 MPa and has a modulus of from about 2 MPA to about 20 MPa.

Abstract: An elastic multilayer composite includes a pattern unbonded elastic layer attached to at least one extensible facing layer. A method for forming an elastic multilayer composite includes the steps of providing an elastic material; bonding the elastic material to form a pattern unbonded elastic material; and attaching the pattern unbonded elastic material to at least one facing material.

Abstract: An elastic multilayer composite includes a pattern unbonded elastic layer attached to at least one extensible facing layer. A method for forming an elastic multilayer composite includes the steps of providing an elastic material; bonding the elastic material to form a pattern unbonded elastic material; and attaching the pattern unbonded elastic material to at least one facing material.

Abstract: An absorbent elastic laminate includes an elastic backing layer and a flexible thermoplastic absorbent foam layer. The flexible absorbent foam layer gathers when the laminate is in the relaxed state, permitting the elastic backing and the overall laminate to exhibit elastic stretch and recovery properties. The absorbent elastic laminate is useful in a wide variety of personal care absorbent articles, medical absorbent articles and absorbent wiping articles.

Abstract: A breathable, elastic, film laminate including layers of an inherently breathable, elastic polymer film alternately stacked with layers of a filled plastic polymer. The laminate may be made by grafting a thermoplastic polymer to an elastomer to form an inherently breathable elastic polymer, extruding, the elastic polymer through a die, extruding the filled plastic polymer through a die, stacking the extruded elastic polymer with the extruded plastic polymer while the polymers are in a melt-extrudable state to create a multilayer film laminate, and stretching the laminate.

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 breathable, elastic film/support layer laminate includes a thermoplastic elastomer film sheet of a thermoplastic elastomer and a filled semi crystalline predominantly linear polymer. The film 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 percent elastomeric polymer. The filler is closely associated with the semi-crystalline linear polymer. The film demonstrates a load loss value at a 50 percent elongation of less than 50 percent, and a breathability of greater than 100 g/m2/24 hours and is laminated to a nonwoven layer.

Abstract: High loft, low density nonwoven webs suitable for use in a variety of applications requiring strong fabric layers are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of crimpable, e.g., side by side or eccentric sheath/core (A/B) configuration which are unheated prior to collection. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the Z-direction and produce a web of lofted material of greater uniformity than attained with comparable material whose fibers are drawn by a heated process. The resultant nonwoven material can then be pattern bonded or laminated for additional strength without interfering with the desired loft of the low density nonwoven. The additionally strengthened nonwoven may then be further processed such as by lamination or the like to further increase its utility.

Abstract: A thermoplastic elastomer film includes a thermoplastic elastomer and a filled semi crystalline predominantly linear polymer. The film 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 filler is closely associated with the semi-crystalline linear polymer. The elastic film demonstrates a load loss value at a 50 percent elongation of less than about 50 percent, and a breathability of greater than about 100 g/m2/24 hours.

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 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: High loft, low density nonwoven webs suitable for use in a variety of applications requiring strong fabric layers are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of crimpable, e.g., side by side or eccentric sheath/core (A/B) configuration which are unheated prior to collection. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the Z-direction and produce a web of lofted material of greater uniformity than attained with comparable material whose fibers are drawn by a heated process. The resultant nonwoven material can then be pattern bonded or laminated for additional strength without interfering with the desired loft of the low density nonwoven. The additionally strengthened nonwoven may then be further processed such as by lamination or the like to further increase its utility.

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: 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.