Abstract: Materials in the form of foam sheet comprising destructured or complexed starch expanded as a continuous phase, having a density lying between 20 and 150 kg/m3, cell dimensions in the range lying between 25 and 700 &mgr;m and with a cell distribution such that 80% of them have a dimension lying between 20 and 400 &mgr;m in the absence of stretching.

Abstract: A wound covering comprising a synthetic polymer material comprising zeolites containing metal ions.

Abstract: A mouse pad including a fibrous sheet made of ultrafine fibers, and a substrate. The mouse pad may be incorporated into a mouse pad package so that a part of the surface of the mouse pad provided by the fibrous sheet or a separate piece made of substantially the same material is exposed so that a consumer can touch it directly to confirm its touch and test its likely behavior as a mouse pad.

Abstract: A filter medium which has an average pore diameter of more than 0.5 &mgr;m, a pressure loss of 2-50 mmH2O determined when air is permeated therethrough at a velocity of flow of 5.3 cm/sec, and a PF value of 18-12, which is calculated in accordance with the following equation on the basis of this pressure loss and a collection efficiency using DOP of a grain size of 0.10-0.12 &mgr;m.

Abstract: A breathable microlayer polymer film comprising a plurality of coextruded microlayers including a first layer comprising a first melt-extrudable polymer and a second layer comprising second melt-extrudable polymer, the first melt-extrudable polymer having a first water vapor transmission rate and the second melt-extrudable polymer having a second water vapor transmission rate less than the first water vapor transmission rate. A method for making such a breathable film is also disclosed. The microlayer polymer film is breathable, but can also be a barrier to liquid, microbial organisms, organic toxins, and body fluids, and is suitable as a covering material for disposable items such as diapers. While the first polymer is more breathable, the second polymer can impart other properties to the microlayer film such as enhanced tensile properties.

Abstract: There is provided a laminated sheet comprising: (i) a foamed sheet containing a polypropylene resin; and (ii) a non-woven fabric, wherein the foamed sheet has an expansion ratio, &khgr;, of from about 2 to 10, a cell diameter of not more than about 300 &mgr;m, and a thickness, h (cm), satisfying the following formula (1), (100/E(1−(1−1/&khgr;)⅔))⅓≦h≦2  (1) wherein E (kgf/cm2) is a modulus of elasticity in bending of the resin which is to be a constituent of the foamed sheet and is not yet foamed.

Abstract: Absorber elements are described of at least one composite material having absorbent elements on a support, in which a plurality of elements of a superabsorbent foam are arranged on at least one support in a grid pattern at distances such that the elements in the swollen state touch at their peripheries.

Abstract: Disclosed are protective, flexible mats for absorbing liquids on floors and other surfaces which contain a waterproof component and a polymeric foam sheet formed by polymerizing a high internal phase water-in-oil emulsion. The mats can also contain a non-skid material and/or at least one liquid pervious sheet. The mats are suitable for absorbing hydrophilic and hydrophobic liquids.

Abstract: A thermoformed contoured three-dimensional laminated structure having improved sound absorbing characteristics and which can be formed with shorter mold cycle times includes a porous thermoformable fibrous batt layer and a rigid foam layer. The laminated articles are suitable for use as decorative sound absorbing panels for automotive applications, and are well suited for use as vehicle headliners.

Abstract: A moisture vapor permeable, substantially liquid impermeable composite sheet material comprising a fibrous substrate and a moisture vapor permeable thermoplastic film layer. The moisture vapor permeable film has an average thickness of less than 25 microns, a peel strength of at least 0.1 N/cm, a dynamic fluid transmission of less than about 0.75 g/m2 when subjected to an impact energy of about 2400 joules/m2, a hydrostatic head of at least 60 cm, and a moisture vapor transmission rate, according to the desiccant method, of at least 2800 g/m2/24 hr. The moisture vapor permeable film is preferably comprised of at least about 50% by weight of polymer selected from the group of block copolyether esters, block copolyether amides, polyurethanes, polyvinyl alcohol, and combinations thereof. A method for making such a sheet material is also provided.

Abstract: An absorbent article including a liquid-permeable top layer, an absorbent core layer, a breathable outer cover, and an inner nonwoven filament layer between the absorbent core and breathable outer cover. The outer cover includes a breathable film and an outer nonwoven filament layer. The inner nonwoven filament layer has a mean fiber denier which is higher than the mean fiber denier of the outer nonwoven filament layer. The inner nonwoven filament layer serves as a dampness inhibitor which reduces or prevents perceived dampness on the external surface of the outer cover by lowering thermal conductivity between the absorbent core and the outer cover surface.

Abstract: A laminated support for pressure-relief including an upper layer of visco-elastic foam, a middle layer of visco-elastic foam having a greater hardness, and a bottom layer of highly resilient polyurethane foam. These layers are sandwiched between two layers of reticulated filter polyurethane foam.

Abstract: Single and double density biopolymer foams, composite biopolymer foams including both single and double density foams, and methods of preparing these foams and composite foams are described. Also described are biocompatible constructs which include single or double density biopolymer foams and extracellular matrix particulates and methods of preparing these constructs. The foams, composite foams, and biocompatible constructs of the invention can be used in tissue repair and reconstruction.

Abstract: A panel adaptable for use in automotive trim applications has a laminate of a support layer and an A-side layer made of vinyl or cloth. The support layer is made of a thermoformable material such as foam, felt or polypropylene. The laminate is thermoformed to impart the contour of a rigid substrate to which the panel will be attached. The support layer retains the desired contour without the use of other materials. The panel may have a shirred appearance imparted thereto by the inclusion of a plurality of gathers therm.

Abstract: The present invention provides a molding media and method of producing resin stabilized polymeric fiber mats useful as thermal and acoustical insulation. The molding media and method of the invention lower the cost of producing such mats while still maintaining the necessary mechanical and acoustical properties. One embodiment of the molding media and method of the invention further provides environmental advantages over glass fiber and foam mats.

Abstract: Described is a surface element (10) which is provided for controlledly transporting moisture and for the storage of moisture and which has an air-permeable carrier (14) provided with an adsorbent. The surface element (10) also has an absorbent, moisture-storing fleece layer (12), wherein the adsorber carrier (14) and the fleece layer (12) are connected together in areal relationship by needling (16) to give an air-permeable composite material (22; 22'). The needling (16) is oriented from the fleece layer (12) towards the adsorber carrier (14). The fiber barbs (18) of the needling (16) extend from the fleece layer (12) to the adsorber carrier (14) and through the adsorber carrier (14). The fiber barbs (18) provide a wick action for the moisture, whereby moisture transport to the fleece layer (12) is optimized. Particularly upon saturation of the fleece layer (12) excess moisture is stored in the adsorbent of the adsorber carrier (14).

Abstract: A non-woven fabric laminate having stretch properties constructed using hydroentanglement methods is disclosed. The laminate is comprised of at least two layers and utilizes a foam layer as a component in the preferred embodiment, replacing conventional use of fibrous materials. A superior elastomeric fabric utilizing an open or closed cell foam layer as one element of the composite structure and as the elastic member of the fabric results in superior fabric characteristics when compared to similar hydroentangled fabrics which are constructed from fibrous materials.

Abstract: The present invention provides a fire retardant noise absorbing material, with excellent water proof properties, fire resistance, noise absorption, and improved tear resistance if necessary, and a method of producing the same efficiently in a short time in a simple and easy manner. The fire retardant noise absorbing material having gas permeability of a section of 10 mm in thickness from a surface of the film layer in the range of 5 to 80 ml/cm.sup.2.sec, is produced following the steps of; superposing a polyester film or a polyethylene film onto fire retardant soft urethane foam; laminating a sheet of mold releasing paper thereon; heating the paper while pressure is applied thereto from the surface of the paper by means of a hot plate to affix the film layer on the fire retardant soft urethane foam by hot melting; removing the laminated material from the hot plate in a heated condition; and separating the mold releasing paper from the laminated material after the film has solidified.

Abstract: A dimensionally stable and fireproof acoustic panel includes an underlying panel covered on one or both sides by a cover panel. The underlying panel can be produced with a cover layer on the interior side thereof. The cover layer is composed of two layers, a coarse-pored stabilizing intermediate layer which in turn is covered by a second, fine-pored outer layer, both of which are bonded to one another and to the underlying panel by a matrix of adhesive material.

Abstract: The waterproof/breathable moisture transfer liner for a snowboard boot includes an inner liner selected from technically advanced fabrics which are carefully selected. A series of layers are provided outside the inner liner including foam material layers, breathable membranes, a supportive mesh or a moldable foam, and an outer shell fabric. The applicability of the liner to alpine, cross country and hiking boots, along with appropriate variations for each application.

Abstract: A breathable barrier laminate is disclosed having a first film layer comprising a microporous breathable barrier film; a second film layer comprising a breathable filled film which comprises about 50% to about 70% by weight filler and an amorphous polymer such as an elastomeric ethylene polymer having a density less than 0.89 g/cm.sup.3 ; and a third fibrous layer comprising a breathable outer layer, such as a nonwoven web of spunbonded fibers. The multiple layers can be thermally laminated wherein laminate has a peel strength in excess of 200 grams and a WVTR in excess of 300 g/m.sup.2 /day.

Abstract: A composite substrate for plastic reinforcement, which comprises a fiber mat and a closed cell foam sheet which are integrated by needling.

Abstract: A composite nonwoven fabric is constructed to have high breathability, a low modulus and a good hand. The composite is comprised of a fibrous nonwoven material attached to a highly elastic breathable foam film substrate. The foam film substrate is dimensioned to be thin enough to provide numerous apertures and/or voids therethrough. The attachment of the fibrous nonwoven material to the foam film substrate is accomplished by needlepunching portions of at least some strands of the nonwoven material through the apertures in the elastic foam film. During the needlepunching process, the numerous apertures and/or voids in the foam film facilitate the passage of strands of the nonwoven material through the foam film by the needles while minimizing damage to the structure of the foam film by the needles. Alternatively, the composite nonwoven textile is constructed by attaching fibers to the breathable elastic foam film by flocking.

Abstract: Layered composite materials adapted to be formed into predetermined shaped components disposed for contact with moisture and body fluids having a cover layer for contact with the moisture and body fluids and a foam layer including one or more sorbents in a hydrophilic polyurethane foam matrix, wherein the foam layer is bonded to the cover layer so that moisture and body fluids in contact with the cover layer are transferred through the cover layer to the foam layer. The foam layer is established by combining an aqueous mixture including the sorbent in a predetermined ratio with the hydrophilic polyurethane. The foam layer may include other active ingredients such as odor absorption and bactericidal components, thermal phase change components and finely ground rubber tire materials to vary the characteristics of the composite material.

Abstract: The present invention relates to a breathable laminate including an oriented microporous elastomeric film and at least one support layer bonded to the film. The present invention also relates to a process for forming the breathable laminate including the step of stretching a filled film to produce a microporous film before bonding it to a support.

Abstract: Disclosed are materials capable of distributing and releasing aqueous fluids, e.g., urine, to a storage material, and absorbent articles comprising such fluid distribution materials. These fluid distribution materials have A) a ratio of capillary desorption height (i.e., height at 50% capacity) to capillary absorption height (i.e., height at 50% capacity) of not more than about 1.8:1; B) a capillary desorption height of not more than about 50 cm; C) the ability to wick synthetic urine at 31.degree. C. to a height of 15 cm in not more than about 25 minutes; and D) a vertical wicking capacity at 15 cm of at least about 6 g/g.

Abstract: Disclosed is an adhesive that exhibits desired oil-resistance and processing properties. The adhesive is suitable for use in elastic composites and disposable absorbent products. In one embodiment, the adhesive exhibits the following properties: an Elastic Modulus value that is greater than about 4.times.10.sup.5 dynes per square centimeter at 40.degree. C. across the frequency range of about 0.1 to about 100 radians per second; an Elastic Modulus in Oil value that is greater than about 4.times.10.sup.5 dynes per square centimeter at 40.degree. C. across the frequency range of about 0.1 to about 100 radians per second; a Viscosity value of less than about 40,000 centipoise at a temperature of about 275.degree. F.; and a Viscosity value of greater than about 60,000 centipoise at a temperature of about 250.degree. F.

Abstract: The invention relates to a substrate provided with super-absorbent material to be manufactured by allowing suitable monomers to polymerize in the presence of a catalyst in order to obtain a polymer solution, adding a cross-linking agent to the polymer solution to obtain a pasty composition, subsequently applying the composition on or in a substrate and allowing the applied composition to dry and cross-link in order to obtain the substrate with the super-absorbent material. The pasty composition further contains other additives. The invention further relates to a method for manufacturing such a substrate. The substrates can be used as sheathing material in cables, in hygiene products such as baby napkins, sanitary towels and incontinence products, in or as packagings and packaging materials and in agricultural substrates. The invention also relates to such products.

Abstract: A laminated insole (2) for a footwear has an upper layer (4) of a resilient foam material having an outline (6) shaped for incorporation in the footwear, and a bottom layer of a fibrous mat (10) and having a shape conforming with the outline (6) of the upper layer (4). The fibrous mat (10) includes a multiplicity of fibers (12), a number of which penetrate the foam material of the upper layer (4) for bonding the bottom layer (10) to the upper layer (4), and a stiffening portion (14) for providing stiffness to the insole (2). Preferably, each of the fibers (12) of those penetrating the foam material (4) emerges from the outer surface (16) thereof and thereby provides a pilosity (17) thereon. The laminated product (2) is suitable for use as an insole as well as a slip-in insole in any footwear. It takes advantage of the resilient properties of the foam, the stiffness and thermoformability of the fibrous mat and the comfort provided by the pilosity covering the upper layer of foam.

Abstract: A washable fabric covered mattress pad involves the combination of a layer of resilient foam with a layer of fabric, both of which layers are machine washable and dryable. The fabric, either manmade or natural fiber material, is flame laminated to one side of the layer of foam. The non-covered side of the foam layer frictionally engages a mattress for non-slip self-positioning of the mattress pad without requiring straps or other specific holding mechanisms. A second or additional layers of foam of varying physical characteristics and/or thicknesses may be added through heat bonding thereof in a predetermined pattern to the non-covered side of the first layer of foam. Such arrangement results in a fabric covered, completely washable self-positioning mattress pad, such as having a preferred thickness generally in a range of from about one to about four inches.

Abstract: The present invention includes a foam flame bonded fabric laminate that is wind-resistant, breathable, and supple along with a low cost process for producing it. The apparatus of the present invention comprises a foam bonding agent layered between fabrics or other materials where the foam possesses wind-resistant and breathable characteristics independent of the other layers. The process of the present invention involves two-step foam flame bonding with each step accomplished in a separate pass through a laminating device. In one embodiment, the first step includes lightly exposing a thin polymer foam (such as polyester polyurethane or polyether polyurethane) to a flame without preheating, then pressing it against the inner face of mesh or tricot. The second step includes more vigorously exposing the foam face of the foam-mesh or foam-tricot laminate to a flame, then pressing it against the inner face of a berber, pile, or fleece fabric.

Abstract: A tissue which has at least one fibrous ply. A hydrophobically treated foam stratum is placed on at least one of the fibrous plies in order to prevent the penetration of moisture through the tissue. A hydrophobically treated foam can also be impregnated into one or more fibrous plies in order to provide a barrier to the penetration of moisture through the tissue. The invention also comprises a process for making tissue with a foam moisture barrier.

Abstract: A floor mat includes an upper layer having a top surface and a bottom surface with the upper layer capable of absorbing liquid and wicking the liquid from the top surface toward the bottom surface of the top layer. The upper layer allows water to evaporate from the floor mat so that it may dry. The mat also includes an upper intermediate layer disposed adjacent the upper layer. The upper intermediate layer is capable of wicking liquid from the upper layer and retaining the liquid within its body. A lower intermediate layer is disposed adjacent the upper intermediate layer. The lower intermediate layer is also capable of absorbing and retaining liquid from the upper intermediate layer when the upper intermediate layer is fully saturated. A liquid impervious layer is disposed below the lower intermediate layer such that water may not seep out of the bottom of the lower intermediate layer.

Abstract: A self-regulating breathable microporous film layer transmits water vapor at normal use conditions, and reduces or eliminates the vapor transmission when the vapor in the environment becomes excessive. The film layer includes a voided polymer matrix and a plurality of fine water-swellable filler particles disposed within the voids. When there is an excess of vapor, the filler particles swell to block or partially block transmission of vapor through the voids and the film layer.

Abstract: A breathable multi-layer film laminate including microporous filled film bonded to continuous film. A support layer such as a fibrous web can be adhered to the film laminate on one or both surfaces.

Abstract: Single and double density biopolymer foams, composite biopolymer foams including both single and double density foams, and methods of preparing these foams and composite foams are described. Also described are biocompatible constructs which include single or double density biopolymer foams and extracellular matrix particulates and methods of preparing these constructs. The foams, composite foams, and biocompatible constructs of the invention can be used in tissue repair and reconstruction.

Abstract: Improved pin-reinforced sandwich structure ties the face sheets (typically on opposite sides of a foam core) together with a plurality of Z-pins that extend into each face sheet (through the core). The pins are arranged in a tetrahedral or hat section configuration in 2-dimensional or 3-dimensional arrangements to provide enhanced reinforcement, particularly in shear. We are able to improve the pulloff strength additionally by dimpling the core surrounding the pins to produce adhesive fillets along the pins.

Abstract: A sheet material is provided having a smooth top and a continuous non-slip foam bottom. The material is created by laminating a printed plastic sheet to a foam material carried on a non-spun polyester fabric.

Abstract: Multi-layer covering articles having a base layer adapted to yieldably conform to a surface to be covered and having properties appropriate for a particular application in which the article is to be used, and a thermoplastic surface layer bonded to a surface of the base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article. The reinforcing material permits the surface layer to function as the strength-providing member of the article, permitting the base layer to be designed solely in accordance with the requirements of a particular application without regard to its strength.

Abstract: The present invention is an inexpensive and disposable mat constructed from non-flammable material for placement beneath fluid leaking machinery. The mat is manufactured from at least one layer of non-woven fluid absorbing polypropylene that is bonded to at least one fluid impervious backing sheet such a polyester or polyethylene by use of heat sensitive adhesive. The assembled mat forms a high strength bonded mat that resists tearing and will retain fluids. The backing sheet prevents fluids from penetrating so as to confine all fluids to the non-woven portion of the mat where they disperse and, depending on the type of fluid absorbed, may evaporate.

Abstract: The invention relates to a sound insulating structure including low-density and high-density layers. The low-density layer has first and second fibrous layers and ranges from 0.5 to 1.5 kg/m.sup.2 in surface density. The first and second fibrous layers are respectively made of first and second thermoplastic synthetic fibers. The first and second fibers respectively have first and second single fiber diameters, each of which diameters is in a range of from 3 to 40 .mu.m, and first and second fiber lengths, each of which lengths is in a range of from 10 to 100 mm. The high-density layer is formed on the low-density layer and is made of an air-impermeable polymer material and has a surface density that is higher than that of the low-density layer and ranges from 1 to 10 kg/m.sup.2. The low-density layer is high in sound-absorption coefficient and at the same time low in spring constant. Therefore, the sound insulating structure becomes substantially improved in sound insulating capability.

Abstract: An absorbent article having, as a back sheet, a porous sheet obtainable by preparing, by melt blending, a melt blended solution comprising 30 to 90 parts by weight of a crystalline polyolefin and 10 to 70 parts by weight of a compound with which the crystalline polyolefin is miscible and in which the crystalline polyolefin will dissolve at or above the melting point of the crystalline polyolefin but which will phase separate below the melting point of the crystalline polyolefin, molding the blended solution into a sheet, and stretching the sheet in at least one direction. The crystalline polyolefin is a polypropylene having a weight average molecular weight (Mw) to number average molecular weight (Mn) ratio (Mw/Mn) of no more than 6.0.

Abstract: Layered composite materials adapted to be formed into predetermined shaped components disposed for contact with moisture and body fluids having a cover layer for contact with the moisture and body fluids and a foam layer including one or more sorbents in a hydrophilic polyurethane foam matrix, wherein the foam layer is bonded to the cover layer so that moisture and body fluids in contact with the cover layer are transferred through the cover layer to the foam layer. The foam layer is established by combining an aqueous mixture including the sorbent in a predetermined ratio with the hydrophilic polyurethane. The foam layer may include other active ingredients such as odor absorption and bactericidal components, thermal phase change components and finely ground rubber tire materials to vary the characteristics of the composite material.

Abstract: An ink jet recording sheet, having high ink absorption, water resistance, persistency, a satisfactory fabric-like soft touch, mechanical strength and being capable of recording ink images having a high quality, includes a foamed undercoat layer formed on a surface of a substrate sheet and comprising a polymeric binder and an ink-receiving layer formed on the foamed undercoat layer from a mixture of 50 to 90% by weight of an amorphous silica having an oil absorption value of 100 to 400 ml/100 g with 10 to 50% by weight of a polymeric binder, and provided with a surface thereof having a Bekk smoothness of 10 seconds or less determined by JIS P 8119.

Abstract: Low density collapsed absorbent foams materials that, upon contact with aqueous fluids, in particular urine, can expand and absorb these fluids. These low density foams typically have an expanded thickness from about 6 to about 10 times the thickness of the foams in their collapsed state. These low density foams are made by polymerizing high internal phase emulsions (HIPEs) where the volume to weight ratio of the water phase to the oil phase is in the range of from about 55:1 to about 100:1.

Abstract: An improved shaped article comprising a thermoformed composite sheet, which is a layer of thermoplastic polymer attached to a surface of a lightweight conformable fabric, the other surface of the fabric being attached to a layer of rigid foam, provides the article with improved wall thickness uniformity and impact resistance.

Abstract: A chemical protective fabric for use in garments worn by persons in a cheally hostile environment comprises a layer of felted foam impregnated with superactivated carbon, a polyurethane emulsion binder for bonding the superactivated carbon to the foam, a first stretchable material layer bonded to the layer of foam on a first of the major surfaces thereof, and a second stretchable material layer bonded to the layer of foam on a second of the major surfaces thereof.