METHODS OF FORMING COMPOSITE MATERIALS
A method of forming a substantially air-impermeable composite material includes introducing a sheet-form film and a loop material into a nip formed between a first roll and a second roll, introducing molten resin into the nip between the film and the loop material, and allowing the molten resin to cool so that the film becomes attached to the loop material by the cooled resin.
1 . A method of forming a composite material, the method comprising:
introducing a sheet-form film and a hook-engageable material into a nip formed between a first roll and a second roll;
introducing molten resin into the nip between the film and the hook-engageable material; and
allowing the molten resin to cool so that the film becomes attached to the hook-engageable material by the cooled resin,
wherein each of the film, the hook-engageable material, and the molten resin includes at least about 85 percent by weight of a first polymer.
2 . The method of claim 1 , wherein the composite material is substantially air-impermeable.
3 . (canceled)
4 . The method of claim 1 , wherein fibers extending from a surface of the hook-engageable material are capable of engaging hooks of hook fasteners after the film is attached to the hook-engageable material by the cooled resin.
5 . The method of claim 1 , wherein the first polymer is polypropylene.
6 . The method of claim 5 , wherein the film and the hook-engageable material consist essentially of polypropylene.
7 . The method of claim 6 , wherein the molten resin is at least about 90 percent by weight polypropylene.
8 . The method of claim 7 , wherein the molten resin further comprises polyethylene.
9 . The method of claim 1 , wherein the hook-engageable material comprises a 17 grams per square meter spunbond polypropylene substrate through which a plurality of loop shaped staple fibers extend.
10 . The method of claim 1 , wherein the hook-engageable material comprises a 30 grams per square meter SMS polypropylene substrate through which a plurality of loop shaped staple fibers extend.
11 . The method of claim 1 , wherein the molten resin introduced into the nip has a thickness of about one mil, the film has a thickness of about three mils, and the hook-engageable material has a weight of about 1.3 to about 2.0 osy.
12 . (canceled)
13 . The method of claim 1 , wherein the molten resin is at a temperature of at least about 500 degrees Fahrenheit when introduced into the nip.
14 - 15 . (canceled)
16 . The method of claim 1 , wherein the film is a cast film.
17 . The method of claim 1 , wherein the molten resin is introduced into the nip in a manner such that the molten resin contacts the film and the hook-engageable material at substantially the same time.
18 . The method of claim 1 , wherein the molten resin is introduced into the nip by applying the molten resin to the hook-engageable material and rotating the first and second rolls to carry the film, the hook-engageable material, and the molten resin into the nip.
19 . The method of claim 1 , wherein the molten resin is introduced into the nip by applying the molten resin to the film and rotating the first and second rolls to carry the film, the hook-engageable material, and the molten resin into the nip.
20 . The method of claim 1 , wherein at least one of the first and second rolls is chilled to facilitate cooling of the molten resin.
21 . (canceled)
22 . The method of claim 1 , further comprising embossing the composite material.
23 . The method of claim 22 , wherein embossing the composite material comprises passing the composite material between an embossing roll and a backing roll, the embossing roll have a plurality of raised features that compress the composite material between the embossing roll and the backing roll.
24 . The method of claim 23 , wherein the embossing roll is a heated roll.
25 . A method of forming a composite material, the method comprising:
introducing a sheet-form film and a hook-engageable material into a nip formed between a first roll and a second roll;
introducing molten resin into the nip between the film and the hook-engageable material; and
allowing the molten resin to cool so that the film becomes attached to the hook-engageable material by the cooled resin,
wherein each of the film, the hook-engageable material, and the molten resin includes at least about 90 percent by weight of a first polymer, the composite material is substantially air-impermeable, and fibers extending from a surface of the hook-engageable material are capable of engaging hooks of hook fasteners after the film is attached to the hook-engageable material by the cooled resin.