Claims
- 1. A laminate of non-woven fibrous web and microporous polymer film comprising:a microporous polymer film; and at least one strip of a non-woven fibrous web having opposite edges, the strip laminated to the film to form a laminated area along the length of the film and unlaminated film areas along the opposite edges, each of said opposite strip edges defining a boundary area between the laminated area and the unlaminated areas; wherein each boundary area is substantially unstretched and the laminated area and the unlaminated areas are interdigitally stretched such that each boundary area is substantially pinhole free.
- 2. The microporous laminate sheet of claim 1 wherein the film and non-woven laminate areas and the unlaminated polymer film areas are interdigitally stretched in the cross-machine direction.
- 3. The microporous laminate sheet of claim 1 wherein the polymer film comprises:a polyolefin; and a pore initiator.
- 4. The microporous laminate sheet of claim 1 wherein the polymer film comprised a blend of linear low density polyethylene and low density polyethylene.
- 5. The microporous laminate sheet of claim 1 wherein the polymer film comprises: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 50% by weight calcium carbonate filler particles, and about 2% to about 6% by weight of a rubber compound.
- 6. The microporous laminate sheet of claim 5 wherein said polymer film consists essentially of about 42% by weight linear low density polyethylene, about 4% by weight low density polyethylene, about 44% calcium carbonate filler particles, and about 3% by weight triblock polymer.
- 7. The microporous laminate sheet of claim 5 wherein said polymer film further comprises about 0-5% by weight high density polyethylene, about 0-4% by weight titanium dioxide, and about 0.1% to about 0.2% by weight processing aid.
- 8. The microposous laminate sheet of claim 7 wherein said polymer film comprises about 4% by weight high density polyethlene, about 3% by weight titanium dioxide, and about 0.1% by weight fluorocarbon polymer processing aid.
- 9. The microporous laminate sheet of claim 8 wherein said fluorocarbon polymer processing aid is 1-propene, 1,1,2,3,3,3-hexafluoro copolymer with 1,1-difluoroethylene.
- 10. The microporous laminate sheet of claim 5 wherein said rubber compound is a triblock copolymer of styrene selected from the group consisting of styrene-butadiene-styrene, styrene-isoprene-styrene, and styrene-ethylene-butylene-styrene.
- 11. The microporous laminate sheet of claim 10 wherein said triblock polymer is preblended with oil, hydrocarbon, antioxidant and stabilizer.
- 12. A microporous laminate sheet of a polymer film layer and a non-woven fibrous web comprising:a microporous polymer film layer; and at least one non-woven fibrous web having opposite edges laminated to the microporous polymer film layer forming a laminated area and an unlaminated area of the polymer film layer and having boundary areas at the edges of the laminated non-woven fibrous web; wherein the laminated area and the unlaminated polymer film area are interdigitally stretched and the boundary areas are substantially unstretched such that the boundary areas are substantially pinhole free.
- 13. The microporous laminate sheet of claim 12 wherein the polymer film comprises:a polyolefin; and a particulate filler.
- 14. The microporous laminate sheet of claim 12 wherein the polymer film comprises: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 50% by weight calcium carbonate filler particles, and about 2% to about 6% by weight of a rubber compound.
- 15. The microporous laminate sheet of claim 12 wherein the polymer film comprises:about 42% by weight linear low density polyethylene, about 4% by weight low density polyethylene, about 44% calcium carbonate filler particles, and about 3% by weight triblock polymer.
- 16. The microporous laminate sheet of claim 15 wherein the triblock polymer is a styrene-butadiene rubber.
RELATED APPLICATION
This is a continuation application of U.S. application Ser. No. 09/124,583 filed Jul. 29, 1998, now U.S. Pat. No. 6,265,645.
US Referenced Citations (33)
Foreign Referenced Citations (1)
Number |
Date |
Country |
141592 |
May 1985 |
EP |
Non-Patent Literature Citations (1)
Entry |
Schwarz, Eckhard C. A., New Fibrillated Film Structures, Manufacture and Uses, Pap. Synth. Conf. (TAPPI), 1976, pp. 33-39. No Month. |
Continuations (1)
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Number |
Date |
Country |
Parent |
09/124583 |
Jul 1998 |
US |
Child |
09/910241 |
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US |