Multi-ply puckered films formed by discontinuous lamination of films having different rebound ratios

摘要

Methods of increasing the loft of a multi-ply thermoplastic film include stretching thermoplastic films with different rebound ratios, non-continuously laminating the films together, and releasing the films to create puckers in one or more of the films. The puckers can comprise billowing of one of the films. The non-continuous laminated areas can maintain the puckers in the films. The puckers can increase the loft of the film, improve the feel of the film, and/or modify the look of the film. The loft of such multi-ply puckered thermoplastics films vary independent of the basis weight of the films. Thus, multi-ply puckered thermoplastics films with increased loft of one or more implementations can look and feel thicker while using reduced amounts of thermoplastic material.

主权项

1. A multi-ply, puckered thermoplastic film comprising:
a first ply of a first thermoplastic material having a first ply maximum gauge, wherein the first ply has been cold formation stretched to form comprises alternating thick linear areas of un-stretched material and that alternate with thin linear areas of stretched material; a second ply of the first thermoplastic material having a second ply maximum gauge and adjacent to the first ply, wherein the second ply is a flat ply; a plurality of non-continuous bonds securing the thick areas of the first ply directly to the second ply such that the multi-ply, puckered thermoplastic film is devoid of layers between the first ply and the second ply, wherein the bonds between the first ply and the second ply are formed with the first ply in the stretched condition; and a plurality of puckers in the second thermoplastic ply, the puckers being located between and maintained by adjacent laminated areas and the puckers having a height of at least 1.25 times the sum of the first ply maximum gauge and the second ply maximum gauge; wherein a loft of the multi-ply, puckered thermoplastic film is increased between 4.3% and 33% while a basis weight of the multi-ply, puckered thermoplastic film has a percent decrease between 10% and 30% compared to a combination of the first and second plies in an un-stretched state.