阅读说明：本技术 具有低力延伸度图案的膜和袋 (Film and bag having low force extensibility pattern ) 是由 E·B·塔克 R·T·多尔西 M·G·博哈特 朱然一 杰尔科·维多维克 于 2018-11-02 设计创作，主要内容包括：披露了一种热塑性膜,所述热塑性膜在被拉伸或伸长并且然后释放时沿着至少一条轴线展现出似弹性行为。所述热塑性膜包括在垂直于所述热塑性膜的主表面的方向上延伸的多个凸肋状元件。所述热塑性膜进一步包括围绕所述多个凸肋状元件定位的多个连接区域。所述多个凸肋状元件和所述多个连接区域布置成复杂图案。所述复杂图案在所述膜被拉伸或伸长时提供视觉和触觉提示。所述复杂图案可以使所述热塑性膜具有低力延伸度。(A thermoplastic film that exhibits an elastic-like behavior along at least one axis when stretched or elongated and then released is disclosed. The thermoplastic film includes a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film. The thermoplastic film further comprises a plurality of connecting regions positioned around the plurality of fin-like elements. The plurality of fin-like elements and the plurality of connecting regions are arranged in a complex pattern. The complex pattern provides visual and tactile cues when the film is stretched or elongated. The complex pattern may provide the thermoplastic film with low force elongation.)

1. A thermoplastic film having one or more strainable networks formed by an elastic-like structure process, the thermoplastic film comprising:

a plurality of fin-like elements;

a plurality of parting regions positioned around the plurality of fin-like elements, wherein the plurality of parting regions extend in a first direction; and is

Wherein the plurality of fin-like elements and the plurality of parting zones are sized and positioned such that the thermoplastic film provides low force extensibility when subjected to an applied force in a direction parallel to the first direction.

2. The thermoplastic film of claim 1, wherein the thermoplastic film is comprised of a split region extending in the first direction.

3. The thermoplastic film of claim 1, further comprising a plurality of second parting regions extending in a second direction, the second direction being non-parallel to the first direction.

4. The thermoplastic film of claim 3, wherein at least fifty percent of the split areas of the combination of the first and second plurality of split areas extend in the first direction.

5. The thermoplastic film of claim 1, wherein the low force elongation when subjected to a tensile stress equal to between 300 and 350 pounds per square inch is comprised between 0.04 and 0.12 inches per repeating unit.

6. The thermoplastic film of claim 5, wherein the low force elongation comprises 0.08 inches per repeat unit when subjected to a tensile stress equal to 338 pounds per square inch.

7. The thermoplastic film of claim 1, wherein the thermoplastic film is formed into a bag.

8. The thermoplastic film of claim 1, wherein the plurality of fin-like elements comprises a first plurality of fin-like elements arranged in a first pattern and a second plurality of fin-like elements arranged in a second pattern, wherein the first pattern and the second pattern are separated by at least a portion of the plurality of parting zones.

9. The thermoplastic film of claim 8, wherein a first pattern of fin-like elements, the second pattern of fin-like elements, and the plurality of parting zones repeat throughout the thermoplastic film.

10. The thermoplastic film of claim 9, wherein the first pattern of fin-like elements, the second pattern of fin-like elements, and the plurality of parting zones repeat to form a checkerboard pattern.

11. A thermoplastic bag exhibiting low force extensibility, the thermoplastic bag comprising:

a first sidewall and a second sidewall joined together along a first side edge, a second side edge, and a bottom edge;

an opening opposite the bottom edge;

a plurality of rib-like elements formed in the first and second side walls, the plurality of rib-like elements extending in a first direction perpendicular to the first and second side edges; and

a plurality of parting regions positioned around the plurality of fin-like elements, the plurality of parting regions extending in a direction parallel to the first side edge and the second side edge;

wherein, when the thermoplastic bag is subjected to an applied force in a direction parallel to the first side edge and the second side edge:

the plurality of parting zones resist deformation in the direction parallel to the first side edge and the second side edge; and is

The portions of the first and second sidewalls that include the rib-like elements form waves.

12. The thermoplastic bag of claim 11, wherein the waves comprise one or more of a height greater than 3000 microns or a width greater than 3000 microns.

13. The thermoplastic bag of claim 11, wherein the plurality of fin-like elements comprises a first plurality of fin-like elements arranged in a first pattern and a second plurality of fin-like elements arranged in a second pattern.

14. The thermoplastic bag of claim 13, wherein the waves are in an area of the thermoplastic film comprising the rib-like elements of the first pattern.

15. The thermoplastic bag of claim 14, wherein the area of the thermoplastic film comprising the second pattern of fin-like elements is free of undulations and comprises the parting region.

16. The thermoplastic bag of claim 14, wherein:

the first pattern of element comprises a macro pattern; and is

Said second pattern of element comprises a micro-pattern.

17. The thermoplastic bag of claim 13, wherein the first sidewall and the second sidewall comprise a low force elongation of between 0.04 and 0.12 inches per repeating unit when subjected to a tensile stress equal to between 300 and 350 pounds per square inch.

18. The thermoplastic bag of claim 11, wherein the plurality of parting zones do not rotate when the thermoplastic bag is subjected to the applied force in a direction parallel to the first side edge and the second side edge.

19. A method for making a thermoplastic film exhibiting low-force extensibility, the method comprising:

passing a thermoplastic film between a first intermeshing roll and a second intermeshing roll, wherein at least one of the first intermeshing roll and the second intermeshing roll comprises repeating units of a plurality of ridges, a plurality of notches, and a plurality of grooves,

wherein the repeating units form a complex stretch pattern in the thermoplastic film, the complex stretch pattern comprising a plurality of rib-like elements and a plurality of parting zones positioned to extend in a first direction; and is

Wherein the plurality of fin-like elements and the plurality of parting zones are sized and positioned such that the thermoplastic film provides a low force elongation when subjected to an applied force in the first direction.

20. The method of claim 19, further comprising applying and then releasing a force to the thermoplastic film in the first direction such that:

the plurality of parting zones resist deformation in the first direction; and is

The portion of the thermoplastic film that includes the rib-like elements forms a wave.

Background

Thermoplastic films are a common component in a variety of commercial and consumer products. For example, cargo bags, trash bags, sacks, and packaging materials are products that are commonly made from thermoplastic films. In addition, feminine hygiene products, baby diapers, adult incontinence products, and many other products include thermoplastic films to one degree or another.

The cost of producing a product comprising a thermoplastic film is directly related to the cost of the thermoplastic film. Recently, the cost of thermoplastic materials has risen. Accordingly, some have attempted to control manufacturing costs by reducing the amount of thermoplastic material in the product. One way manufacturers can attempt to reduce production costs is to stretch the thermoplastic film, thereby increasing its surface area and reducing the amount of thermoplastic film required to produce a product of a given size.

While thinner gauge materials may be cost effective for manufacturers, using thinner gauge films may result in less durability. While some recent technologies may in some cases produce relatively thinner gauge films that may be at least as strong as their thicker counterparts, thinner gauge materials are naturally perceived by consumers from previous experiences to be lower in quality and durability.

For example, some of the cues for the lower quality and durability of a film to a customer are how thick or thin the film feels and how thin or weak the film "looks". Customers tend to perceive a film that looks or feels thin as having a relatively low strength. Thus, while some mechanisms may improve some aspects of membrane strength while using thinner gauges, the look and feel of such membranes often causes customers to think that the membranes are still of low quality.

To provide additional strength and flexibility, some manufacturers have attempted to provide elastic-like behavior to thermoplastic films by adding elastomeric materials or using specialized processing of the films. While elastic-like behavior provides various advantages, how easily the film stretches may suggest a level of strength to the consumer. For example, an easily stretched film may indicate to the user that the film is weak and may fail quickly.

Accordingly, there are various considerations regarding thermoplastic films and products formed therefrom.

Disclosure of Invention

One or more implementations of the present disclosure solve one or more problems in the art with a thermoplastic film having a complex stretch pattern that provides low force extensibility, and an apparatus and method for producing the same. The complex stretch pattern provides visual and tactile cues when the film is stretched/elongated. In one or more implementations, the complex stretch pattern causes a first portion of the thermoplastic film to deform by expanding in a direction of an applied force, while a second portion resists deformation in the direction of the applied force. Additionally, in one or more implementations, the difference in deformation between the first portion and the second portion may cause the first portion to wave when stretched/elongated and subsequently released, thereby providing greater loft (loft) to the film.

One or more implementations of the present disclosure include a thermoplastic film having one or more strainable networks formed by an elastic-like structure process. The thermoplastic film comprises a plurality of rib-like elements and a plurality of parting regions (landarea) positioned around the plurality of rib-like elements. The plurality of parting regions extend in a first direction. The plurality of fin-like elements and the plurality of parting zones are sized and positioned such that the thermoplastic film provides low force extensibility when subjected to the applied force in a direction parallel to the first direction.

One or more additional implementations include a thermoplastic bag exhibiting low-force extensibility. The thermoplastic bag includes a first sidewall and a second sidewall joined together along a first side edge, a second side edge, and a bottom edge. The thermoplastic bag further comprises an opening opposite the bottom edge. The thermoplastic bag further comprises a plurality of rib-like elements formed in the first sidewall and the second sidewall. The plurality of fin-like elements extend in a first direction perpendicular to the first side edge and the second side edge. The thermoplastic bag further comprises a plurality of parting zones positioned about the plurality of fin-like elements. The plurality of parting zones extend in a direction parallel to the first side edge and the second side edge. The plurality of parting zones resist deformation in the direction parallel to the first side edge and the second side edge when the thermoplastic bag is subjected to an applied force in the direction parallel to the first side edge and the second side edge. Further, when the thermoplastic bag is subjected to an applied force in the direction parallel to the first and second side edges, the portions of the first and second side walls that include rib-like elements form waves.

One or more additional implementations of the present disclosure include a method for making a thermoplastic film exhibiting low-force extensibility. The method includes passing a thermoplastic film between a first intermeshing roll and a second intermeshing roll. At least one of the first and second intermeshing rolls comprises repeating units of a plurality of ridges, a plurality of notches, and a plurality of grooves. The repeating units allow complex stretch patterns to be formed in the thermoplastic film. The complex stretch pattern comprises a plurality of fin-like elements and a plurality of parting zones positioned to extend in a first direction. The plurality of fin-like elements and the plurality of parting zones are sized and positioned such that the thermoplastic film provides a low force elongation when subjected to the applied force in the first direction.

One or more implementations of the present disclosure include a thermoplastic film comprising a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film. The thermoplastic film further comprises a plurality of connecting regions positioned around the plurality of fin-like elements. The plurality of fin-like elements and the plurality of connecting regions are sized and positioned such that a stretch curve of the thermoplastic film has a complex shape when subjected to an applied load. For example, in one or more implementations, the thermoplastic film has: a tensile curve comprising a plurality of inflection points, a tensile curve having a derivative with a positive slope in the initial elongation zone, and/or a tensile curve having a derivative that does not constitute a bell shape. Additional implementations include a bag having sidewalls formed from such a film and methods of making such films and bags.

One or more implementations of the present disclosure include a thermoplastic film comprising a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film. The thermoplastic film further comprises a plurality of connecting regions positioned around the plurality of fin-like elements. The plurality of fin-like elements and the plurality of connecting regions are sized and positioned such that the thermoplastic film undergoes both geometric and molecular deformation when subjected to an applied load and during an initial elongation zone of from zero to five percent. Additional implementations include a bag having sidewalls formed from such a film and methods of making such films and bags.

One or more implementations of the present disclosure include a thermoplastic film comprising a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film. The thermoplastic film further comprises a plurality of connecting regions positioned around the plurality of fin-like elements. The plurality of fin-like elements and the plurality of connecting regions are sized and positioned such that the thermoplastic film undergoes a plurality of stages when subjected to an applied load, wherein a major portion of the deformation of the thermoplastic film is geometric deformation. Additional implementations include a bag having sidewalls formed from such a film and methods of making such films and bags.

One or more implementations of the present disclosure include a thermoplastic film comprising a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film. The thermoplastic film further comprises a plurality of connecting regions positioned around the plurality of fin-like elements. The plurality of fin-like elements and the plurality of connecting regions are sized and positioned such that when subjected to an applied and subsequently released load, waves are formed in the thermoplastic film having one or more of a height greater than 3000 micrometers or a width greater than 3000 micrometers. Additional implementations include a bag having sidewalls formed from such a film and methods of making such films and bags.

Additional features and advantages will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.

Drawings

In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the disclosure briefly described above will be rendered by reference to specific implementations that are illustrated in the appended drawings. It should be noted that the figures are not drawn to scale and that elements having similar structures or functions are generally represented by like reference numerals throughout the figures for illustrative purposes. Understanding that these drawings depict only typical implementations of the disclosure and are not therefore to be considered to be limiting of its scope, the disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

fig. 1A-1C illustrate partial side cross-sectional views of films having different numbers of sub-layers in accordance with one or more implementations of the present disclosure;

fig. 2 shows a perspective view of a pair of SE L F-polarized rollers for forming complex stretch patterns in a film in accordance with one or more implementations of the present disclosure;

fig. 3 shows a perspective view of a SE L F polarized film with a complex stretch pattern in accordance with one or more implementations of the present disclosure;

fig. 4 shows a perspective view of a multilayer SE L F-polarized film having a complex stretch pattern in accordance with one or more implementations of the present disclosure;

FIG. 5A illustrates a partial perspective view of a film having a complex stretch pattern in the form of a checkerboard pattern in accordance with one or more implementations of the present disclosure;

FIG. 5B illustrates a partial perspective view of the membrane of FIG. 5A after being subjected to an applied and subsequently released load in accordance with one or more implementations of the present disclosure;

FIG. 5C shows a partial side cross-sectional view of the membrane of FIG. 5B;

fig. 6A illustrates a profile obtained from a photomicrograph of a film having a complex stretch pattern after being subjected to an applied and subsequently released strain in accordance with one or more implementations of the present disclosure;

fig. 6B illustrates a profile obtained from a photomicrograph of another film having a complex stretch pattern after being subjected to an applied and subsequently released strain in accordance with one or more implementations of the present disclosure;

fig. 6C illustrates a profile obtained from a photomicrograph of a prior art SE L F-polarized film after being subjected to an applied and subsequently released strain in accordance with one or more implementations of the present disclosure;

FIG. 7A illustrates a front view of a prior art film having a stretched pattern in the shape of a "diamond", wherein the parting region is oriented non-parallel to the direction of the applied force, in accordance with one or more implementations of the present disclosure;

FIG. 7B illustrates a front view of the film of FIG. 7A after being subjected to an applied and subsequently released strain in accordance with one or more implementations of the present disclosure;

fig. 8A illustrates a front view of a film having a complex stretch pattern in the form of diamond-shaped micro and macro patterns, wherein the parting region is parallel to the direction of the applied force, according to one or more implementations of the present disclosure;

FIG. 8B illustrates a front view of the film of FIG. 9A after being subjected to an applied and subsequently released strain in accordance with one or more implementations of the present disclosure;

FIG. 9A shows a graph representing the stretch curve of a conventional SE L F-polarized film;

FIG. 9B shows a graph representing the derivative of the stretch curve of FIG. 10A;

fig. 10A shows a graph representing stretch curves for two films with complex stretch patterns according to one or more implementations of the present disclosure;

FIG. 10B shows a graph representing the derivative of the pull curve of FIG. 11A;

FIG. 11 illustrates a perspective view of a bag having a complex stretch pattern in accordance with one or more implementations of the present disclosure;

FIG. 12 is a front side view of a bag having a complex stretch pattern in the form of a hexagon, according to an implementation of the present disclosure;

FIG. 13 is a front side view of a bag having a complex stretch pattern in the form of hexagons and diamonds according to an implementation of the present disclosure;

FIG. 14 is a front side view of a bag according to an implementation of the present disclosure, with complex stretch patterns in strips that span the width of the bag but are only a portion of the height of the bag;

FIG. 15 is a front side view of another bag in which the complex stretch pattern is in a strip across the width of the bag but only over a portion of the height of the bag, according to an implementation of the present disclosure;

FIG. 16 illustrates a schematic diagram of a process for manufacturing bags with complex stretch patterns, according to one or more implementations of the present disclosure; and is

Fig. 17 illustrates a schematic diagram of a process for manufacturing a thermoplastic bag with a complex stretch pattern according to one or more implementations of the present disclosure.

Detailed Description

One or more implementations of the present disclosure include a thermoplastic film having a complex structured elastic-like film (SE L F) pattern as described below, complex stretch or SE L F patterns provide various advantages to thermoplastic films and products made therefrom.

One or more implementations include a thermoplastic film having a strainable network formed by a SE L F-forming process, the strainable network may include a plurality of rib-like elements extending in a direction perpendicular to a major surface of the thermoplastic film, the rib-like elements being surrounded by a plurality of connecting regions, the rib-like elements and the connecting regions may include a strainable network that provides an elastic-like behavior to the thermoplastic film, hi particular, the rib-like elements may initially undergo substantially geometric deformation when subjected to an applied load and then undergo substantially molecular-level deformation when subjected to the applied load.

In addition to the above-mentioned elastic-like properties and other benefits described in the above-incorporated patents, implementations of the present disclosure include a strainable network sized and positioned to provide a complex pattern of previously unrealized film properties and characteristics. For example, one or more implementations include sizing and positioning the plurality of fin-like elements and the plurality of connection regions such that the stretch curve of the thermoplastic film has a complex shape when subjected to an applied load. As used herein, a tensile curve refers to how a film elongates when subjected to an applied load. The stress-strain plot or stress-elongation plot shows the tensile curve of a thermoplastic film. Details regarding the creation of the stress elongation plot are provided below. Non-limiting examples of complex stretch curves or stretch curves having complex shapes include stretch curves having multiple inflection points, stretch curves having derivatives with positive slopes in the initial elongation region, and stretch curves having derivatives that do not constitute a bell shape. Each of the complex stretch curves mentioned above may provide various benefits, such as tactile feedback to the user indicating strength, resistance to elongation (e.g., low force elongation), or multi-stage geometric elongation, as explained in more detail below.

In addition, one or more implementations include sizing and positioning the plurality of rib-like elements and the plurality of connection regions such that the thermoplastic film undergoes both geometric and molecular deformation in an initial elongation zone when subjected to an applied load.

Further, one or more implementations include sizing and positioning the plurality of fin-like elements and the plurality of connection regions such that the thermoplastic film undergoes a plurality of different phases when subjected to an applied load, wherein a major portion of the deformation is geometric deformation. For example, a plurality of rib-like elements may be arranged in a plurality of patterns comprising rib-like elements of different shapes and different sizes. The main portion of the deformation is the multiple different stages of geometric deformation that may be at least in part because the different configurations of the pattern of rib-like elements undergo geometric deformation at different points during elongation of the thermoplastic film. The different stages of geometric deformation, the main part of the deformation, may include stages that require less force to elongate the thermoplastic film than the force in the immediately adjacent elongation stage. The main part of the deformation is that the different stages of the geometric deformation provide the film with a reduced resistance to stretching in the different stages. This differential stretch resistance may provide sensory feedback to the consumer and indicate strength. As used herein, "primarily" refers to a non-negligible amount that meaningfully contributes to the effect. For example, "predominantly" may include amounts (percentages) of about 20% to 100%. In one or more embodiments, it is predominantly 30%, 40%, 50%, or 50% or more. As used herein, "dominant" refers to an amount that provides the majority of the effect. Thus, the dominant includes a percentage greater than 50%.

Additionally, one or more implementations include sizing and positioning the plurality of fin-like elements and the plurality of connection regions such that when subjected to an applied and subsequently released load, waves are formed in the thermoplastic film. In some implementations, the waves can impart a thicker and stronger appearance to the film at the same time using the same amount of material as compared to conventional films. In addition, the waves may provide an increased perception of stretch performance compared to conventional films. In one or more embodiments, the waves have one or more of a height greater than 3000 microns or a width greater than 3000 microns.

For example, such products include, but are not limited to, grocery bags, trash bags, packaging bags and materials, feminine hygiene products, baby diapers, adult incontinence products, or other products.

Membrane material

As a first matter, the thermoplastic material of the film of one or more implementations of the present disclosure can include thermoplastic polyolefins, including polyethylene and copolymers thereof and polypropylene and copolymers thereof. The olefin-based polymer may include ethylene-or propylene-based polymers such as polyethylene, polypropylene, and copolymers such as Ethylene Vinyl Acetate (EVA), Ethylene Methyl Acrylate (EMA), and Ethylene Acrylic Acid (EAA), or blends of such polyolefins.

Other examples of polymers suitable for use as membranes according to the present disclosure may include elastomeric polymers. Suitable elastomeric polymers may also be biodegradable or environmentally degradable. Elastomeric polymers suitable for use in the film include poly (ethylene-butene), poly (ethylene-hexene), poly (ethylene-octene), poly (ethylene-propylene), poly (styrene-butadiene-styrene), poly (styrene-isoprene-styrene), poly (styrene-ethylene-butylene-styrene), poly (ester-ether), poly (ether-amide), poly (ethylene-vinyl acetate), poly (ethylene-methyl acrylate), poly (ethylene-acrylic acid), oriented poly (ethylene-terephthalate), poly (ethylene-butyl acrylate), polyurethane, poly (ethylene-propylene-diene), ethylene-propylene rubber, nylon, and the like.

The term "linear low density polyethylene" (LL DPE) as used herein is defined to mean a copolymer of ethylene with a minor amount of an olefin containing 4 to 10 carbon atoms, having a density of from about 0.910 to about 0.930 and a Melt Index (MI) of from about 0.5 to about 10. for example, some examples herein use an octene comonomer solution phase LL DPE (MI 1.1; ρ 0.920). additionally, other examples use a gas phase 2 DPE, which is a hexene gas phase LL DPE mixed with slip/AB (slip/antiblock) (MI 1.0; ρ 0.920). still other examples use a gas phase LL DPE, which is a hexene gas phase LL DPE mixed with slip/AB (MI 1.0; ρ 0.926). it will be appreciated that the disclosure is not limited to "HDPE films made from high density polyethylene" (HDPE expressly disclosed herein) and that the disclosure may include any combination of high density polyethylene "(HDPE L).

Some implementations of the present disclosure may include any flexible or pliable thermoplastic material that may be formed or stretched into a web or film. Further, these thermoplastic materials may comprise a single layer or multiple layers. The thermoplastic material may be opaque, transparent, translucent, or colored. Furthermore, the thermoplastic material may be breathable or non-breathable.

As used herein, the term "flexible" refers to a material that: can be bent or curved (particularly repeatedly) such that they are pliable and yieldable in response to externally applied forces. Thus, "flexible" means essentially the opposite of the terms inflexible, rigid, or unyielding. Thus, flexible materials and structures can be altered in shape and structure to accommodate external forces and to conform to the shape of objects in contact therewith without losing their integrity. According to further prior art materials, web materials are provided which exhibit an "elastic-like" behavior in the direction of the applied strain without the use of added traditional elastic materials. As used herein, the term "elastic-like" describes the behavior of web materials when subjected to an applied strain, the web materials extending in the direction of the applied strain and returning to their pre-strained state to some extent when the applied strain is released.

As used herein, the term "substantially" with reference to a given parameter, property, or state refers to meeting the given parameter, property, or state to the extent one of ordinary skill in the art would understand that within a certain degree of variation, such as within acceptable manufacturing tolerances. For example, depending on the particular parameter, property, or condition being substantially satisfied, the parameter, property, or condition may be satisfied by at least 70.0%, at least 80.0%, at least 90%, at least 95.0%, at least 99.0%, or even at least 99.9%.

Additional additives that may be included in one or more implementations include slip agents, anti-blocking agents, voiding agents, or tackifiers. Additionally, one or more implementations of the present disclosure include a film without a voiding agent. Some examples of inorganic voiding agents that may further provide odor control include, but are not limited to, the following: calcium carbonate, magnesium carbonate, barium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, calcium oxide, magnesium oxide, titanium oxide, zinc oxide, aluminum hydroxide, magnesium hydroxide, talc, clay, silica, alumina, mica, glass powder, starch, charcoal, zeolite, any combination thereof, and the like. Organic voiding agents, polymers that are incompatible with each other in the main polymer matrix, may also be used. For example, polystyrene may be used as a voiding agent in polyethylene and polypropylene films.

One of ordinary skill in the art will appreciate in view of this disclosure that a manufacturer can form a film or web to be used in the present disclosure by using a wide variety of techniques. For example, a manufacturer may form a precursor mixture of a thermoplastic material and one or more additives. The manufacturer may then form a film from the precursor mixture using conventional flat or cast film extrusion or coextrusion to produce single, dual or multilayer films. Alternatively, the manufacturer may form the film using a suitable process (such as a blown film process) to produce a single layer, bi-layer, or multi-layer film. Manufacturers may orient these films by trapping bubbles, tenter frames, or other suitable processes, if desired for a given end use. In addition, the manufacturer may then optionally anneal the films.

An optional part of the film making process is a process called "orientation". The orientation of a polymer is a reference for its molecular organization, i.e., the orientation of the molecules relative to each other. Similarly, the process of orientation is a process of imparting directionality (orientation) to the polymer arrangement in the film. The process of orientation is used to impart desirable properties to the film, including making the cast film tougher (higher tensile properties). Depending on whether the film is made as a flat film by casting or as a tubular film by blowing, the orientation process may require different procedures. This is related to the different physical properties possessed by films made by conventional film making processes (e.g., casting and blowing). In general, blown films tend to have greater stiffness and toughness. In contrast, cast films generally have the advantage of greater film clarity and uniformity of thickness and flatness, generally permitting the use of a wider range of polymers and producing higher quality films.

When the film has been stretched in a single direction (uniaxial orientation), the resulting film may exhibit strength and stiffness along the direction of stretching, but may be weaker in other directions (i.e., across the stretch), often splitting when bent or pulled. To overcome this limitation, bi-directional or biaxial orientation may be employed to more evenly distribute the strength properties of the film in both directions. Most biaxial orientation processes use equipment that sequentially stretches the film first in one direction and then in the other.

In one or more implementations, the film of the present disclosure is a blown film or a cast film. Both blown and cast films can be formed by extrusion. The extruder used may be a conventional extruder using a die that will provide the desired specifications. Some useful extruders are described in U.S. Pat. nos. 4,814,135; 4,857,600; 5,076,988; 5,153,382; each of which is incorporated herein by reference in its entirety. Examples of the various extruders that may be used to produce the films to be used in the present disclosure may be single screw types modified with blown film die, gas ring, and continuous take off equipment.

In one or more implementations, a manufacturer may use multiple extruders to supply different melt streams that may be forced by a feedblock into different channels of a multi-channel die. Multiple extruders may allow a manufacturer to form films having layers of different compositions. Such multilayer films may then be provided with complex stretch patterns to provide the benefits of the present disclosure.

In a blown film process, the die may be a right circular cylinder with a circular opening. The roller may pull the molten thermoplastic material upward away from the die. The gas ring may cool the film as it travels upward. The air outlet may force compressed air into the center of the extruded circular profile, thereby creating a bubble. Air can expand the extruded circular cross-section by many times the die diameter. This ratio is called the "blow-up ratio". When using a blown film process, the manufacturer may collapse the film to double the number of layers of the film. Alternatively, the manufacturer may cut and fold the film, or cut without folding the film.

In any case, in one or more implementations, the extrusion process can orient the polymer chains of the blown film. The "orientation" of a polymer is a reference to its molecular organization, i.e., the orientation of molecules or polymer chains relative to each other. In particular, the extrusion process can orient the polymer chains of the blown film primarily in the machine direction. Orientation of the polymer chains can result in increased strength in the direction of orientation. As used herein, predominantly oriented in a particular direction means that the polymer chains are more oriented in that particular direction than in another direction. However, it is understood that a film that is oriented primarily in a particular direction may still include polymer chains that are oriented in directions other than the particular direction. Thus, in one or more implementations, an initial or starting film (a film prior to being stretched or bonded or laminated according to the principles described herein) may comprise a blown film oriented primarily in the machine direction.

The process of blowing the tubular billet or bubble may further orient the polymer chains of the blown film. In particular, the inflation process can biaxially orient the polymer chains of the blown film. Despite being biaxially oriented, in one or more implementations, the polymer chains of the blown film are primarily oriented in the machine direction (i.e., more oriented in the machine direction than in the transverse direction).

The membranes of one or more implementations of the present disclosure may have starting specifications in the following ranges: between 0.1 mils and about 20 mils, suitably from about 0.2 mils to about 4 mils, suitably in the range of about 0.3 mils to about 2 mils, suitably from about 0.6 mils to about 1.25 mils, suitably from about 0.9 mils to about 1.1 mils, suitably from about 0.3 mils to about 0.7 mils, and suitably from about 0.4 mils to about 0.6 mils. Additionally, the starting gauge of the film of one or more implementations of the present disclosure may not be uniform. Accordingly, the starting gauge of the film of one or more implementations of the present disclosure may vary along the length and/or width of the film.

One or more layers of the films described herein may comprise any flexible or pliable material, including thermoplastic materials that may be formed or drawn into a web or film. As noted above, the film comprises multiple layers of thermoplastic film. Each individual film layer may itself comprise a single layer or multiple layers. In other words, the individual layers of the multilayer film may themselves each comprise a plurality of laminate layers. Such layers may be bonded together significantly more tightly than the bonding provided by the intentionally weaker discontinuous bond in the finished multilayer film. Both tight and relatively weak lamination can be accomplished by: joining the layers together by mechanical pressure, joining the layers together with an adhesive, joining using heat and pressure, brushing, extrusion coating, ultrasonic bonding, electrostatic bonding, cohesive bonding, and combinations thereof. Adjacent sublayers of the individual layers may be coextruded. The coextrusion results in a tight bond such that the bond strength is greater than the tear strength of the resulting laminate (i.e., instead of allowing adjacent layers to peel apart by rupture of the laminate bond, the film will tear).

A film having a complex stretch pattern may comprise a single film formed from one, two, three, or more layers of thermoplastic material. Fig. 1A to 1C are partial cross-sectional views of a multilayer film that can form a complex stretch pattern. Such films may then be used to form products, such as thermoplastic bags. In some implementations, the film can include a single layer film 102a, as shown in fig. 1A, that includes a single layer 110. In other embodiments, the film may comprise a bilayer film 102B, as shown in fig. 1B, comprising a first layer 110 and a second layer 112. The first layer 110 and the second layer 112 may be coextruded. In such implementations, the first layer 110 and the second layer 112 can optionally include different grades of thermoplastic materials and/or include different additives, including polymeric additives. In still other implementations, the film may be a three layer film 102C, as shown in fig. 1C, which includes a first layer 110, a second layer 112, and a third layer 114. In still other implementations, the film may include more than three layers. The three layer film 102C may comprise an a: B: C configuration in which all three layers differ in one or more of gauge, composition, color, transparency, or other properties. Alternatively, the three-layer film 102c may comprise an a: B structure or an a: B: a structure, wherein the two layers have the same composition, color, transparency, or other properties. In the A: A: B structure or the A: B: A structure, the A layers may include the same specifications or different specifications. For example, in an a: B structure or an a: B: a structure, the film layers may include layer ratios of 20:20:60, 40:40:20, 15:70:15, 33:34:33, 20:60:20, 40:20:40, or other ratios.

Typically, the stretchable portion of a complex stretch pattern comprises regions that are SE L F-polarized or stretched by opposing rollers in a process known as Transverse Direction Ring Rolling (TDRR). The rollers comprise a collection of Machine Direction (MD) oriented raised elements (e.g., rib-like elements or any other pattern). The compression nip formed by two opposing rollers raises the film such that it is thinned between the ribs.

For example, fig. 2 illustrates a pair of SE L F-mated intermeshing rolls 202, 204 (e.g., a first SE L F-mated intermeshing roll 202 and a second SE L F-mated intermeshing roll 204) for producing a strainable network having a complex pattern as illustrated in fig. 2, a first SE L F-mated intermeshing roll 202 may include a plurality of ridges 206 and grooves 208 extending generally radially outward in a direction orthogonal to the axis of rotation 210, thus, the first SE L F-mated intermeshing roll 202 may be similar to a transverse direction ("TD") intermeshing roll, such as the TD intermeshing roll described in U.S. patent No. 9,186,862 to bourboning et al, the disclosure of which is incorporated herein by reference in its entirety, a second SE L F-mated intermeshing roll 204 may also include a plurality of ridges 212 and grooves 214 extending generally radially outward in a direction orthogonal to the axis of rotation 215, as illustrated in fig. 2, in some embodiments, the second SE L F-mated intermeshing roll may include a plurality of spaced apart notches 216.

As shown in FIG. 2, passing a film (such as film 102c) through SE L F intermeshing rolls 202, 204 may produce a thermoplastic film 200 having one or more strainable networks formed by an elastic-like structure process, wherein the strainable networks have a complex pattern 220 in the form of a checkerboard pattern.

Referring collectively to fig. 2 and 3, as the film passes through SE L F intermeshing rolls 202, 204, teeth 216 may extrude a portion of the film out of a plane defined by the film to cause the portion of the film to permanently deform in the Z-direction, for example, teeth 216 may intermittently stretch a portion of film 102c in the Z-direction the portion of film 102c passing between notched regions 217 of teeth 216 will remain substantially unformed in the Z-direction.

As shown in FIG. 3, the strainable network of film 200 may include first thicker regions 306, second thicker regions 308, and stretched thinner transition regions 310 connecting the first thicker regions 306 and the second thicker regions 308 the first thicker regions 306 and the stretched thinner regions 310 may form the strainable network of rib-like elements 304. in one or more embodiments, the first thicker regions 306 are the portions of the film having the greatest displacement in the Z-direction. in one or more embodiments, the overall length and width of the film is substantially unchanged when the film is subjected to SE L Fconversion in one or more embodiments of the invention, as a result of the displacement of the film in the Z-direction by pushing the rib-like elements 304 in a direction perpendicular to the major surface of the thermoplastic film (thereby stretching the regions 310 upward). In other words, the film 102c (before being subjected to SE L Fconversion) may have substantially the same width and length as the film 200 resulting from SE L Fconversion.

As shown in fig. 3, the rib-like elements may have a major axis and a minor axis (i.e., the rib-like elements are elongated such that their length is greater than their width). As shown in fig. 2 and 3, in one or more embodiments, the major axis of the rib-like elements is parallel to the machine direction (i.e., the direction in which the film is extruded). In an alternative embodiment, the major axis of the rib-like elements is parallel to the transverse direction. In still other embodiments, the major axes of the rib-like elements are oriented at an angle between 1 degree and 89 degrees relative to the machine direction. For example, in one or more embodiments, the major axes of the rib-like elements are at an angle of 45 degrees to the machine direction. In one or more embodiments, the long axis is linear (i.e., in a straight line), and in alternative embodiments, the long axis is curved or otherwise has a non-linear shape.

As used herein, the term "molecular-level deformation" refers to a deformation that occurs at the molecular level and is not discernible by the normal naked eye, that is, one cannot discern the deformation that is allowed or caused to occur even though one may be able to discern the effect of the molecular-level deformation (e.g., elongation or tearing of the film).

Thus, upon application of force, the rib-like elements 304 may undergo geometric deformation before undergoing molecular-level deformation. For example, a strain applied to the film 200 perpendicular to the long axis of the rib-like elements 304 can pull the rib-like elements 304 back into the plane of the connection regions 302 before any molecular-level deformation of the rib-like elements 304. Geometric deformation may result in significantly less resistance to applied strain than molecular level deformation exhibits.

As described above, the rib-like elements 304 and the connection regions 220 may be sized and positioned so as to create a complex stretch pattern. Complex stretch patterns may provide one or more of the benefits discussed herein. For example, the complex stretch pattern may cause the film (when subjected to an applied load) to have or exhibit one or more of the following: a stretch curve having a complex shape, both geometric and molecular deformation in an initial elongation zone (i.e., elongation from zero to five percent), a major portion of the deformation of the thermoplastic film being multiple stages of geometric deformation, a stretch curve including multiple inflection points, a derivative of the stretch curve having a positive slope in the initial stretch zone, or a wave having one or more of a height greater than 3000 microns or a width greater than 3000 microns.

As shown in fig. 2 and 3, the sets of rib-like elements 304 may be arranged in different arrangements to form complex stretch patterns. For example, a first plurality of fin-like elements 304a may be arranged in a first pattern 310 and a second plurality of fin-like elements 304b arranged in a second pattern 312. The first pattern 310 and the second pattern 312 of rib-like elements 304a, 304b may be repeated throughout the thermoplastic film 200. As shown in fig. 2, the first pattern 310 and the second pattern 312 of the fin-like elements 304a, 304b may form a checkerboard pattern 220.

In one or more implementations, the first pattern 310 is visually distinct from the second pattern 312. As used herein, the term "visually distinct" refers to a characteristic of a web material that is readily discernible to the normal unaided eye when the web material or an object embodying the web material is subjected to normal use.

In one or more embodiments, the fin-like elements 304a of the first pattern 310 comprise a macro-pattern, while the fin-like elements 304b of the second pattern 312 comprise a macro-pattern. As used herein, a macro pattern is a pattern that is larger in one or more aspects than a micro pattern. For example, as shown in fig. 2, the macro pattern 310 has fin-like elements 304a that are larger/longer than the fin-like elements 304b of the micro pattern 312. In an alternative embodiment, the surface area of a given macro pattern 310 covers more surface area than the surface area covered by a given micro pattern 312. In still other embodiments, the macro-pattern 310 may include larger/wider connecting portions between adjacent rib-like elements than between adjacent rib-like elements of the micro-pattern 312.

As discussed above, the male rib-like elements 304a are longer than the male rib-like elements 304 b. In one or more embodiments, the fin-like element 304a has a length that is at least 1.5 times the length of the fin-like element 304 b. For example, the rib-like element 304a may have a length between 1.5 and 20 times the length of the rib-like element 304 b. In particular, the fin-like element 304a may have a length that is 2, 3, 4, 5,6, 8, or 10 times the length of the fin-like element 304 b.

In one or more implementations, the film having the complex stretch pattern may comprise two or more different thermoplastic films (i.e., two films extruded separately.) the different thermoplastic films may be discontinuously bonded to each other, for example, in one or more embodiments, the two film layers may be passed together through a pair of SE L F rollers to produce a multi-layer lightly bonded laminate film 200a having the complex stretch pattern 220, as shown in FIG. 4. the multi-layer lightly bonded laminate film 200a may comprise a first thermoplastic film 402 that is partially discontinuously bonded to a second thermoplastic film 404. in one or more embodiments, the bond between the first thermoplastic film 402 and the second thermoplastic film 404 is aligned with the first thicker region 306 and is formed by the pressure of the SE L F rollers displacing the rib-like elements 304a, 304 b. thus, the bond may be parallel to the rib-like elements 304a, 304b and positioned between the rib-like elements 304a, 304b of the first thermoplastic film 402 and the second thermoplastic film 404.

As used herein, the terms "laminate," "laminate," and "laminated film" refer to a process and resulting product made by bonding two or more layers of film or other materials together. The term "bonded" when used in reference to bonding multiple layers of a multilayer film may be used interchangeably with "lamination" of the layers. According to the method of the present disclosure, adjacent layers of the multilayer film are laminated or bonded to one another. The bond intentionally results in a relatively weak bond between the layers having a bond strength that is lower than the strength of the weakest layer of the film. This allows the laminate bond to fail before the film layer, and thus the bond, fails.

The term laminate is also a generic term for coextruded multilayer films comprising one or more tie layers. By verb, "laminate" is meant that two or more separately manufactured film articles are adhered or bonded to each other (e.g., by adhesive bonding, pressure bonding, ultrasonic bonding, corona lamination, electrostatic bonding, polymeric bonding, etc.) so as to form a multilayer structure. By the term "laminate" is meant a product produced by adhesion or bonding as just described.

As used herein, the term "partially discontinuous bonding" or "partially discontinuous lamination" refers to lamination of two or more layers, wherein the lamination is substantially continuous in the machine direction or in the cross direction, but discontinuous along the other of the machine direction or the cross direction. Alternatively, partially discontinuous lamination refers to lamination of two or more layers, wherein the lamination is substantially continuous across the width of the article but not continuous across the height of the article, or substantially continuous across the height of the article but not continuous across the width of the article. More specifically, partially discontinuous lamination refers to lamination of two or more layers in which a plurality of repeating bond patterns in the machine or cross direction are interrupted by a plurality of repeating unbonded areas.

In one or more embodiments, first film 402 and second film 404 may be discontinuously bonded together via one or more of the methods of bonding films as commonly described in U.S. patent No. 8,603,609, the disclosure of which is incorporated herein by reference in its entirety, in particular, first film 402 and second film 404 may be bonded via one or more of MD rolling, TD rolling, DD ring rolling, SE L F forming, pressure bonding, corona laminating, adhesives, or combinations thereof.

In addition, any of the pressure techniques (i.e., bonding techniques) described in U.S. patent No. 8,603,609 may be combined with other techniques to further increase the strength of the bonded area while maintaining a bond strength that is lower than the strength of the weakest layer of the multi-layer laminate film. For example, heat, pressure, ultrasonic bonding, corona treatment, or coating with an adhesive (e.g., printing) may be employed. Treatment with corona discharge can enhance any of the above methods by increasing the tackiness of the film surface to provide a stronger lamination bond, but the lamination bond is still weaker than the tear resistance of the individual layers.

Discontinuously bonding the first film 402 and the second film 404 together creates unbonded areas and bonded areas between the first film 402 and the second film 404. For example, discontinuously bonding the first film 402 and the second film 404 together may result in unbonded areas and bonded areas, as described in U.S. patent No. 9,637,278, the disclosure of which is incorporated herein by reference in its entirety.

Additional details of the benefits of the complex stretch pattern will be described with respect to fig. 5A-5C. Fig. 5A is a perspective view of a portion of a thermoplastic film 200 having a complex stretch pattern 220 in an unstrained configuration (i.e., prior to being subjected to an applied load). Fig. 5B is a perspective view of a portion of a thermoplastic film 200 having a complex stretch pattern 220 after being strained (i.e., after being subjected to an applied and subsequently released load). On the other hand, fig. 5C shows a cross-sectional view of a portion of a thermoplastic film 200 having a complex stretch pattern 220 after straining.

As shown, after the load is released, the thermoplastic film 200 returns to its state before being subjected to the load to a large extent. As shown by a comparison of fig. 5A-5C, in some implementations, waves 500 are formed in the thermoplastic film 200 when subjected to an applied and subsequently released load. The waves 500 may extend at least partially outward from the plane of the thermoplastic film 200 and may form a convex shape. For example, the waves 500 may have a generally square dome shape (i.e., a dome with a square base). It is understood that the configuration of the waves 500 may be based on a given complex stretch pattern.

As used herein, the term "undulation" refers to a fold of the thermoplastic film such that the thermoplastic film is not in a planar position. As shown in fig. 5C, the wave 500 may include a height 502 and a width 504. The height 502 is measured at a point farthest from the base of the wave 500 in the Z direction. In one or more embodiments, the waves 500 have one or more of an average height 502 greater than 3000 microns or an average width 504 greater than 3000 microns. More specifically, the wave 500 may be between 4000 and 16000 microns wide and between 3000 and 5000 microns high.

In some implementations, the height 502 is in a range of about 2800 μm to about 3600 μm. In further implementations, the height 502 is in a range from about 3000 μm to about 3400 μm. In yet other implementations, the height 502 is about 3200 μm. In some cases, the width 504 may be in a range of about 8000 μm to about 14500 μm. In further implementations, the width 504 can be in a range from about 8400 μm to about 14000 μm.

For example, an activated film having a complex stretch pattern (a film that is SE L F and then strained) may have a height that is 100 to 350 times the original gauge of the film (i.e., the gauge prior to passing through the SE L F roller). In one or more embodiments, an activated film having a complex stretch pattern may have a height that is 125 to 350 times the original gauge of the film, 150 to 250 times the original gauge of the film, 175 to 250 times the original gauge of the film, 200 to 250 times the original gauge of the film, or 225 to 250 times the original gauge of the film.

The original rib-like elements of one or more embodiments of the film having a complex stretch pattern may comprise a height of about 1.50 millimeters to about 3.00 millimeters. Thus, upon activation, the bulk or height of the film having the complex stretch pattern may have a height of 1.2 to 15.0 times the original gauge of the film, a height of 1.5 to 12.0 times the original gauge of the film, a height of 2.6 to 10.6 times the original gauge of the film, a height of 5.3 to 10.6 times the original gauge of the film, or a height of 5 to 7.5 times the original gauge of the film.

Furthermore, implementations of the present invention allow the loft of a film to be adjusted (e.g., increased) independently of the basis weight (raw material amount) of the film. Thus, one or more implementations may provide increased loft to the film despite the reduction in thermoplastic material. Thus, one or more implementations may reduce the materials required for producing a product while maintaining or increasing the loft of the film.

As shown in fig. 5B, the waves 500 are in the region of the thermoplastic film that includes the rib-like elements of the first pattern 310 (e.g., a macro-pattern), while the region of the rib-like elements that includes the second pattern 312 (e.g., a micro-pattern) is free of waves having a height greater than 3000 microns. Accordingly, the region of the thermoplastic film including the rib-like elements of the first pattern 310 may have a first stretch resistance. The region of the thermoplastic film that includes the rib-like elements of the second pattern 312 may have a second stretch resistance that is greater than the first stretch resistance, as explained in more detail below.

In addition, the waves 500 (e.g., the region of the thermoplastic film that includes the rib-like elements of the first pattern 310) have a first visual characteristic. The non-waved regions (e.g., the regions of the thermoplastic film that include the rib-like elements of the second pattern 312) have a second visual characteristic that is different from the first visual characteristic. For example, the waves 500 may have different colors, gloss, haze, transparency, refractive index, and the like. The different visual characteristics may highlight or otherwise visually highlight the waves.

Although fig. 5C illustrates a conceptual view of the waves 500, fig. 6A and 6B illustrate actual cross-sections of the waves 500a, 500B of a thermoplastic film having a complex stretched pattern fig. 6C, on the other hand, illustrates a cross-section of a conventional SE L F film having conventional waves 600 fig. 6C, in particular, illustrates a cross-section of a conventional SE L F film having rib elements in a diamond pattern, as described in U.S. patent No. 5,650,214, as shown, a thermoplastic film having a complex stretched pattern may have waves 500a, 500B having heights 502a, 502B between 1.2 and 3.5 times the height 602 of the waves 600 of a conventional SE L F film, similarly, as shown, a thermoplastic film having a complex stretched pattern may have waves 500a, 500B having widths between 2 and 6 times the widths of the waves 600 of a conventional SE L F film.

Fig. 7A and 7B illustrate prior art patterns that provide greater force extensibility than the complex stretch patterns of the present disclosure. For example, the thermoplastic film 700 in fig. 7A includes a conventional stretch pattern 701 (e.g., a diamond pattern). As shown in fig. 7A, the stretching pattern 701 includes a plurality of isolated deformed, raised, rib-like elements 704 (e.g., forming "diamonds") separated by parting regions 702. In at least one embodiment, the stretch pattern 701 is characterized by a proportion of ribs of about 78.4% area per repeating unit.

The tensile pattern 701 has a high force elongation equal to 0.16 inches per repeat unit or greater when subjected to a tensile stress between 300psi and 350 psi. For example, as shown in fig. 7A, prior to applying stress in the lateral direction, the parting region 702 is oriented approximately 125 degrees from the lateral direction 708. After applying stress in the transverse direction, as shown in fig. 7B, this angle increases to about 142 degrees. In other words, when a stress is applied to the thermoplastic film 700 having the tensile pattern 701, the parting regions 702 rotate along their length to approximate the direction of the applied stress, resulting in a higher measured linear deformation. In at least one embodiment, this rotation is even greater with a higher degree of applied stress.

In one or more embodiments, the degree of rotation of the stretch pattern (such as stretch pattern 701) by the high force extension is due, at least in part, to the orientation of the typing region 702. For example, greater stretching of the tensile pattern 701 is due to the tensile pattern 701 utilizing a parting region 702 that fails to include any portion parallel to the direction of the applied stress (e.g., in the TD direction). As discussed in more detail below, such parallel portions resist deformation and provide low force elongation to the thermoplastic film.

Fig. 8A is a top view of a portion of a thermoplastic film 200a having a complex stretch pattern 220a prior to being subjected to an applied load. Fig. 8B is a view of the portion of the thermoplastic film 200a having the complex stretch pattern 220a after being strained (i.e., after being subjected to an applied and subsequently released load). As shown, the rib-like elements 304a of the strained thermoplastic film 200a may be strained to a greater extent than the rib-like elements 304 b. This may be because the micro-pattern 312a provides greater stretch resistance than the macro-pattern 310a and/or provides a particular arrangement of connecting or parting regions between the raised rib-like elements 304 b. In addition, the greater strain of the fin-like elements 304a of the macro pattern 310a may create the waves described above.

In addition, as shown in fig. 8A and 8B, the complex stretch pattern 220a includes parting regions 302B between the rib-like elements 304B. In one or more embodiments, these parting regions 302B enable the complex stretch pattern 220a to provide a perception of low-force extensibility that is significantly equivalent to existing patterns (e.g., fig. 7A and 7B), while exhibiting a measured low-force extensibility that is substantially lower than existing patterns. In at least one embodiment, this is due to the nature of the visual deformation that occurs during the application of stress. Thus, a film having a complex stretch pattern 220a including a parting region 302b is perceived as stronger because it yields less when a given tensile stress is applied.

The factors that affect the measured extension and visible deformation are the shape of the complex stretch pattern 220a relative to the direction of the tensile stress (e.g., the transverse direction or TD.) typically, in the case of a drawtape garbage bag, the film is subjected to SE L Fing such that the direction of the tensile stress applied by the user during lifting is in the transverse direction of the film.

The shape and orientation of the parting zone between the complex stretch patterns is particularly important for producing low distortion portions in order to produce a force elongation perception that is significantly equivalent to the existing pattern. In one or more embodiments, the parting region on the film will resist deformation when the length of the parting region is oriented parallel to the direction of the applied tensile stress (e.g., in the TD direction). In at least one embodiment, this resistance is due to the absence of thinning of the film in the parting regions, and thus, these parting regions provide greater yield strength relative to the thinned regions (e.g., the fin-like elements 304 a). Conversely, when the membrane includes a parting region that is oriented such that the parting region is not parallel to the direction of the applied stress (e.g., as with parting region 702 shown in fig. 7A and 7B), the parting region can be rotated along its length such that it is pulled parallel to the direction of the stress. This non-parallel parting region does not yield much because it rotates to effectively extend the amount of bulk film deformation in the direction of the stress.

Thus, as shown in fig. 8A and 8B, to exhibit low force elongation properties, the film 200a is characterized by a complex stretch pattern 220a comprising: 1) deformable regions (e.g., first pattern 310a) that provide visible expansion under stress; and 2) a parting region (e.g., parting region 302b) that resists deformation by including a length dimension oriented in the direction of the applied stress (e.g., in the TD direction). For example, as shown in fig. 8B, the parting region 302B remains oriented parallel to the TD direction under the applied stress along the TD direction. This is different from the non-parallel parting regions 702 shown in fig. 7B, which rotate in the direction of the applied stress.

In the embodiment shown in fig. 8A and 8B, the repeating units forming the complex stretch pattern 220a comprise 76.5% MD rib-like elements. Of these rib-like elements, 50% are continuous rib-like elements (e.g., as in the first pattern 310a), which constitute deformable regions that provide visible expansion under TD tensile stress. The remaining 26.5% of the MD rib-like elements are shorter than the discontinuous structure (e.g., as in the second pattern 312 a). As further shown in fig. 8A and 8B, the repeating units forming the complex stretched pattern 220a also include 23.5% unthinned profiled regions (e.g., profiled regions 302B) all oriented to a length parallel to the TD axis. In at least one embodiment, these parting zones 302b resist deformation.

In use, the complex stretch pattern 220a shown in fig. 8A and 8B exhibits low force extensibility under applied stress. For example, in one or more embodiments, the low-force elongation of the film 200a is an elongation between 0.04 and 0.12 inches per repeating unit when subjected to a tensile stress equal to between 300 and 350 pounds per square inch. In yet other embodiments, the low force elongation is equal to 0.08 inches per repeat unit when subjected to a tensile stress equal to 338psi (0.25 lbs per inch wide of specimen at 0.74 mils thickness). As described above, other conventional patterns (e.g., such as the "diamond" pattern illustrated in fig. 7A and 7B) that include non-parallel typing regions exhibit greater measured force extensibility. For example, in at least one embodiment, the patterns shown in fig. 7A and 7B exhibit a force elongation equal to 0.16 inches per repeat unit when subjected to a tensile stress equal to 338psi (0.25 lbs per inch wide of specimen at 0.74 mils thickness). Accordingly, the stretched pattern in fig. 7A and 7B stretches twice the elongation of the complex stretched pattern 220B in fig. 8A and 8B without providing an additional appearance of visible distortion.

Furthermore, the greater degree of stretch exhibited by the stretch pattern 701 in fig. 7A and 7B is not solely due to the proportion of its rib-like elements. As described above, the stretch pattern 701 is characterized by about 78.4% rib-like elements per repeating unit. Similarly, the complex stretched pattern 220B in fig. 8A and 8B is characterized by about 76.4% rib-like elements per repeating unit. Thus, both complex stretched pattern 220a and complex stretched pattern 220b are characterized by a substantially equal proportion of rib-like elements per repeating unit. Thus, as discussed above, the greater degree of stretching seen in the complex stretch pattern 220a is largely due to the positioning and orientation of the parting region relative to the direction of the applied force.

In additional or alternative embodiments, films exhibiting low-force extensibility properties may include the same or different features as those described with reference to fig. 8A and 8B. For example, an alternative embodiment may include a film wherein no more than 76.5% of the major surface is comprised of rib-like elements. Alternatively, the film may comprise more than 76.5% of the major surface constituted by rib-like elements. Additionally, while the parting region 302B of the complex stretch pattern 220a discussed with reference to fig. 8A and 8B is fully (e.g., 100%) oriented in the TD direction, other embodiments may include parting regions that are only partially oriented in the TD direction (e.g., as will be discussed below with reference to fig. 12 and 13).

As described above, the complex stretch patterns described above may provide complex stretch curves (e.g., stretch curves having complex shapes) to the thermoplastic film. In particular, one or more implementations include sizing and positioning the plurality of fin-like elements and the plurality of connection regions such that the stretch curve of the thermoplastic film has a complex shape when subjected to an applied load. As used herein, a tensile curve refers to how a film elongates when subjected to an applied load. The stress-strain plot or stress-elongation plot shows the tensile curve of a thermoplastic film. Non-limiting examples of complex stretch curves or stretch curves having complex shapes include stretch curves having multiple inflection points, stretch curves having derivatives with positive slopes in the initial elongation region, and stretch curves having derivatives that do not constitute a bell shape.

FIG. 9A illustrates a tensile curve 902 for a conventional SE L F-polarized film (i.e., a film as disclosed by U.S. Pat. No. 5,650,214.) As seen in FIG. 9A, a conventional SE L F-polarized film exhibits elongation behavior in three stages or zones 904, 906, and 908.

The second elongation zone 906 is the transition zone where the rib-like elements become aligned with the applied elongation, in the second elongation zone 906, the conventional SE L F-polarized film begins to change from geometric deformation to molecular-level deformation, shown by the increased resistance to elongation shown by the increasing slope of the tensile curve 902. the third elongation zone begins at inflection point 910 in the tensile curve 902. in the third elongation zone, the film is undergoing substantial molecular-level deformation. inflection point 910 marks the change in the tensile curve 902 from concave up to concave down.

The graph 900a of fig. 9B is the derivative 902a of the pull curve 902 of fig. 9A. As shown, the derivative 902a of the tensile curve 902 includes a local maximum 912 indicating the location of an inflection point 910 of the tensile curve 902. As shown in fig. 9B, the derivative 902a of the stretch curve 902 has a bell shape. The bell shape is a generally concave downward parabolic shape that may optionally include an elongated beginning and/or ending tail. In other words, the derivative 902a of the stretch curve 902 indicates that the stretch curve 902 has an uncomplicated shape.

Fig. 10A illustrates a graph 1000 showing a stretch curve 1004 of a film 200 having a complex stretch pattern 220A (see, e.g., fig. 8A and 8B). Fig. 10B includes a graph 1000a illustrating a derivative 1004a of the pull curve 1004.

In one or more embodiments, the radius of the teeth of the SE L F roller may be adjusted to affect the slope of the stretch curve 1004.

As shown in fig. 10B, the derivative 1004a shows that the pull curve 1004 has a complex shape. In particular, the derivative 1004a does not consist of a bell shape. For example, the derivative 1004a has a plurality of turning extrema (local maxima and/or minima). Local extrema in the derivative 1004a indicate an inflection point(s) in the tensile curve 1004. More specifically, derivative 1004a has three inflection points 1012a, 1012b, 1014: a first maximum 1012a, a second maximum 1012b, and a local minimum 1014 located between the first maximum and the second maximum.

The thermoplastic film 200 undergoes both geometric and molecular deformation in the initial elongation zone (from about 0% to about 8%), this is shown by the derivative 1004a of the tensile curve 1004 with a positive slope in the initial elongation zone it is noted that this is in contrast to conventional SE L F-ized films discussed above with respect to FIGS. 9A and 9B.

In addition to the foregoing, the derivative 1004a indicates that the thermoplastic film 200 having a complex stretch pattern undergoes multiple stages, where the major portion of the deformation of the thermoplastic film is geometric deformation.

For example, a thermoplastic film having a complex stretch pattern may undergo a predominant geometric deformation in an initial elongation zone or stage from 0% elongation or strain to about 8% elongation or strain. The thermoplastic film with the complex stretch pattern may then undergo a predominant geometric deformation in a subsequent elongation zone from about 23% elongation to about 31% elongation. In some implementations, a thermoplastic film having a complex stretch pattern may exhibit multiple stages of geometric deformation due to the combination of macro-patterned, fin-like elements and micro-patterned, fin-like elements. For example, when the thermoplastic film is initially subjected to strain, the rib-like elements of the macro-pattern may be geometrically deformed first. The micro-patterned fin-like elements may be geometrically deformed behind the macro-patterned fin-like elements in different elongation zones or stages.

Further, in one or more implementations, the thermoplastic films with complex stretch patterns of the present disclosure can provide films that are more tear resistant than conventional films due to two different geometric deformations. For example, the films of the present disclosure may provide increased tear resistance because any force applied to a thermoplastic film with a complex stretch pattern must overcome two separate different geometric deformations before causing substantial molecular deformation and eventual failure.

As described above, one or more implementations of the present disclosure include products made from or utilizing thermoplastic films having complex stretch patterns. For example, such products include, but are not limited to, grocery bags, trash bags, packaging bags and materials, feminine hygiene products, baby diapers, adult incontinence products, or other products. The remaining figures describe various bags comprising complex stretch patterns and methods of making the same. For example, fig. 11 is a perspective view of a thermoplastic bag 1100 having a complex stretch pattern 220, according to an implementation of the present disclosure. A thermoplastic bag 1100 having a complex stretch pattern includes a first sidewall 1102 and a second sidewall 1104. Each of the first and second sidewalls 1102, 1104 includes a first side edge 1106, a second opposing side edge 1108, a bottom edge 1110 extending between the first and second side edges 1106, 1108, and a top edge 1111 extending between the first and second side edges 1106, 1108 opposite the bottom edge. In some implementations, the first sidewall 1102 and the second sidewall 1104 are joined together along a first side edge 1106, a second opposing side edge 1108, and a bottom edge 1110. The first and second sidewalls 1102, 1104 may be joined along the first and second side edges 1106, 1108 and the bottom edge 1110 by any suitable process, such as, for example, heat sealing. In alternative implementations, the first sidewall 1102 and the second sidewall 1104 may not be joined along a side edge. Rather, the first sidewall 1102 and the second sidewall 1104 may be a single, unitary piece. In other words, the first sidewall 1102 and the second sidewall 1104 may form a sleeve or balloon structure.

In some implementations, the bottom edge 1110 or one or more of the side edges 1106, 1108 can include a fold. In other words, the first sidewall 1102 and the second sidewall 1104 may comprise a single unitary piece of material. The top edges 1111 of the first sidewall 1102 and the second sidewall 1104 may define an opening 1112 to the interior of the thermoplastic bag 1100 having a complex stretch pattern. In other words, the opening 1112 may be oriented opposite the bottom edge 1110 of the thermoplastic bag 1100 having a complex stretch pattern. Further, when placed in a trash receptacle, the top edges 1111 of the first and second sidewalls 1102, 1104 may fold over the edges of the receptacle.

In some implementations, the thermoplastic bag 1100 having the complex stretch pattern can optionally include a closure mechanism 1114 positioned adjacent the top edge 1111 for sealing the top of the thermoplastic bag 1100 having the complex stretch pattern to form an at least substantially fully enclosed container or vessel. As shown in fig. 11, in some implementations, the closure mechanism 1114 includes a draw tape 1116, a first hem 1118, and a second hem 1120. In particular, the first top edge 1111 of the first sidewall 1102 may be folded back into the interior volume and may be attached to the interior surface of the first sidewall 1102 to form the first hem 1118. Similarly, the second top edge 1111 of the second sidewall 1104 folds back into the interior volume and may be attached to the interior surface of the second sidewall 1104 to form a second hem 1120. The draw tape 1116 extends through the first and second hems 1118, 1120 along the first and second top edges 1111. The first hem 1118 includes a first aperture 1122 (e.g., a notch) extending through the first hem 1118 and exposing a portion of the draw tape 1116. Similarly, the second hem 1120 includes a second aperture 1124 extending through the second hem 1120 and exposing another portion of the draw tape 1116. During use, pulling the pull strip 1116 through the first and second apertures 1122, 1124 will cause the first and second top edges 1110 to contract. Thus, pulling the draw tape 1116 through the first and second apertures 1122, 1124 will at least partially close or reduce the size of the opening 1112 of a thermoplastic bag having a complex stretch pattern. The draw tape closure 1114 may be used with any of the implementations of the reinforced thermoplastic bags described herein.

Although the thermoplastic bag 1100 having a complex stretch pattern is described herein as including the draw tape closure 1114, one of ordinary skill in the art will readily recognize that other closure mechanisms 1114 may be implemented into the thermoplastic bag 1100 having a complex stretch pattern. For example, in some implementations, the closure 1114 can include one or more of the following: a flap, tape, a fold closure, an interlocking closure, a slider closure, a zipper closure, or any other closure structure known to those skilled in the art for closing a bag.

As shown in fig. 11, a thermoplastic bag 1100 may include a complex stretch pattern 220 formed in one or more of a first sidewall 1102 and a second sidewall 1104, for example, as discussed below, the complex stretch pattern may be formed in the first sidewall 1102 and/or the second sidewall 1104 via one or more of SE L F or micro SE L F rollers, the plurality of rib-like elements and the plurality of connection regions of the complex stretch pattern 220 are sized and positioned such that the thermoplastic bag 1100 has a stretch curve with a complex shape, the thermoplastic bag 1100 undergoes both geometric and molecular deformation in an initial elongation zone when strained, the thermoplastic bag 1100 undergoes multiple stages in which a substantial portion of the deformation of the thermoplastic bag is geometric deformation, and/or forms a wave in the thermoplastic bag 1100 having one or more of a height of greater than 3000 microns or a width of greater than 3000 microns when subjected to an applied and subsequently released load.

Fig. 12 illustrates yet another thermoplastic bag 1200 in which the sidewall includes a complex stretch pattern 220d formed therein. Thermoplastic bag 1200 may comprise the same structure as thermoplastic bag 1100, but with a different complex stretch pattern. In particular, the thermoplastic bag 1200 may include a plurality of rib-like elements 1204 in a hexagonal pattern. As shown, the fin-like element 1204 is surrounded by the parting region 302 c. The plurality of fin-like elements and the plurality of parting zones of the complex drawing pattern 220d are sized and positioned such that: the thermoplastic bag 1200 has a stretch curve with a complex shape; the thermoplastic bag 1200 undergoes both geometric and molecular deformation in the initial elongation zone when strained; the thermoplastic bag 1200 undergoes multiple stages in which a major portion of the deformation of the thermoplastic bag is geometric deformation; and/or when subjected to an applied and subsequently released load, form waves in the thermoplastic bag 1200 having one or more of a height greater than 3000 microns or a width greater than 3000 microns.

As further shown in fig. 12, the complex stretch pattern 220d includes parting regions 302c having portions parallel to the direction of the applied force (e.g., TD direction) and portions that are not parallel to the direction of the applied force. For example, in a use case where a consumer pulls the thermoplastic bag 1200 upward by a draw tape, the direction of the applied force is in the same direction (e.g., substantially vertical) as the consumer pulls. Thus, the parallel portions of the parting region 302c are those portions having a length perpendicular to the top and bottom of the thermoplastic bag 1200. As a result, the non-parallel portions of the parting region 302c are those portions of the length that extend from the top and bottom of the thermoplastic bag 1200 in a non-perpendicular direction (e.g., at an angle other than 180 degrees from vertical).

In one or more embodiments, thermoplastic bag 1200 (e.g., and the thermoplastic film comprising thermoplastic bag 1200) may exhibit low force elongation properties even when only a portion of parting region 302c is oriented parallel to the direction of the applied force. As discussed above with reference to fig. 8A and 8B, when one hundred percent of included parting region is parallel to the direction of the applied force (e.g., TD direction), the film exhibits the best low force elongation properties. In an alternative or additional embodiment, the film may still exhibit advantageous low force elongation properties when only a certain percentage of the typing regions are oriented parallel to the direction of the applied force. For example, in some embodiments, the complex stretch pattern may exhibit low force elongation properties when at least fifty percent of the included parting zone is parallel to the TD direction. Similarly, a complex stretch pattern may exhibit low force elongation properties when less than another one hundred percent (e.g., at least eighty percent) of the included typing zone is parallel to the TD direction.

Fig. 13 illustrates a thermoplastic bag 1300 in which the sidewall includes a complex stretch pattern 220f formed therein. In particular, the complex stretch pattern 220f may include rib-like elements 1304a in an octagonal pattern, rib-like elements 1304b in a diamond pattern, and a parting zone 302d between and surrounding the octagonal pattern and the diamond pattern. The plurality of fin-like elements and the plurality of connecting regions of the complex stretch pattern 220f are sized and positioned such that: the thermoplastic bag 1300 has a stretch curve with a complex shape; the thermoplastic bag 1300 undergoes both geometric and molecular deformation in the initial elongation zone when strained; the thermoplastic bag 1300 undergoes multiple stages in which a major portion of the deformation of the thermoplastic bag is geometric deformation; and/or when subjected to an applied and subsequently released load, form waves in the thermoplastic bag 1300 having one or more of a height greater than 3000 microns or a width greater than 3000 microns.

As discussed above with reference to fig. 12, the thermoplastic bag 1300 exhibits low force elongation properties even if less than one hundred percent of the parting zone 302d is parallel to the direction of the applied force. For example, as shown in fig. 13, the parting regions 302d at the top, bottom and sides of each region of the rib-like elements 1304a in the octagonal pattern are oriented parallel to the TD direction. The remaining typing region 302d is oriented non-parallel to the TD direction. In one or more embodiments, the complex stretch pattern 220f will exhibit favorable low force elongation properties as long as a threshold percentage or portion of the typing regions 302d are oriented parallel to the direction of the applied force (e.g., TD direction).

While the bags shown and described above include complex stretch patterns formed in the entire sidewall of the bag, it will be understood in light of the disclosure herein that the present invention is not so limited. In alternative embodiments, the bag may include complex stretch patterns in multiple zones or regions to provide customized stretch properties to different regions of the bag. For example, fig. 14 illustrates a thermoplastic bag 1400 that includes a complex stretch pattern 220a formed in a strip near a hem 1402 of the bag 1400. Thus, as shown, the bottom portion 1404 (i.e., each sidewall) of the bag 1400 is free of rib-like elements.

Fig. 15 illustrates another thermoplastic bag 1500 that includes a complex stretch pattern 220a formed in a strip near the hem 1502 of the bag 1500. Instead of the intermediate portion 1504 (i.e., each sidewall) of the bag 1500 being free of rib-like elements, the intermediate portion 1504 includes progressively stretched ribs formed by ring rolling, as described in U.S. patent No. 9,637,278, the entire contents of which are incorporated herein by reference. The thermoplastic bag 1500 also includes an unstretched bottom region 1506 that is free of rib-like elements and gradual stretching.

To create bags with complex stretch patterns as described, a continuous web of thermoplastic material may be processed through a high speed manufacturing environment such as that illustrated in fig. 16. In the illustrated process 1600, production can begin by unwinding a first continuous web or film 1680 of thermoplastic sheet material from a spool 1604 and advancing the web in a machine direction 1606. Unwound web 1680 may have a width 1608 that may be perpendicular to machine direction 1606, as measured between a first edge 1610 and an opposite second edge 1612. Unwound web 1680 can have an initial average thickness 1660 measured between first surface 1616 and second surface 1618. In other manufacturing environments, web 1680 may be provided in other forms or even extruded directly from a thermoplastic forming process. To provide the first and second side walls of the finished bag, web 1680 may be folded about machine direction 1606 by folding operation 1620 into first half 1622 and an opposing second half 1624. When so folded, the first edge 1610 may move adjacent to the second edge 1612 of the web. Thus, the width of web 1680 advancing in the machine direction 1606 after the folding operation 1620 may be a width 1628 that may be half of the initial width 1608. As can be appreciated, the middle width portion of the unwound web 1680 may become the outer edge of the folded web. In any event, a hem may be formed along adjacent first and second edges 1610, 1612, and a draw tape 1632 may be inserted during the hem and draw tape operation 1630.

To form the complex stretch pattern 1668, the processing equipment may include SE L F intermeshing rolls 1642, 1643, such as those described above, referring to fig. 16, the folded web 1680 may be advanced along a machine direction 1606 between SE L F intermeshing rolls 1642, 1643, which may be arranged to rotate in opposite rotational directions to impart the final complex stretch pattern 1668 to facilitate patterning of the web 1680, the first roll 1642 and the second roll 1643 may be urged or guided against each other by, for example, hydraulic actuators.

In the illustrated implementation, the complex stretch pattern 1668 intermeshing rollers 1642, 1643 can be arranged such that they are coextensive with or wider than the width 1608 of the folded web 180. In one or more implementations, the complex stretch pattern 1668 intermeshing rollers 1642, 1643 can extend from near the folded edge 1626 to adjacent edges 1610, 1612. To avoid imparting the complex stretch pattern 1668 onto the portion of the web that includes the draw tape 1632, the corresponding ends 1649 of the rollers 1642, 1643 may be smooth and free of ridges and grooves. Thus, adjacent edges 1610, 1612 and corresponding portions of the web near those edges that pass between the smooth ends 1649 of the rollers 1642, 1643 may not be imparted with a complex stretch pattern 1668.

More specifically, the thermoplastic film 1680 is passed between a first intermeshing roll 1642 and a second intermeshing roll 1643, wherein at least one of the first and second intermeshing rolls comprises repeating units of a plurality of ridges, a plurality of notches, and a plurality of grooves. Wherein the repeating units form a complex stretch pattern in the thermoplastic film, the complex stretch pattern comprising a plurality of rib-like elements and a plurality of parting zones positioned to extend in the first direction. The plurality of fin-like elements and the plurality of parting zones are sized and positioned such that the thermoplastic film provides low force extensibility when subjected to an applied force in a first direction

The processing equipment can include pinch rollers 1662, 1664 to accommodate the width 1658 of the web 1680. To produce the finished bag, the converting equipment may further process the folded web to have a complex stretch pattern. For example, to form the parallel side edges of the finished bag, the web may be advanced through a sealing operation 1670, wherein a heat seal 1672 may be formed between the folded edge 1626 and the adjacent edges 1610, 1612. The heat seals may fuse adjacent halves 1622, 1624 of the folded web together. The heat seals 1672 may be spaced along the folded web and, in combination with the folded outer edges 1626, may define individual pockets. The heat seal may be formed with a heating device, such as a heated knife. A perforation operation 1681 may perforate 1682 the heat seal 1672 with a perforation device (such as a perforation knife) such that individual bags 1690 may be separated from the web. In one or more implementations, the web may be folded one or more times, and then the folded web may be directed through a perforating operation. The web 1680 embodying the bag 1684 may be wound into a reel 1686 for packaging and dispensing. For example, the reel 1686 may be placed in a box or bag for sale to a customer.

In one or more implementations of the process, cutting operation 1688 may replace piercing operation 1680. Prior to winding onto spool 1694 for packaging and distribution, the web is directed through a cutting operation 1688 that cuts the web into individual bags 1692 at location 1690. For example, the reel 1694 may be placed in a box or bag for sale to a customer. The bags may be interleaved before being wound into a spool 1694. In one or more implementations, the web may be folded one or more times and then the folded web cut into individual bags. In one or more implementations, the pocket 1692 may be positioned in a box or pocket rather than on the spool 1694.

FIG. 17 illustrates a modified high-speed manufacturing 1600a that involves unwinding a second continuous web or film 1682 of thermoplastic sheet material from a spool 1602 and advancing the web in a machine direction 1606 the second film 1682 may comprise a similar or the same thermoplastic material, width, and/or thickness as the first film 1680 in an alternative one or more implementations, one or more of the thermoplastic material, width, and/or thickness of the second film 1682 may be different than the first film 1680. the films 1680, 1682 may be folded together during a folding operation 1620 such that they are passed together through SE L F intermeshing rolls 1642, 1643 to form complex stretch patterns and resulting multi-layer bags.

The sample used for this test is 1 inch wide × 2 inches long with the long axis of the sample cut parallel to the direction of maximum extensibility of the sample.

The grips of the instron machine are comprised of air actuated grips designed to concentrate the overall gripping force along a single line perpendicular to the direction of test stress, these grips having one flat surface and opposing faces with a semi-circle protruding therefrom to minimize slippage of the specimen. The distance between the lines of gripping force should be 2 inches as measured by a steel ruler held alongside the gripping portion. This distance will be referred to as "gauge length" from now on. The sample is mounted in the grip with the long axis of the sample perpendicular to the direction of the applied percent elongation. The crosshead speed was set at 10 inches/minute. The crosshead extended the sample until it broke, at which point the crosshead stopped and returned to its original position (0% elongation).

The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. For example, the implementations shown and described relate to non-continuous (i.e., discontinuous or partially discontinuous lamination) to provide a weak bond. In an alternative implementation, the lamination may be continuous. For example, multiple film layers may be coextruded such that the layers have the bonding strength to provide for delamination before the film fails to provide benefits similar to those described above. The described implementations are, therefore, to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.