US20180126618A1 - Prestretched apertured elastic film with resistance to web breaks

Info

Abstract

Description

Claims

US20180126618A1

Publication number: US20180126618A1
Application number: US15/806,402
Authority: US
Inventors: Jeffrey A. Middlesworth; Brooke D. Kitzmiller; Michael A. Kinnan
Original assignee: Berry Global Inc; Berry Plastics Corp
Current assignee: Berry Global Inc
Priority date: 2016-11-09
Filing date: 2017-11-08
Publication date: 2018-05-10
Also published as: TWI661923B; WO2018089448A1; US11034072B2; TW201821240A; WO2018089440A1; US20180126619A1; TW201821494A

Apertured elastic films include a polyolefin, a styrene block copolymer, a non-styrene block copolymer, or a combination thereof. Methods for forming polymeric films and articles of manufacture prepared therefrom are described.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 62/419,805, filed Nov. 9, 2016, and U.S. Provisional Application Ser. No. 62/455,827, filed Feb. 7, 2017, each of which is expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to polymeric materials, and particularly to polymeric films. More particularly, the present disclosure relates to elastic films formed from polymeric material.

SUMMARY

According to the present disclosure, an elastic film is made using a manufacturing process. The manufacturing process comprises the steps of extruding a composition to form a molten web and casting the molten web to form a quenched film.
In illustrative embodiments, the manufacturing process used to form the elastic film further includes stretching the quenched film to form a stretched film, relaxing the stretched film to form a relaxed film, and perforating the relaxed film to form at least one aperture therein. Optionally, the manufacturing process may further include the step of ageing the quenched film to form an aged film.
In illustrative embodiments, the composition extruded to form the molten web comprises an elastomer. The quenched film is formed by casting the molten web against a surface of a chill roll using a vacuum box and/or blowing air (e.g., an air knife and/or an air blanket). The quenched film is stretched in a machine direction in at least a 2:1 draw to form the stretched film.
In illustrative embodiments, an apertured elastic film comprises a polyolefin, a styrene block copolymer, a non-styrene block copolymer, or a combination thereof. The apertured elastic film has a basis weight of less than or equal to about 30 gsm. A notched elongation to break of the apertured elastic film is equal to or greater than a notched elongation to break of a comparative apertured elastic film prepared without the stretching.
In illustrative embodiments, an apertured elastic film comprises an elastomer, at least one slit that extends from a top surface of the film through to a bottom surface of the film. At least one edge of the apertured elastic film is folded, thereby providing at least one tear-resistant edge to the apertured elastic film. The apertured elastic film has a basis weight of less than or equal to about 30 gsm.
In illustrative embodiments, an elastic film comprises an elastomer. At least one edge of the elastic film is folded, thereby providing at least one tear-resistant edge to the elastic film. The elastic film has a basis weight of less than or equal to about 30 gsm.
In illustrative embodiments, a personal hygiene product comprises at least one apertured elastic film and at least one outer non-woven layer. The at least one apertured elastic film is configured to contact skin and/or clothing of a user of the personal hygiene product.
Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:

FIG. 1 is a diagrammatic view of a representative embodiment of an apertured elastic film that includes a core layer and two skin layers;

FIG. 2 is a diagrammatic view of an exemplary process for casting a molten web against a chill roll using a vacuum box;

FIG. 3 is a diagrammatic view of an exemplary process for casting a molten web against a chill roll using an air knife;

FIG. 4 is a diagrammatic view of an exemplary process for machine direction (MD) stretching of a polymeric film;

FIG. 5 is a diagrammatic view of an exemplary in-line process for extruding, quenching, stretching, relaxing, and perforating a polymeric film;

FIG. 6 is a diagrammatic view of a representative embodiment of an elastic film that includes a folded edge;

FIG. 7 is a diagrammatic view of a representative process for forming an elastic film having a folded edge;

FIG. 8 is a diagrammatic view of a representative process for post-stretching an apertured elastic film and ultrasonically bonding the post-stretched apertured elastic film to a non-woven material; and

FIG. 9 is a diagrammatic view of a representative embodiment of a multi-layer apertured elastic film bonded to a non-woven material.

DETAILED DESCRIPTION

In some embodiments, the present disclosure provides a multi-layer apertured elastic film that includes a core layer interposed between one or more outer skin layers adjacent to the core layer. A first embodiment of a multi-layered apertured elastic film 2 in accordance with the present disclosure is shown, for example, in FIG. 1. The multilayer apertured elastic film 2 includes a core layer 4 interposed between a first skin layer 6 and a second skin layer 8. The apertured elastic film 2 further includes one or more slits 10 that extend from a top surface 11 through to a bottom surface 12. Although the apertured elastic film 2 is shown in FIG. 1 as including the first skin layer 6 and the second skin layer 8, one or both of these two outer skin layers is optional and, in some embodiments, may not be present. Thus, in some embodiments, the present disclosure alternatively provides a monolayer apertured elastic film. A monolayer apertured elastic film in accordance with the present disclosure is analogous to the core layer 4 shown in FIG. 1 without the first skin layer 6 and the second skin layer 8.
The core layer 4 may include a thermoplastic polymer (or combination of thermoplastic polymers), whereas the outer skin layers 6 and 8 may have either the same composition as the core layer 4 or a different composition than the core layer 4. By way of example, one or both of the first skin layer 6 and the second skin layer 8 may contain a thermoplastic polymer or combination of thermoplastic polymers. The choice of the thermoplastic polymer or combination of thermoplastic polymers in each of the core layer 4, the first skin layer 6, and the second skin layer 8 shown is FIG. 1 is independent of the other layers.
In one example, an apertured elastic film 2 in accordance with the present disclosure is formed via a blown film process. In another example, an apertured elastic film 2 in accordance with the present disclosure is formed via a cast film process. The cast film process involves the extrusion of molten polymers through an extrusion die to form a thin film. The film is pinned to the surface of a chill roll with an air knife, an air blanket, and/or a vacuum box.
In illustrative embodiments, a process for making an apertured elastic film 2 in accordance with the present disclosure includes (a) extruding a composition containing a thermoplastic polymer to form a molten web, (b) casting the molten web against a surface of a chill roll using an air knife, an air blanket, a vacuum box, or a combination thereof to form a quenched film, (c) stretching the quenched film in a machine direction in at least a 2:1 draw to form a stretched film, (d) relaxing the stretched film to form a relaxed film, and (e) perforating the relaxed film to introduce at least one aperture therein. Optionally, the process for making an apertured elastic film 2 in accordance with the present disclosure further includes ageing the quenched film to form an aged film, which has an increased elasticity relative to the quenched film, prior to performing the stretching.
It has been discovered that by pre-stretching the quenched film (e.g., in a machine direction in at least a 2:1 draw), a notched elongation to break of the resultant apertured elastic film will be equal to or greater than a notched elongation to break of a comparative apertured elastic film prepared without the stretching. In other words, with pre-stretching, a notch put into a sample film does not reduce the break elongation of the film nearly as much as the same notch put into a similar un-stretched sample. Moreover, it has further been discovered that by using a vacuum box, blowing air (e.g., an air knife and/or an air blanket), or a vacuum box in combination with blowing air to cast the molten web against a chill roll in accordance with the present disclosure, apertured elastic films 2 exhibiting surprisingly and unexpectedly improved properties as compared to other elastic films may be prepared. As further described below, these properties may include reduced basis weight.
In some embodiments, the thermoplastic polymer-containing compositions may be extruded in a cast-embossed process with an engraved pattern (matte or less than about 2-mil depth). In other embodiments, the compositions may be extruded via a blown co-extrusion process. In illustrative embodiments, as further explained below, the film extrusion is performed using a vacuum box casting process, which circumvents the limitations of draw resonance that may affect embossed films, as well as bubble instability that may affect blown films.
In illustrative embodiments, the molten web is cast against the surface of the chill roll under negative pressure using a vacuum box as shown in simplified schematic form in FIG. 2. A vacuum box works by evacuating air between the film and the surface of the chill roll. For example, as shown in FIG. 2, a film 46 is extruded from an extrusion die 40 in the direction of arrow 47 and quenched from the molten state with a vacuum box 42. The vacuum box 42 draws a vacuum behind the molten web 46 in the direction of arrow 44 to draw the film 46 down onto the chill roll 38. The vacuum drawn in the direction of arrow 44 removes the entrained air between the surface of the chill roll 38 and the film 46. The vacuum box process is not subject to draw resonance for high molecular weight polymers that would tend to extrude unstable thickness in a nipped quench process due to the draw resonance phenomenon.
When a vacuum box 42 is used, the molten polymer may exit the die 40 and hit the chill roll 38 within a smaller distance than in an embossed process. For example, in some embodiments, the melt curtain is configured to hit the chill roll 38 within a distance of less than about 12 inches, 11 inches, 10 inches, 9 inches, 8 inches, 7 inches, 6 inches, 5 inches, 4 inches, 3, inches, 2 inches, or 1 inch. In illustrative embodiments, the melt curtain is configured to exit the die and hit the roll within a distance of less than about 3 inches and, in some examples, within a distance of about or less than 1 inch. One advantage of reducing the distance between the die 40 and the roll surface 38 as compared to in a nipped quench process is that smaller distances are less susceptible to the phenomenon of neck-in. Neck-in refers to a reduction in width of the molten web that occurs as the web leaves the die. By drawing the film 46 onto a surface of the chill roll 38 over a short distance as shown in FIG. 2, the vacuum box 42 may enhance web cooling, facilitate higher line speeds, reduce film neck-in, and/or reduce drag at the lip exit.
In another example, the molten web is cast against the surface of the chill roll under positive pressure using an air knife or air blanket, as shown in simplified schematic form in FIG. 3. An air knife works to promote web quenching by gently blowing a high-velocity, low-volume air curtain over the molten film, thereby pinning the molten film to the chill roll for solidification. For example, as shown in FIG. 3, a film 54 is extruded from an extrusion die 50 in the direction of arrow 55 and quenched from the molten state with an air knife 52 blowing an air curtain over the molten film 54, thereby pinning the molten web 54 against a surface of the chill roll 48. An air blanket (a.k.a. “soft box”) works similarly to an air knife and promotes web quenching by gently blowing an air curtain over the molten film. However, in the case of an air blanket, the air curtain is low velocity and high volume.
In a further example, the molten web is cast against the surface of the chill roll under a combination of negative pressure from a vacuum box, as shown in FIG. 2, and positive pressure from an air knife, as shown in FIG. 3. In illustrative embodiments, in the casting of the molten web against a surface of the chill roll, an exit temperature of cooling fluid passing through the chill roll is between about 50 degrees Fahrenheit and about 130 degrees Fahrenheit and, in some examples, between about 75 degrees Fahrenheit and about 130 degrees Fahrenheit.
Thermoplastic materials that have elastomeric properties are typically called elastomeric materials. Thermoplastic elastomeric materials are generally defined as materials that exhibit high resilience and low creep as though they were covalently crosslinked at ambient temperatures, yet process like thermoplastic non-elastomers and flow when heated above their softening point. The thermoplastic polymer 4 (or combination of thermoplastic polymers 4) used to make an apertured elastic film 2 in accordance with the present disclosure is not restricted, and may include all manner of thermoplastic polymers capable of being stretched.
In illustrative embodiments, the thermoplastic polymer is a polyolefin, (including but not limited to homopolymers, copolymers, terpolymers, and/or blends thereof), a non-styrene block copolymer, a styrene block copolymer, or a combination thereof.
Representative polyolefins that may be used in accordance with the present disclosure include but are not limited to low density polyethylene (LDPE), high density polyethylene (HDPE), linear low density polyethylene (LLDPE), ultra-low density polyethylene (ULDPE), medium density polyethylene, polypropylene, isotactic polypropylene, polybutylene, ethylene-propylene copolymers, polymers made using a single-site catalyst, ethylene maleic anhydride copolymers (EMAs), ethylene vinyl acetate copolymers (EVAs) such as those available under the trade designation ELVAX from E. I. DuPont de Nemours, Inc. (Wilmington, Del.), polymers made using Zeigler-Natta catalysts, styrene-containing block copolymers, ethylene acrylic acid copolymers, ethylene methacrylic acid copolymers such as those available under the trade designation SURLYN 1702 from E.I. DuPont de Nemours, Inc., polymethylmethacrylate, polystyrene, ethylene vinyl alcohol, and/or the like, and combinations thereof.
Methods for manufacturing LDPE are described in The Wiley Encyclopedia of Packaging Technology, pp. 753-754 (Aaron L. Brody et al. eds., 2nd Ed. 1997) and in U.S. Pat. No. 5,399,426, both of which are incorporated by reference herein, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
ULDPE may be produced by a variety of processes, including but not limited to gas phase, solution and slurry polymerization as described in The Wiley Encyclopedia of Packaging Technology, pp. 748-50 (Aaron L. Brody et al. eds., 2nd Ed. 1997), incorporated by reference above, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
ULDPE may be manufactured using a Ziegler-Natta catalyst, although a number of other catalysts may also be used. For example, ULDPE may be manufactured with a metallocene catalyst. Alternatively, ULDPE may be manufactured with a catalyst that is a hybrid of a metallocene catalyst and a Ziegler-Natta catalyst. Methods for manufacturing ULDPE are also described in U.S. Pat. No. 5,399,426, U.S. Pat. No. 4,668,752, U.S. Pat. No. 3,058,963, U.S. Pat. No. 2,905,645, U.S. Pat. No. 2,862,917, and U.S. Pat. No. 2,699,457, each of which is incorporated by reference herein in its entirety, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail. The density of ULDPE is achieved by copolymerizing ethylene with a sufficient amount of one or more monomers. In illustrative embodiments, the monomers are selected from 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene, and combinations thereof. Methods for manufacturing polypropylene are described in Kirk-Othmer Concise Encyclopedia of Chemical Technology, pp. 1420-1421 (Jacqueline I. Kroschwitz et al. eds., 4th Ed. 1999), which is incorporated herein by reference, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
In illustrative embodiments, a polyolefin for use in accordance with the present disclosure includes polyethylene, polypropylene, or a combination thereof. In one example, the polyethylene includes linear low density polyethylene which, in some embodiments, includes a metallocene polyethylene. In another example, the polyethylene includes a combination of linear low density polyethylene and low density polyethylene. In a further example, the polyolefin consists essentially of only linear low density polyethylene.
Representative non-styrene block copolymers (elastomers or plastomers) suitable for use in accordance with the present disclosure include but are not limited to ethylene copolymers. Representative ethylene copolymers include but are not limited to ethylene vinyl acetates; ethylene octane; ethylene butane; ethylene/propylene copolymer or propylene copolymer elastomers, such as those available under the trade designation VISTAMAXX® available from ExxonMobil (Irving, Tex.); ethylene/propylene/diene terpolymer elastomers; metallocene polyolefins, such as polyethylene, poly (1-hexane), copolymers of ethylene and 1-hexene, and poly(1-octene); thermoplastic elastomeric polyurethanes, such as that available under the trade designation MORTHANE PE44-203 polyurethane from Morton International, Inc. (Chicago, Ill.) and the trade designation ESTANE 58237 polyurethane from Noveon Corporation, Inc. (Cleveland, Ohio); polyvinyl ethers; poly-α-olefin-based thermoplastic elastomeric materials, such as those represented by the formula —(CH₂CHR)_xwhere R is an alkyl group containing from about 2 to about 10 carbon atoms; poly-α-olefins based on metallocene catalysis, such as ENGAGE 8200, ethylene/poly-α-olefin copolymer available from Dow Plastics Co. (Midland, Mich.); polybutadienes; polybutylenes; polyisobutylenes such as VISTANEX NM L-80, available from Exxon Chemical Co.; polyether block amides such as PEBAX available from Elf Atochem North America, Inc. (Philadelphia, Pa.); and/or the like; and combinations thereof.
Thermoplastic elastomeric materials, in particular block copolymers, useful in accordance with the present disclosure include but are not limited to linear, radial, star, and tapered block copolymers, such as styrene block copolymers. Representative styrene block copolymers for use in accordance with the present disclosure include but are not limited to KRATON® or KRATON®-based styrene block copolymers available from Kraton Polymers, Inc. (Houston, Tex.), styrene-isoprene block copolymers, styrene-(ethylene-butylene) block copolymers, styrene-(ethylene-propylene) block copolymers, styrene-butadiene block copolymers, and/or the like, and combinations thereof. In some embodiments, thermoplastic elastomeric materials in accordance with the present disclosure include polyether esters such as those available under the trade designation HYTREL G3548 from E.I. DuPont de Nemours, and/or polyether block amides such as those available under the trade designation PEBAX from Elf Atochem.
Additional thermoplastic materials which may be used in accordance with the present disclosure include but are not limited to polyesters including amorphous polyester, polyamides, fluorinated thermoplastics such as polyvinylidene fluoride; halogenated thermoplastics such as chlorinated polyethylene, polyether-block-amides such as those available under the trade designation PEBAX 5533 from Elf-Atochem, and/or the like, and combinations thereof.
A precursor film containing a thermoplastic polymer that is stretched, relaxed, and apertured to form an apertured elastic film 2 in accordance with the present disclosure may be prepared by mixing together the thermoplastic polymer (or a combination of thermoplastic polymers) and any optional components until blended, heating the mixture, and then extruding the mixture to form a molten web. A suitable film-forming process may be used to form a precursor film en route to forming an apertured elastic film. For example, the precursor film may be manufactured by casting or extrusion using blown-film, co-extrusion, or single-layer extrusion techniques and/or the like. In one example, the precursor film may be wound onto a winder roll for subsequent stretching in accordance with the present disclosure (e.g., following optional ageing of the quenched film to allow for elasticity of the film to increase over time). In another example, the precursor film may be manufactured in-line with a film stretching apparatus such as shown in FIG. 4.
In addition to containing one or more thermoplastic polymers, the precursor film may also contain other optional components to improve the film properties or processing of the film. Representative optional components include but are not limited to anti-oxidants (e.g., added to prevent polymer degradation and/or to reduce the tendency of the film to discolor over time) and processing aids (e.g., added to facilitate extrusion of the precursor film). In one example, the amount of one or more anti-oxidants in the precursor film is less than about 1% by weight of the film and the amount of one or more processing aids is less than about 5% by weight of the film. Additional optional additives include but are not limited to whitening agents (e.g., titanium dioxide), which may be added to increase the opacity of the film. In one example, the amount of one or more whitening agents is less than about 10% by weight of the film. Further optional components include but are not limited to antiblocking agents (e.g., diatomaceous earth) and slip agents (e.g. erucamide a.k.a. erucylamide), which may be added to allow film rolls to unwind properly and to facilitate secondary processing (e.g., diaper making). In one example, the amount of one or more antiblocking agents and/or one or more slip agents is less than about 5% by weight of the film. Further additional optional additives include but are not limited to scents, deodorizers, pigments other than white, noise reducing agents, and/or the like, and combinations thereof. In one example, the amount of one or more scents, deodorizers, pigments other than white, and/or noise reducing agents is less than about 10% by weight of the film.
The type of stretching used to transform a quenched film into an apertured elastic film 2 in accordance with the present disclosure is not restricted. All manner of stretching processes—and combinations of stretching processes are contemplated for use. In illustrative embodiments, the stretching includes MD stretching. In other examples, the stretching may include one or more of CD IMG stretching, MD IMG stretching, cold draw, and/or the like.
In illustrative embodiments, the type of stretching used to transform a quenched film into an apertured elastic film 2 in accordance with the present disclosure includes MD stretching. In addition, in illustrative embodiments, at least a portion of the MD stretching is performed at ambient temperature (i.e., room temperature). In some embodiments, the stretching in the machine direction is in at least a 3:1 draw and, in other embodiments, in at least a 4:1 draw.
In one example, stretching may be achieved via machine direction (MD) orientation by a process analogous to that shown in simplified schematic form in FIG. 4. For example, the film 14 shown in FIG. 4 may be passed between at least two pairs of rollers in the direction of an arrow 15. In this example, first roller 16 and a first nip 20 run at a slower speed (V₁) than the speed (V₂) of a second roller 18 and a second nip 22. The ratio of V₂/V₁determines the degree to which the film 14 is stretched. Since there may be enough drag on the roll surface to prevent slippage, the process may alternatively be run with the nips open. Thus, in the process shown in FIG. 4, the first nip 20 and the second nip 22 are optional.
In illustrative embodiments, a process for making an apertured elastic film 2 in accordance with the present disclosure may be executed as shown in simplified schematic form in FIG. 5. The process includes extruding a composition containing a thermoplastic polymer 4 from a die 60 to form a molten web. The molten web is cast against a surface of a chill roll 64 under negative pressure from a vacuum box 62 to form a quenched film 66. The quenched film 66 is stretched by MD stretching from a series of rollers moving at different speeds (e.g., machine direction stretching) at an MD stretching station 68, and subsequently relaxed at an MD relaxation station 70. The MD-relaxed film exiting MD relaxing station 70 receives subsequent perforating at a slitting station 74 to form an apertured elastic film 2 in accordance with the present disclosure. The apertured elastic film 2 exiting the slitting station 72 in the direction 74 may be sent for winding.
In the MD stretching station 68, the elastic co-extrusion is stretched in a series of three closely spaced rolls with nips. In illustrative embodiments, the film is stretched 100% (2:1) between the first and second roll and an additional 100% (2:1) between the second and third roll. Thus, the total stretch is 4:1 (2×2).
In the relaxing station 70, the speed of downstream rolls is reduced to allow the web to nearly relax and be wound up. Somewhere within the area of relaxation, the perforation may be implemented via the slitting station 74.
As shown in FIG. 5, the extruding, the casting, the stretching, the relaxing, and the perforating are all achieved via in-line processing. However, this is not required. In some embodiments, it may be beneficial to perform the stretching in an out-of-line operation. The reason is that some elastic materials may need extra time after extrusion to achieve their full elastic potential. As a result, any break issues or downtime may be less costly in an out-of-line operation. Therefore, in some embodiments, it may be advantageous to age the quenched film to form an aged film prior to performing the stretching. For example, some elastomeric materials (e.g., polypropylene-based elastomers such as those sold under the trade designation VISTAMAXX) may require additional time to crystallize in order to achieve optimum elasticity. For such materials, the aged film has increased elasticity relative to the quenched film, and better results may be obtained when stretching is performed on the aged film.
In some embodiments, the extruding and the casting are achieved via in-line processing, and one or more of the stretching, the relaxing, and the perforating is achieved via post-processing of the quenched film. In other embodiments, at least the extruding, the casting, and the stretching are achieved via in-line processing. In further embodiments, at least the extruding, the casting, the stretching, and the relaxing are achieved via in-line processing. In additional embodiments, each of the extruding, the casting, the stretching, the relaxing, and the perforating is achieved via in-line processing.
In illustrative embodiments, perforating is performed in a machine direction. Perforation of a relaxed film in accordance with the present disclosure may be achieved by a wide array of physical processes, including but not limited to those described in U.S. Patent Application Publication Nos. 2005/0158513 A1 and 2007/0237924 A1. The entire contents of both of these documents are hereby incorporated herein by reference, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
For elastic films that are to be perforated in a relaxed state and subsequently subjected (e.g., by an end user) to post-stretching ranging from about 2:1 to about 2.5:1, a wide array of perforation techniques may be implemented in accordance with the present disclosure. By way of example, a score cutting assembly with gaps between the cutting teeth may be used, and blades or other perforating surfaces may be mounted side by side for cutting against a hardened steel cutting roll. Alternatively, die cutting may be used to form slits aligned nearly with the machine direction In other embodiments, perforation techniques including but not limited to hot needles, water jets, laser perforation, and/or the like, and combinations thereof may be used.
Prior to stretching, the precursor film may have an initial basis weight of less than about 100 grams per square meter (gsm). In one example, the precursor film has an initial basis weight of less than about 75 gsm. The precursor film may be a monolayer film, in which case the entire precursor film comprises the thermoplastic polymer (or combination of thermoplastic polymers). In another example, the precursor film may be a multilayer film as suggested in FIG. 1.
In illustrative embodiments, as noted above, an apertured elastic film 2 prepared in accordance with the present disclosure (e.g., by using a vacuum box and/or air knife to cast a molten web containing a thermoplastic polymer (e.g., an elastomer) against a chill roll) may have reduced basis weight as compared to conventional apertured elastic films.
The basis weight of an apertured elastic film 2 in accordance with the present disclosure may be varied based on a desired end use (e.g., the desired properties and/or applications of the apertured elastic film). In one example, the basis weight ranges from about 5 gsm to about 30 gsm. In another example, the basis weight ranges from about 6 gsm to about 25 gsm. In some examples, the basis weight is less than about 50 gsm and, in illustrative embodiments, less than about 45 gsm, 40 gsm, 35 gsm, 30 gsm, 25 gsm, or 20 gsm. In illustrative embodiments, the basis weight is between about 20 gsm and about 30 gsm. Although basis weights outside this range may also be employed (e.g., basis weights above about 30 gsm), lower basis weights minimize material cost as well as maximize consumer satisfaction (e.g., a thinner film may provide increased comfort to the user of a personal hygiene product that includes the film). The basis weight of an apertured elastic film 2 in accordance with the present disclosure may be one of several different values or fall within one of several different ranges. For example, it is within the scope of the present disclosure to select a basis weight to be one of the following values: about 30 gsm, 29 gsm, 28 gsm, 27 gsm, 26 gsm, 25 gsm, 24 gsm, 23 gsm, 22 gsm, 21 gsm, 20 gsm, 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, 8 gsm, 7 gsm, 6 gsm, or 5 gsm.
It is also within the scope of the present disclosure for the basis weight of the apertured elastic film 2 to fall within one of many different ranges. In a first set of ranges, the basis weight of the apertured elastic film 2 is in one of the following ranges: about 5 gsm to 30 gsm, 6 gsm to 30 gsm, 7 gsm to 30 gsm, 8 gsm to 30 gsm, 9 gsm to 30 gsm, 10 gsm to 30 gsm, 11 gsm to 30 gsm, 12 gsm to 30 gsm, 13 gsm to 30 gsm, and 14 gsm to 30 gsm. In a second set of ranges, the basis weight of the apertured elastic film is in one of the following ranges: about 5 gsm to 29 gsm, 5 gsm to 28 gsm, 5 gsm to 27 gsm, 5 gsm to 26 gsm, 5 gsm to 25 gsm, 5 gsm to 24 gsm, 5 gsm to 23 gsm, 5 gsm to 22 gsm, 5 gsm to 21 gsm, 5 gsm to 20 gsm, 5 gsm to 19 gsm, 5 gsm to 18 gsm, 5 gsm to 17 gsm, 5 gsm to 16 gsm, 5 gsm to 15 gsm, 5 gsm to 14 gsm, 5 gsm to 13 gsm, 5 gsm to 12 gsm, 5 gsm to 11 gsm, 5 gsm to 10 gsm, 5 gsm to 9 gsm, 5 gsm to 8 gsm, and 5 gsm to 7 gsm. In a third set of ranges, the basis weight of the apertured elastic film 2 is in one of the following ranges: about 6 gsm to 29 gsm, 7 gsm to 29 gsm, 7 gsm to 28 gsm, 7 gsm to 27 gsm, 7 gsm to 26 gsm, 7 gsm to 25 gsm, 7 gsm to 24 gsm, 7 gsm to 23 gsm, 7 gsm to 22 gsm, 7 gsm to 21 gsm, 7 gsm to 20 gsm, 7 gsm to 19 gsm, 7 gsm to 18 gsm, 7 gsm to 17 gsm, 7 gsm to 16 gsm, 7 gsm to 15 gsm, 7 gsm to 14 gsm, and 7 gsm to 13 gsm.
In illustrative embodiments, an apertured elastic film 2 in accordance with the present disclosure exhibits a notched elongation to break that is equal to or greater than a notched elongation to break of a comparative apertured elastic film prepared without the pre-stretching. The basis weight of an apertured elastic film 2 in accordance with the present disclosure may be varied based on a desired notched elongation to break. In one example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of about 30 gsm and a notched elongation to break of at least about 50%. In another example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of about 30 gsm and a notched elongation to break of at least about 60%. In a further example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a notched elongation to break of at least about 70%. In a further example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a notched elongation to break of at least about 70%. In a further example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a notched elongation to break of at least about 80%. In a further example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a notched elongation to break of at least about 90%. In a further example, an apertured elastic film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a notched elongation to break of at least about 100%.
The notched elongation to break of an apertured elastic film 2 in accordance with the present disclosure may be one of several different values or fall within one of several different ranges. For example, for an apertured elastic film having a basis weight of less than or equal to about 30 gsm—in some embodiments, less than or equal to about 25 gsm or 20 gsm—it is within the scope of the present disclosure to select a notched elongation to break to be greater than or equal to one of the following values: about 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 100%, 101%, 102%, 103%, 104%, 105%, 106%, 107%, 108%, 109%, 110%, 111%, 112%, 113%, 114%, 115%, 116%, 117%, 118%, 119%, 120%, 121%, 122%, 123%, 124%, or 125%.
It is also within the scope of the present disclosure for the notched elongation to break of the apertured elastic film 2 to fall within one of many different ranges. In a first set of ranges, the notched elongation to break for an apertured elastic film having a basis weight of less than or equal to about 30 gsm—in some embodiments, less than or equal to about 25 gsm or 20 gsm—is in one of the following ranges: about 65% to 150%, 65% to 145%, 65% to 140%, 65% to 135%, 65% to 130%, 65% to 125%, 65% to 120%, 65% to 115%, 65% to 110%, 65% to 105%, 65% to 100%, 65% to 95%, 65% to 90%, 65% to 85%, 65% to 80%, and 65% to 75%. In a second set of ranges, the notched elongation to break for an apertured elastic film 2 having a basis weight of less than or equal to about 30 gsm—in some embodiments, less than or equal to about 25 gsm or 20 gsm—is in one of the following ranges: about 66% to 150%, 67% to 150%, 68% to 150%, 69% to 150%, 70% to 150%, 71% to 150%, 72% to 150%, 73% to 150%, 74% to 150%, 75% to 150%, 76% to 150%, 77% to 150%, 78% to 150%, 79% to 150%, 80% to 150%, 81% to 150%, 82% to 150%, 83% to 150%, 84% to 150%, 85% to 150%, 86% to 150%, 87% to 150%, 88% to 150%, 89% to 150%, 90% to 150%, 91% to 150%, 92% to 150%, 93% to 150%, 94% to 150%, 95% to 150%, 96% to 150%, 97% to 150%, 98% to 150%, 99% to 150%, 100% to 150%, 101% to 150%, 102% to 150%, 103% to 150%, 104% to 150%, 105% to 150%, 106% to 150%, 107% to 150%, 108% to 150%, 109% to 150%, 110% to 150%, 111% to 150%, 112% to 150%, 113% to 150%, 114% to 150%, 115% to 150%, 116% to 150%, 117% to 150%, 118% to 150%, 119% to 150%, 120% to 150%, 121% to 150%, 122% to 150%, 123% to 150%, 124% to 150%, and 125% to 150%. In a third set of ranges, the notched elongation to break for an apertured elastic film 2 having a basis weight of less than or equal to about 30 gsm—in some embodiments, less than or equal to about 25 gsm or 20 gsm—is in one of the following ranges: about 60% to 149%, 65% to 145%, 70% to 140%, 75% to 135%, 80% to 135%, 85% to 125%, 90% to 120%, 95% to 115%, 100% to 110%, and 105% to 109%.
In some embodiments, as shown in FIG. 1, the present disclosure provides a multi-layer apertured elastic film 2. In other embodiments, as noted above, the present disclosure provides a monolayer apertured elastic film 2 (i.e., core layer 4 in FIG. 1 without the outer skin layers 6 and 8). In one example, the skin layers may be independently selected from compositions designed to minimize the levels of volatiles building up on the extrusion die. In one example, a pair of skin layers sandwiching a core layer are relatively thin and together account for no more than about 30% of the total film thickness. In some embodiments, the skin layer may be breathable even if perforation is not performed. For example, the skin layer may include one or more discontinuities that are introduced during the stretching process. The likelihood of discontinuities forming in a skin layer may increase as the thickness of the skin layer subjected to stretching decreases.
In one example, a multi-layer apertured elastic films in accordance with the present disclosure may be manufactured by feed block co-extrusion. In another example, a multi-layer apertured elastic films in accordance with the present disclosure may be made by blown film (tubular) co-extrusion. Methods for feed block and blown film extrusion are described in The Wiley Encyclopedia of Packaging Technology, pp. 233-238 (Aaron L. Brody et al. eds., 2nd Ed. 1997), which is incorporated herein by reference, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail. Methods for film extrusion are also described in U.S. Pat. No. 6,265,055, the entire contents of which are likewise incorporated by reference herein, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
In some embodiments, as described above, the present disclosure provides apertured elastic films (e.g., mono-layer or multi-layer). In other embodiments, the present disclosure further provides elastic films that are not apertured but which contain a folded edge that provides tear-resistance to the film.
A non-apertured elastic film 76 comprising an elastomer is shown in FIG. 6. The elastic film 76 includes a core layer 84, a first skin layer 80, and a second skin layer 82. As shown in FIG. 6, at least one edge of the elastic film 76 is folded, thereby providing at least one tear-resistant edge 78 to the elastic film 76. The elastic film has a basis weight of less than or equal to about 30 gsm. Although the elastic film 76 is shown in FIG. 6 as being multi-layer, a monolayer elastic film (not shown) may likewise contain a folded edge in accordance with the present disclosure. Moreover, although the elastic film 76 shown in FIG. 6 does not contain any apertures, the elastic film may, in some embodiments, be subjected to a perforation process as described above.
The at least one folded edge 78 shown in FIG. 6 may provide one or more benefits to the elastic film 76. By way of example, the at least one folded edge 78 shown in FIG. 6 may provide resistance against web tear-offs. For example, web breaks that occur during stretching in a machine direction typically initiate at one edge of the web and then zip across to the other side. The breaks typically do not start in the center of the web but rather occur when the edge of the film is not smooth but contains small cracks or tears. Thus, the folded edge 78 show in FIG. 6 faces inward and is protected since the most significant MD strain is occurring at the fold. The film 76 will be resistant to tear offs especially if the edges of the film are folded on both sides. Moreover, an elastic film 76 having the tear-resistant edge 78 may be subjected to increased stretching forces if the ends of the film are folded prior to stretching, thereby conferring protection against edge tears to the film. In some embodiments, the total stretch of an elastic film containing a folded edge in accordance with the present disclosure may be about 5:1.
In addition, the at least one folded edge 78 may also provide increased retroactive force, whereby the elastic film 76 may be used as a replacement for the synthetic fibers that are conventionally used in the waistbands of incontinence briefs, such as the fibers sold under the tradename LYCRA by Invista (Wichita, Kans.). For example, by replacing the LYCRA strands that form the “belly panel” of the incontinence pants with an elastic film in accordance with the present disclosure, elastic panels with a much flatter appearance may be generated.
The elastic film 76 shown in FIG. 6 may be prepared, for example, using a stretcher of a type commonly used to elongate and thin out stretch wrap film. A representative type of stretcher that may be used in accordance with the present disclosure is the stretcher available under the trade designation NoEL from Davis-Standard (Pawcatuck, Conn.). For example, as shown in FIG. 7, smooth metal folders 86 located on the sides of the elastic film that running through the stretcher equipment may be used to push against the edges of the film, thereby causing the edges to fold in.
In some embodiments, a multi-layer film in accordance with the present disclosure may contain one or a plurality of apertured elastic film layers analogous to the core layer 4 shown in FIG. 1. In other embodiments, a multi-layer film in accordance with the present disclosure may contain one or a plurality of elastic film layers having a folded edge as shown in FIG. 6. The individual film layers in a multi-layer film structure in accordance with the present disclosure may be monolayers or co-extrusions. Each of the individual apertured elastic film layers or elastic film layers having a folded edge may be placed in any order within the inner layers of the multi-layer film structure. When a plurality of individual apertured elastic film layers or elastic film layers having a folded edge in accordance with the present disclosure is used, the individual layers may differ from each other in thickness and/or type of thermoplastic polymer.
Multi-layer films of a type described above are not limited to any specific kind of film structure. Other film structures may achieve the same or similar result as the three-layer apertured elastic film layer 2 shown in FIG. 1 or the three-layered elastic film layer having a folded edge shown in FIG. 6. Film structure is a function of equipment design and capability. For example, the number of layers in a film depends only on the technology available and the desired end use for the film. Representative examples of film structures that may be implemented in accordance with the present disclosure include but are not limited to the following, wherein “A” represents an apertured elastic film layer or an elastic film layer having a folded edge in accordance with the present disclosure, and “B” represents an additional film layer (which, in some embodiments, is an additional apertured elastic film layer or elastic film layer having a folded edge in accordance with the present disclosure):

A-B-A
A-A-B-A
A-B-A-A
A-A-B-A-A
A-B-A-A-A
A-B-A-B-A
A-B-A-A-A-A-A
A-A-B-A-A-A-A
A-A-A-B-A-A-A
A-B-A-A-A-B-A
A-B-A-A-B-A-A
A-B-A-B-A-A-A
A-B-A-B-A-B-A
A-B-A-A-A-A-A-A
A-A-B-A-A-A-A-A
A-A-A-B-A-A-A-A
A-B-A-A-A-A-B-A.

In the above-described exemplary film structures, each of the elastic film layers A may include two or more elastic film layers in order to better control other film properties, such as the ability to bond to nonwovens. For example, when there are two apertured elastic film layers in one “A” elastic film layer, and when “C” represents the second elastic film layer, some exemplary film structures are as follows:

A-C-B-C-A
A-C-A-C-B-C-A
A-C-B-C-A-C-A
A-C-A-C-B-C-A-C-A
A-C-B-C-A-C-A-C-A
A-C-B-C-A-B-C-A

Additionally, die technology that allows production of multiple layers in a multiplier fashion may be used. For example, an ABA structure may be multiplied from about 10 to about 1000 times. The resulting 10-time multiplied ABA structure may be expressed as follows:

A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A

In some embodiments, as described above, the present disclosure provides apertured elastic films 2 (e.g., mono-layer or multi-layer). In other embodiments, the present disclosure further provides personal hygiene products containing one or more apertured elastic films (e.g., mono-layer or multi-layer) in accordance with the present disclosure.
In illustrative embodiments, as shown in FIG. 8, an apertured elastic film 2 in accordance with the present disclosure may be subjected to additional post-stretching (e.g., by an end user of the film). In the exemplary process shown in FIG. 8, the apertured elastic film 2 may be post-stretched in a machine direction by further MD stretching from a series of additional rollers moving at different speeds. For example, a first roller 90 (1×), a second roller 92 (2×), and a third roller 94 (3×) may be used to post-stretch the film in a machine direction. In some embodiments, the resultant post-stretched film 91 may be ultrasonically bonded to a non-woven material 95 by the ultrasonic bond horn 96.
As shown in FIG. 9, a multi-layer apertured elastic film 100 contains a core layer 108 interposed between a first skin layer 104 and a second skin layer 106, and one or more apertures 110. The apertured elastic film 100 is bonded to a non-woven layer 102 to form a multi-layer structure 98 which, in some embodiments, may be used as a backsheet for a diaper, incontinence brief, and/or the like. The multi-layer structure 98 shown in FIG. 9 may be formed using a process as shown in FIG. 8, whereby an apertured elastic film is attached to a nonwoven material using an ultrasonic bond horn 96. In some embodiments, the non-woven layer 102 and at least the second skin layer 106 to which it is adjacent include the same polyolefin. For example, in some embodiments, the non-woven layer 102, the second skin layer 106, and/or the first skin layer 104 include polypropylene. In some embodiments, the non-woven layer 102, the second skin layer 106, and/or the first skin layer 104 include polypropylene, and the non-woven layer 102 is bonded to the second skin layer 106 by an ultrasonic weld.
In some embodiments, a multi-layer structure in accordance with the present teachings, such as the apertured elastic film 2 shown in FIG. 1 and/or the apertured elastic film 100 shown in FIG. 9, is a co-extrusion with a target layer ratio of about 7.5/85/7.5. In other embodiments, the multi-layer structure is a co-extrusion with a target layer ratio of about 10/80/10. In further embodiments, the multi-layer structure is a co-extrusion with a target layer ratio of about 5/90/5.
In illustrative embodiments, the core layer 4 shown in FIG. 2 and the core layer 108 shown in FIG. 9—either of which may be a single layer or multiple co-extruded layers—contains an elastomer-rich formula. The types of elastomers suitable for use in the core layer 4 and the core layer 108 range from polyolefin to block copolymer. Representative elastomers include but are not limited to the polypropylene elastomer available under the trade designation VISTAMAXX, the polyethylene block copolymer elastomer available under the trade designation INFUSE, and/or a combination thereof. In some embodiments, the core layer 4 and the core layer 108 contain a styrene-ethylene-butylene-styrene (SEBS) polymer.
For some embodiments in which the non-woven material 102 contains polypropylene homopolymer, the first skin layer 104 and/or the second skin layer 106 may contain a blend of about 60% C702-20 and 40% Exceed 3518. In other embodiments, the first skin layer 104 and/or the second skin layer 106 may contain a blend of about 85% 35 MFR polypropylene homopolymer and about 15% of an LDPE, such as Equistar NA334.
For some embodiments in which the non-woven material 102 contains bicomponent polyethylene/polypropylene non-woven material, which is sometimes used for softness, the first skin layer 104 and/or the second skin layer 106 may contain a blend of about 60% C702-20 and about 40% Exceed 3518. In other embodiments, the first skin layer 104 and/or the second skin layer 106 may contain (a) a blend of about 75% Exceed 3518 and about 25% of an LDPE, such as Equistar NA334, or (b) 100% of an HDPE resin.
In illustrative embodiments, a personal hygiene product in accordance with the present disclosure includes at least one inner apertured elastic film 2 prepared by a process as described above and at least one outer non-woven layer. The at least one inner apertured elastic film 2 is configured for contacting skin and/or clothing of a user of the personal hygiene product.
In one example, the at least one inner apertured elastic film is bonded to the at least one outer non-woven layer without an adhesive (e.g., via heat sealing, ultrasonic welding, and/or the like). In some embodiments, each of the at least one inner apertured elastic film 2 and the at least one outer non-woven layer comprises polypropylene and/or polyethylene. In illustrative embodiments, each of the at least one inner apertured elastic film 2 and the at least one outer non-woven layer comprises polypropylene. In illustrative embodiments, the at least one apertured elastic film is bonded to the at least one outer non-woven layer via an ultrasonic bond.
For embodiments in which the apertured elastic film to be ultrasonically bonded to a nonwoven material is a co-extrusion analogous to that shown in FIG. 1, the outer skin layers of the apertured elastic film 2 may include a material that will ultrasonically bond with the non-woven material. For example, if the apertured elastic film 2 shown in FIG. 1 is a co-extrusion with a target layer ratio of about 7.5/85/7.5, at least the outer 7.5% layers and the non-woven material may include a material such as polypropylene.
In illustrative embodiments, the personal hygiene product in accordance with the present disclosure is configured as an incontinence brief, a surgical gown, or a feminine hygiene product.
The following numbered clauses include embodiments that are contemplated and non-limiting:
Clause 1. A process for making an apertured elastic film comprising the steps of
extruding a composition comprising a polyolefin, a styrene block copolymer, a non-styrene block copolymer, or a combination thereof to form a molten web.
Clause 2. The process of clause 1, any other suitable clause, or combination of suitable clauses, further comprising casting the molten web against a surface of a chill roll using an air knife, an air blanket, a vacuum box, or a combination thereof to form a quenched film.
Clause 3. The process of clause 2, any other suitable clause, or combination of suitable clauses, further comprising stretching the quenched film in a machine direction in at least a 2:1 draw to form a stretched film.
Clause 4. The process of clause 3, any other suitable clause, or combination of suitable clauses, further comprising relaxing the stretched film to form a relaxed film.
Clause 5. The process of clause 4, any other suitable clause, or combination of suitable clauses, further comprising perforating the relaxed film to introduce at least one aperture therein.
Clause 6. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises polyethylene, polypropylene, or a combination thereof.
Clause 7. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-low density polyethylene, or a combination thereof.
Clause 8. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises linear low density polyethylene.
Clause 9. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises linear low density polyethylene and the linear low density polyethylene comprises a metallocene polyethylene.
Clause 10. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises polypropylene.
Clause 11. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the polyolefin comprises polypropylene impact copolymer.
Clause 12. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the styrene block copolymer comprises styrene-isoprene block copolymer, styrene-(ethylene-butylene) block copolymer, styrene-(ethylene-propylene) block copolymer, styrene-butadiene block copolymer, or a combination thereof
Clause 13. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the molten web is cast against the surface of the chill roll under negative pressure by the vacuum box.
Clause 14. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the molten web is cast against the surface of the chill roll under positive pressure by the air knife.
Clause 15. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein at least the extruding and the casting are achieved via in-line processing.
Clause 16. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the extruding and the casting are achieved via in-line processing, and wherein one or more of the stretching, the relaxing, and the perforating is achieved via post-processing of the quenched film.
Clause 17. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein at least the extruding, the casting, and the stretching are achieved via in-line processing.
Clause 18. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein at least the extruding, the casting, the stretching, and the relaxing are achieved via in-line processing.
Clause 19. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein each of the extruding, the casting, the stretching, the relaxing, and the perforating is achieved via in-line processing.
Clause 20. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the stretching in the machine direction is in at least a 3:1 draw.
Clause 21. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the stretching in the machine direction is in at least a 4:1 draw.
Clause 22. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein at least a portion of the stretching is performed at room temperature.
Clause 23. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the perforating is performed in a machine direction.
Clause 24. The process of clause 5, any other suitable clause, or combination of suitable clauses, further comprising co-extruding one or a plurality of additional compositions substantially contemporaneously with the extruding of the composition.
Clause 25. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the extruding of the composition forms a first film layer, wherein the process further comprises co-extruding at least a second composition to form at least one second film layer and at least a third composition to form at least one third film layer, the second composition and the third composition being identical or different, wherein the first film layer is disposed between the at least one second film layer and the at least one third film layer.
Clause 26. The process of clause 25, any other suitable clause, or combination of suitable clauses, wherein each of the second composition and the third composition comprises a polyolefin, wherein the first film layer is a core layer, and wherein each of the at least one second film layer and the at least one third film layer is an outer skin layer.
Clause 27. The process of clause 25, any other suitable clause, or combination of suitable clauses, wherein each of the second composition and the third composition comprises a polyolefin, and wherein the polyolefin is polyethylene, polypropylene, or a combination thereof.
Clause 28. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 50 gsm.
Clause 29. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 40 gsm.
Clause 30. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 30 gsm.
Clause 31. The process of clause 5, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 20 gsm.
Clause 32. A process for making an apertured elastic film comprising the steps of
extruding a composition comprising an elastomer to form a molten web.
Clause 33. The process of clause 32, any other suitable clause, or combination of suitable clauses, further comprising quenching the molten web to form a quenched film.
Clause 34. The process of clause 33, any other suitable clause, or combination of suitable clauses, further comprising ageing the quenched film to form an aged film.
Clause 35. The process of clause 34, any other suitable clause, or combination of suitable clauses, wherein the aged film has an increased elasticity relative to the quenched film.
Clause 36. The process of clause 35, any other suitable clause, or combination of suitable clauses, further comprising stretching the aged film in a machine direction in at least a 2:1 draw to form a stretched film.
Clause 37. The process of clause 36, any other suitable clause, or combination of suitable clauses, further comprising relaxing the stretched film to form a relaxed film.
Clause 38. The process of clause 37, any other suitable clause, or combination of suitable clauses, further comprising perforating the relaxed film to introduce at least one aperture therein.
Clause 39. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the elastomer comprises a polyolefin, a non-styrene block co-polymer, a styrene block copolymer, or a combination thereof.
Clause 40. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the elastomer comprises an ethylene copolymer, an ethylene/propylene copolymer, a propylene copolymer, an ethylene/propylene/diene terpolymer, a metallocene polyolefin, or a combination thereof.
Clause 41. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the elastomer comprises a polypropylene copolymer.
Clause 42. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the extruding and the quenching are achieved via a first in-line process, and wherein one or more of the stretching, the relaxing, and the perforating is achieved via a second in-line process.
Clause 43. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the stretching in the machine direction is in at least a 3:1 draw.
Clause 44. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the stretching in the machine direction is in at least a 4:1 draw.
Clause 45. The process of clause 38, any other suitable clause, or combination of suitable clauses, wherein the perforating is performed in a machine direction.
Clause 46. An apertured elastic film comprising
a polyolefin, a styrene block copolymer, a non-styrene block copolymer, or a combination thereof.
Clause 47. The apertured elastic film of clause 46, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film is prepared by a process comprising stretching a quenched film in a machine direction in at least a 2:1 draw to form a stretched film, relaxing the stretched film to form a relaxed film, and perforating the relaxed film to introduce at least one aperture therein.
Clause 48. The apertured elastic film of clause 47, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 30 gsm.
Clause 49. The aperture elastic film of clause 48, any other suitable clause, or combination of suitable clauses, wherein a notched elongation to break of the apertured elastic film is equal to or greater than a notched elongation to break of a comparative apertured elastic film prepared without the stretching.
Clause 50. The apertured elastic film of clause 49, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 25 gsm.
Clause 51. The apertured elastic film of clause 49, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 20 gsm.
Clause 52. The apertured elastic film of clause 49, any other suitable clause, or combination of suitable clauses, wherein the film has a multi-layer structure comprising at least one core film layer interposed between at least a first skin layer and at least a second skin layer.
Clause 53. The apertured elastic film of clause 52, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 7.5/85/7.5.
Clause 54. The apertured elastic film of clause 52, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 10/80/10.
Clause 55. The apertured elastic film of clause 52, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 5/90/5.
Clause 56. An apertured elastic film comprising
an elastomer.
Clause 57. The apertured elastic film of clause 56, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film comprises at least one slit that extends from a top surface of the film through to a bottom surface of the film.
Clause 58. The apertured elastic film of clause 57, any other suitable clause, or combination of suitable clauses, wherein at least one edge of the apertured elastic film is folded, thereby providing at least one tear-resistant edge to the apertured elastic film.
Clause 59. The apertured elastic film of clause 58, any other suitable clause, or combination of suitable clauses, wherein the apertured elastic film has a basis weight of less than or equal to about 30 gsm.
Clause 60. The apertured elastic film of clause 59, any other suitable clause, or combination of suitable clauses, wherein the film has a multi-layer structure comprising at least one core film layer interposed between at least a first skin layer and at least a second skin layer.
Clause 61. The apertured elastic film of clause 60, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 7.5/85/7.5.
Clause 62. The apertured elastic film of clause 60, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 10/80/10.
Clause 63. The apertured elastic film of clause 60, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 5/90/5.
Clause 64. The apertured elastic film of clause 59, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 25 gsm.
Clause 65. The apertured elastic film of clause 60, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 20 gsm.
Clause 66. An elastic film comprising
an elastomer,
wherein at least one edge of the elastic film is folded, thereby providing at least one tear-resistant edge to the elastic film.
Clause 67. The elastic film of clause 66, any other suitable clause, or combination of suitable clauses, wherein the elastic film has a basis weight of less than or equal to about 30 gsm.
Clause 68. The elastic film of clause 67, any other suitable clause, or combination of suitable clauses, wherein the film has a multi-layer structure comprising at least one core film layer interposed between at least a first skin layer and at least a second skin layer.
Clause 69. The elastic film of clause 68, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 7.5/85/7.5.
Clause 70. The elastic film of clause 68, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 10/80/10.
Clause 71. The elastic film of clause 68, any other suitable clause, or combination of suitable clauses, wherein the multi-layer structure has a layer ratio of about 5/90/5.
Clause 72. The elastic film of clause 68, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 25 gsm.
Clause 73. The elastic film of clause 68, any other suitable clause, or combination of suitable clauses, wherein the basis weight is less than or equal to about 20 gsm.
Clause 74. A personal hygiene product comprising
at least one apertured elastic film prepared by the process of clause 5, any other suitable clause, or combination of suitable clauses, the at least one apertured elastic film being configured for contacting skin and/or clothing of a user of the personal hygiene product, and
at least one outer non-woven layer.
Clause 75. The personal hygiene product of clause 74, any other suitable clause, or combination of suitable clauses, wherein the at least one apertured elastic film is bonded to the at least one outer non-woven layer without an adhesive.
Clause 76. The personal hygiene product of clause 74, any other suitable clause, or combination of suitable clauses, wherein each of the at least one apertured elastic film and the at least one outer non-woven layer comprises polypropylene.
Clause 77. The personal hygiene product of clause 74, any other suitable clause, or combination of suitable clauses, wherein the product is configured as an incontinence brief.
Clause 78. The personal hygiene product of clause 74, any other suitable clause, or combination of suitable clauses, wherein the product is configured as a feminine hygiene product.
Clause 79. The personal hygiene product of clause 74, any other suitable clause, or combination of suitable clauses, wherein the at least one apertured elastic film is bonded to the at least one outer non-woven layer via an ultrasonic bond.
The following examples and representative procedures illustrate features in accordance with the present disclosure, and are provided solely by way of illustration. They are not intended to limit the scope of the appended claims or their equivalents.

EXAMPLES

General

For production of the example films, an extrusion cast line with up to 3 extruders was used. The “A” and “B” extruders are 2½ in diameter, and the “C” extruder is 1¾ in diameter. The extruders feed into a combining feedblock manufactured by Cloeren Corporation of Orange, Tex., which can layer the A, B and C extruder outputs in a variety of configurations. From the feedblock, the molten polymer proceeds into a monolayer cast die (manufactured by Cloeren) that is about 36″ wide. The die has an adjustable gap. For the samples described herein, the adjustable gap was maintained between 10 and 40 mils. The molten polymer drops down to a chill roll. For the samples described herein, the chill roll had an embossed pattern FST-250 which was engraved by Pamarco of Roselle, N.J. as their pattern P-2739. The embossed pattern P-2739 is a square pattern (e.g., with lines nearly aligned with the Machine Direction) with 250 squares per inch and a depth of about 31 microns. The roll itself has an 18″ diameter with internal water cooling. The engrave roll pattern may be replaced with other patterns that are shallow enough not to interfere with a vacuum box quench. One alternative is a 40 Ra pattern (40 micro-inch average roughness) generated by a sand-blasting process on a chrome plated roll.

Example 1

Polypropylene-Based Elastic Films

In this experiment, elastic films were made from the formulation XC3-828-2358.0 shown in Table 1, the formulation XC3-828-2358.1 shown in Table 2, the formulation XC3-828-2358.5 shown in Table 3, and the formulation XC3-828-2358.6 shown in Table 4.

TABLE 1

Composition of XC3-828-2358.0.

			Amount of
	Layer %		Component
EXTRUDER	(Total)	COMPONENT	(Weight %)

B	85.0	INFUSE ™ 9107	100
		(Dow Chemical
		Company, olefin block
		copolymer
C	7.5/7.5	CP360	60
(split)		(Braskem, homopolymer
		polypropylene, narrow
		MWD)
		PETROTHENE ®	40
		NA334000
		(LyondellBasell, low
		density polyethylene)

TABLE 2

Composition of XC3-828-2358.1.

			Amount of
	Layer %		Component
EXTRUDER	(Total)	COMPONENT	(Weight %)

B	85.0	INFUSE ™ 9507	100
		(Dow Chemical
		Company, olefin block
		copolymer)
C	7.5/7.5	C702-20	60
(split)		(Braskem, impact
		copolymer
		polypropylene)
		EXCEED LL3518	40
		(ExxonMobil,
		metallocene
		polyethylene resin,
		narrow MWD, density =
		0.918 g/cm³)

TABLE 3

Composition of XC3-828-2358.5.

			Amount of
	Layer %		Component
EXTRUDER	(Total)	COMPONENT	(Weight %)

B	85.0	VISTAMAXX ™ 6102	100
		(ExxonMobil,
		propylene-based
		elastomer
C	7.5/7.5	C702-20	60
(split)		(Braskem, impact
		copolymer
		polypropylene)
		EXCEED LL3518	40
		(ExxonMobil,
		metallocene
		polyethylene resin,
		narrow MWD, density =
		0.918 g/cm³)

TABLE 4

Composition of XC3-828-2358.6

			Amount of
	Layer %		Component
EXTRUDER	(Total)	COMPONENT	(Weight %)

B	85.0	VISTAMAXX ™ 6102	91.70
		(ExxonMobil,
		propylene-based
		elastomer
		C702-20	5.00
		(Braskem, Impact
		Copolymer
		Polypropylene)
		EXCEED LL3518	3.30
		(ExxonMobil,
		metallocene
		polyethylene resin,
		narrow MWD, density =
		0.918 g/cm³)
C	7.5/7.5	C702-20	60
(split)		(Braskem, Impact
		Copolymer
		Polypropylene)
		EXCEED LL3518	40
		(ExxonMobil,
		metallocene
		polyethylene resin,
		narrow MWD, density =
		0.918 g/cm³)

Example 2

Notched Tensile Test Data

Tensile strength of notched films prepared from the formulation XC3-828-2358.0 shown in Table 1, the formulation XC3-828-2358.1 shown in Table 2, the formulation XC3-828-2358.5 shown in Table 3, and the formulation XC3-828-2358.6 shown in Table 4 were evaluated using the Standard Tensile Test (ASTM D882). A rectangular sample one-inch wide was placed in Tensile tester grips that were two inches apart. A one-eighth-inch notch was made at the midpoint on one side of each of the film samples. In the test, the upper jaw moves at 20 inches per minute and proceeds until the sample breaks.
The tensile test data for films prepared from formulation XC3-828-2358.0 are summarized in Table 5 below.
The tensile test data for films prepared from formulation XC3-828-2358.1 are summarized in Table 6 below.
The tensile test data for films prepared from formulation XC3-828-2358.5 are summarized in Table 7 below.
The tensile test data for films prepared from formulation XC3-828-2358.6 are summarized in Table 8 below.

TABLE 5

Tensile test data for films prepared from formulation XC3-828-2358.0.

		MD		MD
		Tensile		Tensile		Prestretch		Prestretched MD
Properties	Elong. %	Std.	Elong. %	Notched	Elong. %	MD Tensile	Elong. %	Tensile Notched

Gauge		1.38		1.39		1.38		1.38
(mils)
MD5	5	762	5	102	5	661	5	29
MD10	10	780	10	252	10	768	10	62
MD25	25	840	25	301	25	1026	25	111
MD50	50	954	50	311	50	1451	50	163
MD100	100	1231	100	270	100	2594	100	336
Force at Peak	350	3204	57	312	131	3326	96	344
(grams/inch)
Force at Break	351	3193	91	282	131	3313	105	314
(grams/inch)
Total Energy		2165		69		706		53
Absorbed
(ft-lb/in²)

	No
REDUCTION BY NOTCH	Prestretch	Prestretch

Peak Elongation

84%		27%
Break Elongation
74%		20%
Total Energy	97%		92%

TABLE 6

Tensile test data for films prepared from formulation XC3-828-2358.1.

Gauge		1.35		1.35		1.35		1.35
(mils)
MD5	5	309	5	134	5	160	5	23
MD10	10	312	10	188	10	190	10	44
MD25	25	324	25	237	25	290	25	75
MD50	50	346	50	247	50	446	50	108
MD100	100	401	100	255	100	818	100
Force at Peak	519	1343	159	277	154	1174	96	242
(grams/inch)
Force at Break	520	1237	184	251	154	1174	101	238
(grams/inch)
Total Energy		1197		124		290		35
Absorbed
(ft-lb/in²)

	No
REDUCTION BY NOTCH	Prestretch	Prestretch

TABLE 7

Tensile test data for films prepared from formulation XC3-828-2358.5.

Gauge		1.3		1.3		1.3		1.3
(mils)
MD5	5	805	5	125	5	800	5	29
MD10	10	823	10	187	10	890	10	59
MD25	25	876	25	258	25	1104	25	99
MD50	50	978	50	282	50	1448	50	139
MD100	100	1228	100	247	100	2360	100	248
Force at Peak	302	2801	78	292	132	3088	93	264
(grams/inch)
Force at Break	302	2801	99	269	133	2968	102	239
(grams/inch)
Total Energy		1850		72		758		43
Absorbed
(ft-lb/in²)

	No
REDUCTION BY NOTCH	Prestretch	Prestretch

Peak Elongation

74%		30%
Break Elongation	67%		23%
Total Energy
96%		94%

TABLE 8

Tensile test data for films prepared from formulation XC3-828-2358.6.

Gauge		1.35		1.35		1.35		1.35
(mils)
MD5	5	1200	5	179	5	961	5	38
MD10	10	1230	10	258	10	1113	10	77
MD25	25	1332	25	359	25	1586	25	147
MD50	50	1524	50	404	50	2278	50	241
MD100	100	1981	100	245	100		100
Force at Peak	224	3777	59	407	107	4517	79	369
(grams/inch)
Force at Break	224	3777	59	369	107	4363	88	334
(grams/inch)
Total Energy		1986		77		827		52
Absorbed
(ft-lb/in²)

	No
REDUCTION BY NOTCH	Prestretch	Prestretch

Peak Elongation

	74%		26%
	Break Elongation
	74%		18%
	Total Energy
	96%		94%

The physical properties of the resultant films prepared from formulations XC3-828-2358.0, XC3-828-2358.1, XC3-828-2358.5, and XC3-828-2358.6 are shown in Table 9 below. All of the films had a 7.5/85/7.5 A/B/A layering.

TABLE 9

Physical Properties of Elastic Films Prepared
from Formulations XC3-828-2358.0, XC3-828-2358.1,
XC3-828-2358.5, and XC3-828-2358.6.

		XC3-828-	XC3-828-	XC3-828-	XC3-828-
Properties	Units	2358.0	2358.1	2358.5	2358.6

Basis Weight	g/m²	30	30	29	29
Tensile	mil	1.34	1.39	1.26	1.37
Gauge MD
Force @ Peak	g/in	3,573	1,318	2,467	4,171
MD
Strain @ Peak	%	776	679	649	626
MD
Force @ Break	g/in	3,566	1,315	2,464	4,166
MD
Strain @ Break	%	776	679	649	626
MD
Force @ Yield	g/in	241	234	175	237
MD
Strain @ Yield	%	11	16	11	11
MD
Force @ 5%	g/in	152	122	95	130
Strain MD
Force @ 10%	g/in	231	193	165	228
Strain MD
Force @ 25%	g/in	296	258	243	338
Strain MD
Force @ 50%	g/in	312	265	268	393
Strain MD
Force @ 100%	g/in	336	274	295	441
Strain MD
TEA MD	FtLb/	2,561	1,095	1,640	2,284
	in²
Elmendorf Tear	g	400	200	200	200
MD Arm
††††Elmendorf	gf	161	135	152	110
Tear MD
Tensile Gauge	mil	1.36	1.33	1.30	1.29
TD
Force @ Peak	g/in	815	503	2,148	2,050
TD
Strain @ Peak	%	818	757	994	957
TD
Force @ Break	g/in	815	503	2,148	2,048
TD
Strain @ Break	%	817	759	994	957
TD
Force @ Yield	g/in	269	192	190	249
TD
Strain @ Yield	%	18	19	15	17
TD
Force @ 5%	g/in	151	99	97	116
Strain TD
Force @ 10%	g/in	231	161	158	199
Strain TD
Force @ 25%	g/in	277	197	220	276
Strain TD
Force @ 50%	g/in	280	202	242	296
Strain TD
Force @ 100%	g/in	280	206	253	303
Strain TD
TEA TD	FtLb/	995	636	1,993	2,045
	in²
Elmendorf Tear	g	1,600	800	800	800
TD Arm
Elmendorf Tear	gf	458	306	200	265
TD
§ Slow	gf	1,071	864	973	—
Puncture -
¼″ (D3)
§ Slow	gf	535
Puncture -
⅛″ —
CD 100%
Hysteresis
1st Cycle Load	gf	290	216	399	339
at Peak
1st Cycle Load	gf	288	213	377	334
at 50%
1st Cycle	gf	22	18	42	45
Unload at 50%
Extension Set,	inches	0.253	0.259	0.089	0.156
second load
	%	12.65	12.95	4.45	7.8
second unload	inches	0.492	0.515	0.383	0.377
	%	24.6	25.75	19.15	18.85

Films prepared from the formulations XC3-828-2358.0, XC3-828-2358.1, XC3-828-2358.5, and XC3-828-2358.6 were subjected to machine direction prestretching. The MD 100% hysteresis testing data are summarized in Table 10 below.

TABLE 10

MD 100% Hysteresis Testing Data For Films After MD Stretching.

Prestretch - From
1″ to 4″	XC3-828-	XC3-828-	XC3-828-	XC3-828-

	Units	2358.0	2358.1	2358.5	2358.6

Final Length	inches	1.9375	1.708	1.5625	1.79
MD 100%
Hysteresis
1st Cycle Load	gf	402	132	178	422
at Peak
1st Cycle Load	gf	212	84	115	191
at 50%
1st Cycle	gf	56	26	46	53
Unload
at 50%
Extension Set,	inches	0.097	0.063	0.126	0.083
second load
	%	4.85	3.15	6.3	4.15
second unload	inches	0.327	0.424	0.259	0.262
	%	16.35	21.2	12.95	13.1

The MD 100% Hysteresis testing data for the films prepared from the formulations XC3-828-2358.0, XC3-828-2358.1, XC3-828-2358.5, and XC3-828-2358.6 that were not subjected to machine direction prestretching are summarized in Table 11 below.

TABLE 11

MD 100% Hysteresis Testing Data
For Films Without MD Stretching.

MD 100%		XC3-828-	XC3-828-	XC3-828-	XC3-828-
Hysteresis	Units	2358.0	2358.1	2358.5	2358.6

1st Cycle Load	gf	367	274	359	490
at Peak
1st Cycle Load	gf	345	267	327	436
at 50%
1st Cycle	gf		47	25	49	61
Unload at 50%
Extension Set,	inches	0.196	0.216	0.149	0.133
second load
	%	9.8	10.8	7.45	6.65
second unload	inches	0.375	0.465	0.36	0.337
	%	18.75	23.25	18	16.85

Peak Elongation

Break Elongation

Total Energy

1. A process for making an apertured elastic film comprising the

steps of

extruding a composition comprising a polyolefin, a styrene block copolymer, a non-styrene block copolymer, or a combination thereof to form a molten web,

casting the molten web against a surface of a chill roll using an air knife, an air blanket, a vacuum box, or a combination thereof to form a quenched film,

stretching the quenched film in a machine direction in at least a 2:1 draw to form a stretched film,

relaxing the stretched film to form a relaxed film, and

perforating the relaxed film to introduce at least one aperture therein.

2. The process of claim 1, wherein the polyolefin comprises low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-low density polyethylene, or a combination thereof.

3. The process of claim 1, wherein the polyolefin comprises linear low density polyethylene.

4. The process of claim 1, wherein the polyolefin comprises linear low density polyethylene and the linear low density polyethylene comprises a metallocene polyethylene.

5. The process of claim 1, wherein the polyolefin comprises polypropylene.

6. The process of claim 1, wherein the polyolefin comprises polypropylene impact copolymer.

7. The process of claim 1, wherein the styrene block copolymer comprises styrene-isoprene block copolymer, styrene-(ethylene-butylene) block copolymer, styrene-(ethylene-propylene) block copolymer, styrene-butadiene block copolymer, or a combination thereof

8. The process of claim 1, wherein the molten web is cast against the surface of the chill roll under negative pressure by the vacuum box.

9. The process of claim 1, wherein the molten web is cast against the surface of the chill roll under positive pressure by the air knife.

10. The process of claim 1, wherein the extruding and the casting are achieved via in-line processing, and wherein one or more of the stretching, the relaxing, and the perforating is achieved via post-processing of the quenched film.

11. The process of claim 1, wherein each of the extruding, the casting, the stretching, the relaxing, and the perforating is achieved via in-line processing.

12. The process of claim 1, wherein the stretching in the machine direction is in at least a 3:1 draw.

13. The process of claim 1, wherein the stretching in the machine direction is in at least a 4:1 draw.

14. The process of claim 1, wherein at least a portion of the stretching is performed at room temperature.

15. The process of claim 1, wherein the perforating is performed in a machine direction.

16. The process of claim 1, further comprising co-extruding one or a plurality of additional compositions substantially contemporaneously with the extruding of the composition.

17. The process of claim 1, wherein the extruding of the composition forms a first film layer, wherein the process further comprises co-extruding at least a second composition to form at least one second film layer and at least a third composition to form at least one third film layer, the second composition and the third composition being identical or different, wherein the first film layer is disposed between the at least one second film layer and the at least one third film layer.

18. The process of claim 17, wherein each of the second composition and the third composition comprises a polyolefin, wherein the first film layer is a core layer, and wherein each of the at least one second film layer and the at least one third film layer is an outer skin layer.

19. The process of claim 17, wherein each of the second composition and the third composition comprises a polyolefin, and wherein the polyolefin is polyethylene, polypropylene, or a combination thereof.

20. The process of claim 1, wherein the apertured elastic film has a basis weight of less than or equal to about 50 gsm.

21. The process of claim 1, wherein the apertured elastic film has a basis weight of less than or equal to about 30 gsm.

22. The process of claim 1, wherein the apertured elastic film has a basis weight of less than or equal to about 20 gsm.