Breathable composite elastic material having a cellular elastomeric film layer and method of making same

A breathable cellular elastomer material having cells created therein by a cell opening agent, said material being at least partially air permeable, capable of transmitting water vapor th through and being elongatable, wherein said material is incorporated into a laminate material produced by a method, comprising:

• a) providing a layer of a spunbond material;
• b) providing a layer of an elastomeric film being essentially free of polystyerene homopolymer and having apertures formed therein by mixing a polymer material with a cell opening agent to form a mixture and extruding said mixture through a die such that apertures are formed therein, said apertures comprising cells, at least a portion of said cells being closed;
• c) stretching said film of step b);
• and,
• d) laminating said stretched elastomeric film of step b) and said spunbond,
• said breathable cellular elastomer being breathable and having an elongation at break of from about 300 to about 600 percent and being retractable by at least 75% of said elongation.

A breathable cellular elastomer material having cells created therein by a cell opening agent, said material being essentially free of polystyrene homopolymer and at least partially air permeable, capable of transmitting water vapor therethrough and being elongatable, wherein said material is incorporated into a laminate material produced by a method, comprising

• a) providing an isocyanate material;
• b) providing a polyol material;
• c) providing a catalyst material;
• d) providing an effective amount of water;
• e) mixing said polyol material, catalyst material and water to form a mixture;
• f) mixing the mixture of step e) with said isocyanate material to form a second mixture;
• g) dispensing said second mixture through a die head onto a surface to form a cellular foam at least a portion of said foam having closed cells;
• h) stretching said from step g) and;
• i) laminating said stretched foam of step h) to at least one layer of a non-extendable material so as to form a breathable elastomeric material;
• said breathable cellular elastomer material being breathable and having an elongation at break of from about 300 to about 600 percent retractable by at least 75% of said elongation.

A breathable cellular elastomer filament material having cells created therein by a cell opening agent said material being at least partially air permeable, capable of transmitting water vapor therethrough and being elongatable, wherein having apertures formed therein by a process, comprising:

• a) providing an elastomeric polymer material essentially Se of polystyrene homopolymer;
• b) providing a cell opening material capable of releasing a gas;
• c) said polymer material and said cell opening material to form a mixture;
• and,
• d) extruding said mixture an extrusion die such that said cell opening material produces a gas whereby apparatus are formed at least partially, within the extruded material, at least a portion of said apertures being closed cells.