A thermoplastic film which exhibits elastic-like behavior along at least one axis when stretched or elongated and then released. The thermoplastic film comprises a plurality of raised rib-like elements extending in a direction perpendicular to a main surface of the thermoplastic film. The thermoplastic film further includes a plurality of web areas positioned about the plurality of raised rib-like elements. The plurality of raised rib-like elements and plurality of web areas are arranged in a complex pattern. The complex pattern provides visual and tactile cues as the films are stretched or elongated. The complex pattern can cause the thermoplastic film to have a low force extension.

A multiple-ply thermoplastic film which exhibits elastic-like behavior along at least one axis when stretched or elongated and then released. The thermoplastic film comprises a plurality of raised rib-like elements extending in a direction perpendicular to a main surface of the thermoplastic film. The thermoplastic film further includes a plurality of web areas positioned about the plurality of raised rib-like elements. The plurality of raised rib-like elements and plurality of web areas are arranged in a complex pattern. The complex pattern, when stretched or elongated and then released, can cause areas of billowing and delamination between plies of the multiple-ply thermoplastic film. The resulting billowed and delaminated areas form billow pockets for capturing liquids that can capture liquids when one of the plies is punctured.

A multiple-ply thermoplastic film which exhibits elastic-like behavior along at least one axis when stretched or elongated and then released. The thermoplastic film comprises a plurality of raised rib-like elements extending in a direction perpendicular to a main surface of the thermoplastic film. The thermoplastic film further includes a plurality of web areas positioned about the plurality of raised rib-like elements. The plurality of raised rib-like elements and plurality of web areas are arranged in a complex pattern. The complex pattern, when stretched or elongated and then released, can cause areas of billowing and delamination between plies of the multiple-ply thermoplastic film. The resulting billowed and delaminated areas form billow pockets for capturing liquids that can capture liquids when one of the plies is punctured.

An elastic laminate is provided including at least one gathered outer facing layer of a fabric and an apertured elastic film attached thereto. The aperture film includes a series of alternating first and second segments that extend continuously along the direction of elasticity. The first segments of the film are substantially devoid of any apertures and the second segments are strewn with apertures of irregular size and shape. The regionally limited and irregular apertures are formed by the controlled rupturing of the film within those segments. The elastic laminate has excellent air-permeability and elastic properties.

Apparatus and methods of stretch-forming pre-preg material are provided. In one example embodiment, a variable material stretch-forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section of a sheet of pre-preg material to a longer length than at least one other section of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.

Apparatus and methods of stretch-forming pre-preg material are provided. In one example embodiment, a variable material stretch-forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section of a sheet of pre-preg material to a longer length than at least one other section of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.

A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

Multi-layer films include at least one cavitated core layer that is microporous and breathable, and at least one skin layer. The cavitated core layer includes a polyolefin and an inorganic filler dispersed in the polyolefin. Methods for forming polymeric films and articles of manufacture prepared therefrom are described.

Multi-layer films include at least one cavitated core layer that is microporous and breathable, and at least one skin layer. The cavitated core layer includes a polyolefin and an inorganic filler dispersed in the polyolefin. Methods for forming polymeric films and articles of manufacture prepared therefrom are described.