Clopay Plastic Products Company, Inc.

Clopay Corporation

Fiberweb France S.a.

Pai-Chuan Wu

Leopoldo V Cancio

Robert M Mortellite

Thomas R Ryle

Thomas G Mushaben

Girish K Sharma

Gregory K Jones

Larry Hughey McAmish

Christopher Aaron Shelley

Kenneth L Lilly

J David Toppen

Mark Andrew Wendorf

James N Fitzsimmons

Gerald W Miller

Philippe Ehret

Dale Eugene Robinson

Robert J Tomany

Frank Moore, Jr

Richard Arnold Bradford

John D Toppen

Wendell R High

Gene W Palmer

Arthur J Raffel

Robert E Byrne

James R Snyder

Thomas C Ryle

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

Thermoplastic films and laminates are made by extrusion and stretching using differential speed rollers employing a short stretching gap of no more than one inch immediately after the extruded film product is formed. The method and apparatus control the thickness of the stretched film and impart desirable mechanical properties thereto such as film products with a high modulus for handling and suitable tensile for softness.

Method and apparatus for uniformly stretching thermoplastic film and products produced thereby

In one embodiment, a breathable, incrementally stretched elastic composite material comprises an inner elastomeric film extrusion-laminated to an outer nonwoven web at each film surface. The inner elastomeric film has a random pattern of incremental stretch-formed macroholes therein and is substantially free of pore-forming filler. In another embodiment, a breathable, incrementally stretched elastic composite material comprises an elastomeric film extrusion-laminated to a nonwoven web at one or both of the film surfaces. The elastomeric film has a random pattern of incremental stretch-formed macroholes therein and is substantially free of pore-forming filler. Methods of manufacturing the composite materials comprise extrusion laminating and incremental stretching. Garments and disposable articles are formed at least in part from the composite material.

Breathable and elastic composite 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

Laminates of thermoplastic films and nonwoven fibrous webs are made at high speeds on the order of about 700 fpm to about 1200 fpm. Bond strengths of film and nonwoven laminates are effectively controlled to make breathable laminates at high speeds. Air cooling devices cause the air to flow substantially parallel to the extruded plastic web during drawdown and provide a plurality of cooling air vortices to effectively cool the web. Film gauge control is also achieved by the method.

High speed method of making plastic film and nonwoven laminates

Thermoplastic film, microporous film, and laminates thereof, are made at high speeds on the order of about 500 fpm to about 1200 fpm. Bond strengths of film and nonwoven laminates are effectively controlled by air cooling devices which cause the air to flow substantially parallel to the extruded web during drawdown and provide a plurality of cooling air vortices to effectively cool the web. Film gauge control is also achieved by the method.

Non-embossed film products permeable to moisture vapor and which act as barriers to liquid are made by a high speed method. The microporous products have high moisture vapor transmission rates (MVTRs) on the order of about 2000 to about 4500 gms/m /day according to ASTM E96E.

Incrementally stretched non-embossed films having high moisture vapor transmission rates (MVTRs)

Microporous film products permeable to moisture vapor and which act as barriers to liquid are made by a high speed method. Such microporous products are made at speeds in the order of above 500 fpm to about 1200 fpm. Thermoplastic polymers are melt blended to contain about 35% to about 45% by weight of a linear low density polyethylene, about 3% to about 10% by weight of a low density polyethylene; about 40% to about 55% by weight calcium carbonate filler particles, and about 2% to about 6% by weight of a triblock polymer of styrene.

High speed method of making microporous film products

A cloth-like microporous laminate of a nonwoven fibrous web and thermoplastic film is made by lamination of a microporous-formable film composition and a nonwoven fibrous web followed by incremental stretching to form the cloth-like microporous laminate. The cloth-like microporous laminate has air and moisture vapor permeabilities, but acts as a barrier to the passage of liquids. The cloth-like laminates are especially useful in fabricating garments in order to provide the breathable qualities of air and moisture vapor transmission with liquid-barrier properties. Such garments include baby diapers, baby training pants, catamenial pads and garments, and the like where moisture vapor and air transmission properties, as well as fluid barrier properties, are needed.

Method of making a cloth-like microporous laminate of a nonwoven fibrous

An elastic laminated sheet of an incrementally stretched nonwoven fibrous web and elastomeric film and method of making are disclosed. The elastic laminates are especially useful in diapers, surgical gowns, sheets, dressings, hygienic products and the like.

Method of making an elastic laminated sheet of an incrementally

A totally biodegradable and/or compostable soft cloth-like composite of totally biodegradable and/or compostable film and totally biodegradable and/or compostable nonwoven and method of manufacture. A totally biodegradable and/or compostable nonwoven fibrous web and a totally biodegradable and/or compostable film are laminated. The laminate is incrementally stretched to produce a totally biodegradable and/or compostable laminate that is softer than that produced when the biodegradable and/or compostable nonwoven web is bonded to the biodegradable and/or compostable film. The soft cloth-like features of the invention are desired in a number of applications including diapers, pants, surgical gowns, sheets, dressings, hygienic products, and the like.

Cloth-like totally biodegradable and/or compostable composites and

Clothing garments and other articles include an elastic laminated sheet having the properties of stretchability and recoverability. The elastic laminated sheet is formed from a nonwoven fibrous web and an elastomeric film laminated to at least one entire web surface. The laminate is incrementally stretched along lines substantially uniformly across its length and width and throughout its depth to form a stretchable and recoverable composite. The elastic laminated sheet is uniquely suited for use in athletic and active wear garments. The composite is also useful for single use or throw away clothing articles such as medical or surgical garments, throw away bathing suits, underpants, undershirts, and garments used in the handling of hazardous or waste materials.

Growing community of inventors

Cincinnati, OH, United States of America

Pai-Chuan Wu