Clopay Plastic Products Company, Inc.

Polymer Group, Inc.

Imerys Pigments, Inc.

Larry Hughey McAmish

Kenneth L Lilly

Christopher Aaron Shelley

Pai-Chuan Wu

Gregory K Jones

Mark Andrew Wendorf

David A Skelhorn

Timothy Huskey

Arrigo D Jezzi

Kevin Paul Osborn

Described herein are spunlaid fibers including at least one polymeric resin and at least one filler having an average particle size of less than or equal to about 5 microns and/or having a top cut of less than about 15 microns. The at least one filler may be present in an amount of less than about 40% by weight, relative to the total weight of the spunlaid fibers. Also described herein is a method for producing spunlaid fibers including adding calcium carbonate to at least one polymeric resin and extruding the resulting mixture. Further described herein are nonwoven fabrics including such spunlaid fibers, and methods for producing them.

Process for producing nonwoven fabric

Embodiments of a breathable multilayer microporous film comprise a first outer film layer, a second inner film layer, and a third outer film layer, wherein each film layer comprises at least one pore-forming filler and one thermoplastic polymer. Each film layer is rendered microporous and breathable by stretching each film layer having the pore-forming filler therein, wherein the first and third outer film layers have first and third maximum pore sizes, respectively, and the second inner film layer has a second maximum pore size different than the respective maximum pore sizes of the first and third outer film layers of the multilayer film. The multilayer microporous film passes ASTM F 1671-03 test.

Multilayer microporous films and composites for barrier protective materials, and methods

Multilayer microporous films comprise first and second microporous film layers. The first film layer has a first maximum pore size and the second film layer has a second maximum pore size different from the first maximum pore size. In a more specific embodiment, the multilayer microporous films comprise coextruded first, second and third microporous film layers. One of the first, second and third film layers has a maximum pore size smaller than the respective maximum pore sizes of the remaining layers of the multilayer film or larger than the respective maximum pore sizes of the remaining layers of the multilayer film, and the one layer does not have an unconstrained surface in the multilayer film. Methods for producing multilayer microporous films provide a first film layer having a maximum pore size upon stretching which is different from that of a second film layer upon stretching.

Multilayer microporous films and methods

A method of making a laminate sheet having a film layer and a fabric layer. The method includes the step of bonding a film layer to a fabric layer in order to form a laminate sheet such that the laminate sheet includes at least one high-bond region whereat the strength of the bond between the film and fabric layers is greater than other regions of the laminate sheet. The method further includes the step of stretching the laminate sheet such that the high-bond regions are either not stretched or are only partially stretched. A method of making a diaper backsheet, as well as a stretched laminate of a polymeric film and a fabric web, is also provided.

Laminated sheet and method of making same

A method of making a microporous laminate sheet having a first film layer and a second layer. The first film layer includes a pore initiator and is bonded to the second layer in order to form a laminate sheet. The laminate sheet is then stretched using at least one CD intermeshing stretcher and at least one MDO stretching unit. Methods of making a microporous film is well as a microporous film laminate are also provided, along with an apparatus for stretching a film or laminate.

Film, laminated sheet and methods of making same

The present invention is directed to the method of extruding a thermoplastic co-polyester EMA (ethyl methyl acrylate) blended film at temperatures well above the melt temperature of the base thermoplastic co-polyester, the co-polyester/EMA film having enhanced barrier properties. Notably, the present invention contemplates extrusion of co-polyester compounds onto suitable substrates without the need to employ antioxidant compounds in the molten polymer material. A further aspect of the present invention entails a film comprising an EMA and co-polyester thermoplastic admixed with a compatibilizer and extruded at a temperature at least 10% higher than the melt temperature, which in turn provides the co-polyester film with durable adhesive properties in addition to good breathability as measured by moisture vapor transmission rate (MVTR).

High temperature polyester film extrusion

A breathable film is composed of a uniform blend of two thermoplastic resins, one having a high moisture vapor transmission rate and the other having a low rate. The blend is melt extruded into a film having good handling characteristics and a controlled degree of moisture vapor transmission, as determined by blend ratio per unit of film thickness.

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Cincinnati, OH, United States of America

Larry Hughey McAmish