Polymer transfer apparatus, methods, and composite webs

A method for producing a composite web, the method comprising:

• providing a forming tool comprising an exterior surface that comprises one or more depressions formed therein;
• delivering a molten thermoplastic composition onto the exterior surface of the forming tool;
• maintaining the exterior surface of the forming tool at a roll temperature that is below a melt processing temperature of the thermoplastic composition;
• wiping the molten thermoplastic composition on the exterior surface of the forming tool, wherein at least some of the molten thermoplastic composition enters the one or more depressions;
• transferring the thermoplastic composition in the one or more depressions to a substrate by contacting a first major surface of the substrate to the molten thermoplastic composition in the one or more depressions;
• separating the substrate and the thermoplastic composition in the one or more depressions from the forming tool after the transferring, wherein a composite web is formed that comprises one or more polymeric structures of the thermoplastic composition located on the first major surface of the substrate, wherein the thermoplastic composition comprises one or more elastomeric polymeric components such that the one or more polymeric structures on the substrate exhibit elastic behavior;
• and
• stretching the composite web and the one or more polymeric structures located thereon such that the substrate exhibits permanent elongation after the stretching and such that a portion of the one or more polymeric structures detaches from the first major surface of the substrate.