Anisotropic Foam-Film Composite Structures

Abstract

Multilayer foam-film composite structures in which the cells of at least one foam layer have an anisotropic orientation exhibit at least one enhanced property of toughness, tear resistance and puncture resistance in comparison with a foam-film composite structure alike in all aspects except for the anisotropic orientation of the cells of at least one foam layer.

1 . A method of a making a multilayer film-foam composite structure comprising at least one film layer and at least one foam layer, the foam layer comprising anisotropic cells, the method comprising co-extruding film-foam laminates and subjecting the co-extruded laminate to a deformation process in at least one direction. 
     
     
         2 . The method of  claim 1  in which the deformation process comprises drawing the structure between a slot die and a film or sheet casting roll at a predetermined drawing ratio. 
     
     
         3 . The method of  claim 1  in which the deformation process comprises parison inflation. 
     
     
         4 . The method of  claim 1  in which the deformation process comprises tenter-frame stretching. 
     
     
         5 . The method of  claim 1  in which the deformation process comprises in-line vacuum forming. 
     
     
         6 . The method of  claim 2  in which the drawing ration is at least about 2:1. 
     
     
         7 . The method of  claim 1  in which the co-extruded laminate is deformed in at least two directions. 
     
     
         8 . The method of  claim 1  in which the co-extruded laminate is deformed in three directions.