CA2243390A1 - Female component for refastenable fastening device having regions of differential extensibility - Google Patents

Abstract

A female component for a refastenable fastening device having an elastomeric adhesive backing (34) and a multiplicity of fibrous elements (30) extending from the backing. The female fastening component is formed by a method comprising the steps of: providing a first lamina comprising an elastomeric, pressure-sensitive adhesive film having a first adhesive surface (31) and a second adhesive surface (33) opposed to said first adhesive surface, a relaxed orientation, an elongated orientation and preferably at least two regions of differential elongations; stretching said first lamina from said relaxed orientation to said elongated orientation; contacting a second lamina comprising a nonwoven web (30) with said first surface of said first lamina in said elongated orientation, thereby directly joining said second lamina and said first lamina to form a laminate; and relaxing said first lamina such that said second lamina is shirred to form catching regions capable of entangling the hooks (28) of a complementary male fastening component (20).

Description

W O 97/25893 PCTrUS97/00635 FEMALE COMPONENT FOR REFASTENABLE FASTENING D~VICE
HAVING REGIONS OF DIFFERENTIAL EXTENSlBILITY

FIELD OF THE INVENTION
The present invention relates to a female component for refastenable hook and loop type fastening devices and. more particularly~ to a low-cost female component for a hook and loop type fastening device having regions of differential l~ elongation.

BACKGROUND O~ THE INVENTION
Refastenable fastening devices of the hook and loop type are currently used widely in a great number of situations. Such ref~ct~n~hle f~ctening devices havebeen particularly useful in clothing. disposable absorbent articles. and the like. Such devices are used when it is desirable to create a ref~cfen~ble bond between two or more articles or between several surfaces of the same article. ln certain applications.
these ref~Pn~ble f~ct~ning devices have replaced conventional buckles. zippers.
buttons. snaps, tie fasteners. and sewing.
~5 A popular type of mech:~nic~l fastener currently in wide use which utilizes mechanical çnt~nglennent to create a ref~cten~hle bond is sold under the trademark "VELCRO". VELCRO fastening devices are described in greater detail in U.S.
Patent 2,717,437, U.S. Patent 3,009,235, U.S. Patent 3,266,113, U.S. Patent 3,550,837. U.S. Patent 4,169,303, and U.S. Patent 4,984,339.
VELCRO f~ctent~rs utilize two components. A male component and a female component. The male and female components are often referred to as the hook and loop components, respectively. The male component contains a plurality of resilient, upct~n~1ing hook shaped elements. The female component of the f~tening device generally consists of a fabric cont~ining a plurality of upstanding 3~ loops on its surface. When the male component and the loop component are pressed together in a face to face relationship to close the f~ct~nin~ device, the hooksentangle the loops forming a plurality of mechanical bonds between the individual _ hooks and loops. When these bonds have been created. the components will not ~enerall- ~liceng~ge under normal cond;tions., This is because it is very difficult to ~e~ldLe the components by attempting to disengage all the hooks at once. However.
when a _radual peeling force is applied to the components. disen~pt~m~nt can be easily effected. Under a peeling force. since the hooks are comprised of a resilient material. thev will readily open to release the loops.
This type of f~ct~ning device has been found especially useful on disposable artic}es such as disposable garments. disposable diapers disposable packages.
cartons. and the like. Such f~ctening devices provide a secure closing means.
o However. the use of existing f~ct~ning devices of this type on disposable articles has been limited due to the fact that such fastening devices are relatively costly. A
major reason that such f~ct~ning devices are costly is that they have high m~mlfa~tllring costs. These high manufacturing costs are associated with both the hook and loop colllpo~ of these devices.
Conventional hook and loop components are typically formed by making a fabric with a number of woven loops ext~n~ling outwardly from a b~ckinp, The loops may be provided by weaving a base fabric contzlinin~ supplem~nt~ry threadsto form the loops. or by knittinp the loops into a fabric. In other hook and loop culllpon~ . the loops may be formed by pleating or corrugating processes. The male components of such f~ctenin~ devices are typically formed by subsequently cutting the loops. The cut loops serve as the hooks of the male component.
These processes generally produce costly hook and loop f~ctening materials because they are relatively slow. The hook and loop components of such f~ct.oning devices are also usually made out of the same relatively expensive material. This m~te~i~l is relatively e~ ,ive because the material used in the male component needs to be resilient so that the hooks can flicpn~ge from the loop component when the device is open.
Several aLlt;l~ have been made to make ~It~rn~tive types of female c~ pone.lts for f~ctening devices. However, such attempts have generally suffered from a number of drawbacks.
U.S. Patent 3.694,867 issued to Stumpf on October 3, 1972. discloses a "separable clasp" having a female component that comprises a "high loft" nonwoven fabric and a b~cking layer of consolidated flexible adhesive. However. the loop component disclosed in the Stumpf patent is ~ ed by performing the steps of:
3~ (1) activating an open pattern adhesive in which the fibers are imberl~i~oA, (2 consolidating the adhesive into a s-lhst~nti~llv continuous backing layer. and (3) W O 97/25893 PCTrUS97/00635 simnltzln~ously looping portions of the fibers such that the fibers form individual loops that extend outwardly from the bz~ckinsg The female component disclosed inthis patent suffers from the drawback that it is made bv processes that involvesmechanicallv manipulating fibers in the forrn of loops. Thus. the female components described therein do not appear to be significantly less expensive tomstnufz~tnre than conventional loop components.
U.S. Patent 4,761.318 issued to Ott. et al. on August ~. 1988, discloses a loop fastener that can collLt~ )o.dlleously be both formed and also zlttz~h~d to a substrate without the need for any additional steps such as sewing or nti~i7in~ pressure o sensitive adhesives to affix it to the substrate. However, the Ott loop fastener comprises a fibrous structure having a multiplicity of loops that is adhered to a layer of thermoplastic resin. Thus. the process disclosed in this patent suffers from the drawback that heat must be applied to bond the fibrous structure to the backing.U.S. Patent 3.70~.~33 issued to Ribich. et al. on January 9. 1973. discloses a n~ refastenable fzlcf~ening device having a female component that comprises reticulated urethane foam secured to a bztl~king layer. The female conl~one-lt disclosed in the Ribich. et al. patent suffers from the drawback that foarns typically do not have enough openin~s for the hooks of conventional male components to ,v .~ dLe. In addition. reticulated foam generally does not have sufficient strength to hold such 20 hooks when forces are applied to the fz~ct~-ning device. Further. mzlmlfzlt~tllring reticulated foam is a relatively expensive process.
U.S. Patent 5,032.~22 issued to Noel, et al. on July 16. 1991. discloses a loop fztcterlinE material having a bz~cking of orientable material and a multiplicitv of fibrous elements ext~on~lin~ from the backing. The fibers are secured to the backing 25 while the bz~ckin~ is in a tlim~n~ionally unstable state. The backing is then caused to be ~ ,r~ ed to its ~lim~ncionally stable state thereby shearing the fibrous e}~m~ntc to form the cz~tcllit~ regions of the loop mzlf~rizl Although the Noel patent discloses an acceptable low cost loop fz~st~ning mzlt~riztl, the search has continued for more economical loop fzlct~nin~ materials and methods for producing 30 such materials.
Thus, it is an object of the present invention to provide an improved fzlct~ning device for disposable articles.
It is another ob~ect of the present invention to provide an improved female coll,ponent of a refastenable hook and loop type ~'I'~ g device.
It is a further object of the present invention to provide a female component for a hook and loop type fzlctening device which may be formed by positioning a W O 97/25893 PCTrUS97/00635 . ~

pluralitv of fil~mcntc on an elastomeric adhesive backing without manipulating the fibers into the form of loops to form a low cost loop f~ctening material.
It is another object of the present invention to provide a female component for a fastening device that can be used with both commerciallv available male components having resilient individual hooks, as well as less expensive male components with more brittle hooks than those currently in use.
These and other objects of the present invention w ill be more readily ellt when considered in reference to the following description and when taken in connection with the accompanying drawings.

SUMMARY OF THE INVENTION
The present invention provides an elastomeric loop f~ctening material having regions of differential elongation. The loop f~ct~ning material preferably has an elastomeric adhesive backing and a multiplicity of fibrous elements extenr1ing from the b~clcin~ The fibrous elements are fomned by fi~m~ntc positioned on the backing when the backing is in an elongated u~ Lion. The fil~m~ntc are preferably positioned on the b~rl~ing ecce~ti~liy parallel to each other and ess~ nti~lly parallel or perp~n~icnl~r to the path of response of the backing material. The fil:~me~tc are ~ r~.dbly i.~ ently secured to each other at spaced. fixed regions so that the fixed regions define therebetween r~tching regions. Thus, the fibrous elements are fomned by shirring of the fil~rn~nts at the r~tchinn regions when the backing material is retumed to its relaxed o. i~l.~lion.
The present invention also relates to a ~ctenin~ device having a hook f~5t~ning material and a loop f~ct~ning material. The loop f~ct~ninsg material comprises the improved loop f~ct~ning material of the present invention. The hook f~ctening material comrrices any of the well known hook f~cteninf~ materials as are known in the art and which have a base and a number of en~inE~ elements e~ct~n-ling from the bace. The loop f~cttonin~ material and the complim~nt~ry hook fastening material provide a secure closing means that will resist shear stress and peel forces encountered during use.
The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

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W O 97/25893 PCTrUS97/00635 BRlEF DESCRIPTION OF THE D~AWINGS
Figure I is a perspective view of the filaments and the backing used to fomm the present invention prior to the fil~mensc being positioned or laid down on the backing.
Figure ~ is a perspective view of the female component of the present invention when the backing is in its elongated orientation.
Figure 3 is a perspective view of the female component of the present invention when the b~cking is in its relaxed orientation.
Figure 4 is a perspective view of a f~ctcning device according to the present o invention.
Figure ~ is a greatly enlarged side view of the fibrous elements of the female component of the present invention.
Figure 6 is a greatly eniarged side view of an altemative tri-1~min~te embodiment of the present invention.
Figure 7 is a y~jyeclive view of a disposable diaper that includes the fz3ctf~ning device of the present invention.
Figure 8 is a y~-~ye~Live view of a disposable diaper that includes the f~ctening device of the present invention.
Figure 9 is a schPm~tic side view of a process for making the female component of the present invention.
Figure 10 is a sch~tn~tic top view of a part of the process for making the female com~ollcnt of the present invention.
Figure 11 is a sch.-m~tic top view of an alternative embodiment of the process for making the female component of the present invention.
Figure 17 is a s~h~m~tic top view of an altemative embodiment of the process for making the female component of the present invention.
Figure 13 is an isometric view of a part of the process for making the female component of the present invention.
Figure 14 is a sch~m~tic side view sf one embodiment of the process for making a tri-l~min~t~ embodiment of the present invention.
Figure 15 is a sch~m~tic side view of an altemati-e embodiment of the process for making a tri-1~min~tc embodiment of the present invention.

W O 97/25893 PCTrUS97100635 DETAILED DESCRIPTTON OF THE INVENTION

Over~ll Characteristics of the Refastenable Fastenin~ Device A preferred embodiment of the ref~cten~hle f~ctening device of the present inveMion. f~ctening device 20~ is shown in FIG. 4. The f~stPning device 20 comprises a nonwoven female component '2 and a complementarv hook f~cterlin component 24.
The female portion of the device. more specifically. the nonwoven female component ~or simply "fema}e component") 22 receives and engages the hooks 28 ofo the male component. The female component '~ shown in FIGS. 3 and 4 comprisesat least one nonwoven web 30 secured to a backing 34. As shown in FIG. 1. the nonwoven web 30 has an outwardly-facing surface 21 and an inwardly-facing surface 23 opposed to the outwardly-facing surface 21. The nonwoven web 30 comprises a pluraiity of fii~m~ntc (or fibers) 36 that entangle the hooks 28 of the male component 24. The b~rking has a first surface 31 and a second surface 33 opposed to the first surface 31. and preferablv comprises an elastomeric adhesive.
The male portion of the device. more specifically, the hook fastening component (or simply "hook component") 24. co,~ ises a base 26 having a first surface ''7 and a second surface 29. The base 26 comprises a plurality of ~-pstzln-lin~
en~ging elements, or "hooks" 28, extenrling from the first surface 27 The term "hook" is nonlimitin~ in the sense that the erlg~gin~ elements may be in any shape known in the art so long as they are adapted to engage a compliment~ry loop f~cteninsg co",ponent or the female component 22 of the present invention. The hooks 28 generally have heads 38 ~or en~ing means) which are disposed on top of 2~ the shanks. or stems 40. that extend from the first surface 27 of the male component 24.
The f~ctenin~ device 20 of the present invention functions in the following manner. The f~ctrning device 20 is closed when the female co,l,l,onent 22 and the male co",~onent 24 are pressed face-to-face against each other. When this happens.
the hooks 28 are ~nt~ngled by the fibers 36 of the nonwoven web 30. The nonwovenweb 30 provides space for the hooks, particularly. the heads 38 of the hooks to occupy when the fQctening device 20 is closed. The backing 34 provides a ,ul~OlLirlg foundation for the nonwoven web 30. With the hooks 28 mech~nir~lly entangled by. or "hooked", onto the fibers 36 (shown in the portion of the f~ctenin~

3' device 20 to the ri~ht side in FIG. 4). the connection between the components resists the forces that may be exerted on the f~creninD device 20.

W O 97/2~893 PCTAUS97/00635 The f~cteninsg device ~0 is opened by peeling the male component 24 away from the female component 22 (or by peeling the female component 72 away from the male component 24) If the male component 24 has resilient hooks. the peelin~action mav cause the hooks to be bent so that they are (licer~g~ged from eManglement with the fibers 36 of the nonwoven web 30 In other cases (particularlv if the hooks 28 are relatively inflexible). the hooks 28 may be separated by breaking the fibers 36 of the female component 2'. In either case. the hooks 28 are disengaged and the male component 24 is completely detached from the female component 22 The f~ctenin~ device 20 is then capable of being refastened in the o manner described above The Female Fastenin~ Component The term "nonwoven female COnlpOri.n~", as used herein refers to a female component for a ref~cten~ble f~ctening device that co-,lp~.ses a nonwoven web joined to a backing. (The nonwoven female component may also be referred to as aloop f~ctening material or simply, a loop fastener ) The terrn "nonwoven web" refers to fabrics made of fibers held together by interlocking or inter-fiber bonding which are not woven. knitted. felted, or the like. However, the nonwoven web referred to herein may comprise fibers ehat are initially c~hst~nr~ y unbonded which are subse~uently bonded to each other.
FIG. 1 shows the backing 34 and the nonwoven web 30 used to form the female coll,~onent 2 prior to their association The backing 34~ preferably an elastomeric adhesive. is shown in an elongated orientation (stretched in a direction parallel to the line clecign~t~d A-A) As used herein. the term "elastomeric" refers to ~s materials that extend in at least one direction when a force is applied and return to ap~lvkil~lately their original ~imencions after the force is released The nonwoven web 30, as shown in FIG. l, p,cf~ldbly com~rices a muitiplicity of fil~ments 36 that are joined with each other by inter-fiber bonds 32 prior to being associated with the backing 34 As used herein, the term "joined" enco., I.~cc~c configurations whereby an element is directly secured to another cl..,l.llL and configurations whereby an element is indirectly secured to another element by ~ffixing an element to int~rme~ te member(s) which in turn are affixed to another element. The terrn "inter-fiber bonds" refers to bonds that join one or more fil~mPntc to one or more other fil~mentc FIG. 2 shows a ~.ef~.. cd embodiment of the female component 22 where the backing 34 is in its elongated orientation after the nonwoven web 30 has been W O 97/25893 PCT~US97/00635 positioned on and joined to the first surface 31 of the backing 34. Preferably. the fil~m~ntc 36 of the nonwoven web 3() are aligned essentially parallel to each other and essentially perpendicular to the path of response of the backing 34. E~owever.
other configurations are contemplated wherein the fil~mPntc 36 are essentially parallel to the path of response of the backing 34. or are randomly or otherwiseoriented with regard to each other and the path of response of the b~rking 34. (The terrn "~cc~nfi~lly parallel". is used herein to mean the fil~mentc~ any individual fil~mPnrls). or portions of any fil~mPnt(s) need not extend absolutely parallel to each other or the path of response so long as the majority of the fil~m~ntc 36 extendo generally perpendicularly to each other or the path of response. ~ccenti~lly perpendicular" is used herein to indicate that the fil~mPntc~ any individual filament(s). or portions of any fil~mPnt(s) need not extend absolutely perpendicular to each other or the path of response so long as the majority of the filaments 36 extend generally perpendicularly to each other or the path of response. As used herein. the term "path of response" refers to the direction in which an elastomeric material in an elongated orientation will respond when the forces acting to elongate the el~ctomPric material are removed. Further, the fil~m~ntc 36 of the nonwoven web 30 are pl~r~ .~bly in an untensioned state when they are joined to the elongated backing 34.) The embodiment described above wherein the fil~mrntc 36 are ~o ecc~nti~lly parallel to each other and ecsPnti~lly perpendicular to the path of onse of the backing 34 helps to ensure that the fil~mPntc 36 will become "shirred" when the backing 34 contracts to its relaxed orientation ~shown in F~Ci.3).
The term "shirred" as used herein. refers to the gathering of the fil~m~ntc 36 of the nonwoven web 30 caused by the contraction of the backing 34 from its elongated orientation to its relaxed orientation such that portions of the fil~m.ontc 36 that are not secured to the backing 34 or other fil~m~ntc 36 bend away from the first surface 31 of the backing 34. The shirred fil~m~ntc 36 form ul~se~ d r~tc~hing regions 37 (loops) capable of ent~ngling the hooks 28 of a compl~ ,y male f~ct~-ning conl~ollcnt 24.
FIG. 3 shows a ~,ere.l~d embodiment of the present invention after the nonwoven web 30 and the b~c~ing 34 have been joined and after the forces acting to elongate the backing 34 have been removed such that the b~rking 34 has contracted to its relaxed orientation. The shirred fil~mAntc 36 form a multiplicity of fibrous elements 35 extPn-ling outwardly from the first surface 31 of the backing 34. Each 3~ of the fibrous elPrnPntc 35 conl~,ises a pair of fixed regions 42 (ioined to the backing 34) and an unsecured c~tching region 37 disposed between the pair of fixed W O 97/25893 PCT~JS97/~0635 ~ 9 re_ions 4~. The c:l~ching regions 37 are capable of securel,v ~ng~ginsg the hooks of a complementary hook f~ct/~ning component to provide a f~ctening device ~0. as is shown in FIG. 4.
FIG. 6 shows an alternative embodiment of the female component '~? of the present invention comprising a second lamina 80 joined to the second surface 33 of the elastomeric adhesive backing 34 to forrn a tri-l~min~f~ 85, Joining a secondlamina 80 to the elastomeric adhesive backing 34 provides the female fact~ning component with additional adv~nS~gec For inct~n~e~ the tri-l~min~te material 85 may be incorporated into a disposable absorbent artiele. sueh as a diaper as an o elastomeric w~icth~ntl capable of eng~ging the hooks of a complem~nt~ry male f~ctening component. Further. the tri-l~min~te 85 provides an elastomeric femalef~ct~ninsg component ~ capable of ~ng~ging the hooks 28 of a complem~nf~tY male f~ct~ning component 24 on two opposing surfaces.
In an espeeially ~fc~ d ~If~tn~five embodiment of the present invention.
the second lamina 80 comprises a nonwoven web such as the nonwoven web 30 described above with respeet to the female f~ctening eomponent _, However. a suitable lamina may be m~nnf~etl~red from a wide range of materials. including plastic films: woven webs of natural fibers (e.g, wood or cotton), synthetic fibers (e.g. polyester or polypropylene). or a eombination of natural and synthetie fibers:
~o foams: or natural or s,vnthetic rubber.
The second lamina 80 may be joined to the elastomeric adhesive b~ekin~ 34 in the manner deseribed with respeet to the nonwoven web 30 or any other method as is known in the art. Further. the seeond lamina 80 may be joined to the backing 34 contemporaneouslv with the nonwoven web 3Q when the backin~ 34 is in an 2~ elongated orientation or at any other time after the adhesive backing 34 is forrned.
Embo-ii..,G.~Ic are also eontemplated wherein the tri-l~min~te 85 eomprises the baeking described below ineluding regions of differential elongation. In a ",G~..~,d embodiment, however, the lamina 80 is joined to the backing 34 after the nonwoven web 30 has been joined to the baeking 34 and after the b~e~insg 34 has been at least partially relaxed. (An elastomerie material in an elongated orientation is "partially relaxed" when the forees stretching the elastomerie material are redueed~ allowing the m~tPri~l to eontraet but not eompletely relax. Thus. an elastomerie material in a - partially relaxed eondition is still eapable of eontraeting further to its relaxed orientation after the forees are eompletely removed.) Joining the second lamina 80 3' after the baeking 34 has been at least partially relaxed ensures that the fibrous elements 35 of the nonwoven web 30 will remain shirred when the female f~ct~?ning W O 97/25893 PCTrUS97tOO635 component 2' is stretched. This is because the second lamina 80 will become fully extended to its elastic limit before the nonwoven we~ 30. thus m~int~ininsg at least some shirring in the fil~rn~nt.c 36 of the nonwoven web 30. Thus. an elastomericnonwo~en female component ~ is provided that will m~intz~in its ability to entangle the hooks 28 of a complementary male fastening component 24 even after the female component '" has been stretched to a point where the second lamina 80 is fully extended. (If the second lamina 80 is joined to the backing 34 when the b~nking 34 is in its fully relaxed orientation, the female component '2 will lose its elastomeric qualities. Thus. such an embodiment is not preferred where the female col.lpo~ to must be capable of stretching.) F~GS. 11 and 12 show the backing 34 of the present invention comprising two or more regions which are subjected to differing amounts of elongation in the cross-machine direction. ~In FIG. I l. the b~cking 34 has regions 34a and 34b. in FIG. ~2. the backing 34 has regions 34a, 34b and 34c.) The differential elongation can provide the female component 22 with a number of unique characteristics. ~Asused herein, the terrns "differential elongation" or "differential stretch" refer to regions of a material that have been subjected to unequal arnounts of elongation.) One unique characteristic that may be provided by differentially stretching the backing 34 is a female co~llpon~.lt 22 having regions that elongate to different~o extents when a given stretching force is applied. For exarnple. region 34a of the backing 34, as shown in FIG. 11. could provide less nosict~n~e- and thus elongate more than region 34b for any given force applied to elongate the female component 22 in the cross-m~ hinP direction. Likewise. as shown in FIG. 12. region 34b would generally elongate more than either region 34a or 34b of backing 34 for any given force applied to the female coll-po~ L 2~. Thus. an elastomeric female component22 could be configured such that portions elongate more than other portions which could. in turn~ provide different ~ng~ging characteristics with regard to mating male colllyollents 24.
Another uniclue characteristic proyided by differentially stretchin~ the backing 34 is a female co~npol.~.lt 22 having regions conl~ ,ing ~t~hing regions 37 of different loft. (As used herein. the terrn "loft" refers to the height or ~lict~nce that a portion of a fi~mcnt 36 is away from the b~rking 34.) When a nonwoven 30 is joined with the backing while the backing 34 is in an elongated configuration.
certain fil~rnentc of the nonwoven will become shirred when the elongation force is 3~ removed. ~f the pattern which joins portions of the fil~m~nt.c 36 is uniform throughout the dif~erentially stretched regions of the barking~ those portions of the W O 97/25893 PCTrUS97/00635 -female component comprising the most elongated portions of the backing 34 shouldcomprise shirred filaments 36 with the greatest loft. (Nonuniforrn patterns of joining the fil~mçntc 36 to the b~cking may be used to exaggerate or reduce the difference in the loft att:~ineci by the different regions of the female component.) Thus. forexample. the fil~m~nt~ 36 joined to the region 34a would generally have more loft than the fil~mentc 36 joined to the region 34b of the backing shown in FIG. 11 if a similar pattern were used to join the nonwoven to the entire backing 34. This could provide an elastomeric female colllyohenl 22 with different çng~ginE characteristics with regard to mating male components 24.
o Yet another unique characteristic made possible by dirr~l~e.,lially stretching the backing 34 is an elastomeric female component 2'' that is capable of m~ir~t~ )g its ability to engage a mating male component 24 when elongation forces are applied. As noted above. when a nonwoven web 30 is joined with a backing 34 having regions of differential stretch, the loft of the fil~m~nt~ 36 may vary throughout the female con-~onent 22. Thus. where the fil~mPntc 36 have less loft, that portion of the female conlpollel.L 22 will generally reach its elastic limit prior to the regions of greater loft when a force is applied to elongate the female component 2~ in the cross-m~rhin~ direction. (As used herein. the term "elastic limit" refers to the point at which a material has been elongated to the point at which the material can no longer be aLI~L~ ed without rupture, tearing or sl~hst~nti~l deforrnation of the fil~m~-nt~ 36 and/or the b~c~ing 34.) In some in~t~n~es. an elastomeric female component or portions of an ela~ ,.;c female component that have been elongated will lose the ability to effectively engage a mating male colllpolltllt 24 because the c~t~hing regions 37 comprising shirred fii~ment~ 36 have been elongated so as toremove the loft associated with the shirring of the filaments 36. Therefore. it is advantageous to be able to configure an elastomeric female colllponenl 72 such that certain decign5lt~ri low loft regions stretch to their elastic limit before other higher loft regions. thus preventing the higher loft regions from losing the ability to engage a mating male component 24. (The above-mentioned examples should not be considered to limit the scope of the invention in any way. It is understood that a - female c~,.. pc .. e.. ~ could be configured such that the low loft regions stretch to their elastic limit with the same of less force than some or all of the higher loft regions do.
- Thus. it is not i.llpO-~-t which region(s~ reach their elastic limit with the least force, but rather that at least one region has sufficient lofted filz~mentc 36 so as to provide a 3~ suitable entanglement zone for the specified need considering the forces that the whole or portions of the female component will be subjected to.

CA 02243390 l998-07-l7 W O 97/2~893 PCT~US97/0063 1 The Nonwoven Web The fibrous elements 35 of the present invention are preferably formed from filzlmentc36 positioned on and secured to the backing 34. As used herein. the term "filament" defines a member having a high ratio of length to diameter or width.
(FIG 5 shows a portion of the female f~ctening component ~ greatly enlarged to show the filaments 36 in detail ) Thus. a filament may be a fiber. a thread. a strand.
a yarn or anv other member or combination of these members. including fii~mentc that are pr~ h~0d together in nonwoven webs. as are known in the art. Suitable o materials for such fii~mentc 36 include natural fibers such as cotton or wool:
synthetic fibers of nylon. polvamides. polyesters. or polyolefins: spun varns;
polyethylene fibers; polypropylene fibers; nylon fibers. non-woven webs: or any other material or combination of materials known in the art and suitable for use herein.
The fil~m~ntc 36 may be m~nllf~rtllred using a number of m~nllf~rJllring techniques inclu~iing those such that the fil~m~ntc are spun. blown. or the like.
Preferably, each fil~mrnt 36 comprises a polypropylene fibers of between about ~and about 15 denier. The individual fil~m~ontc 36 are preferably comprised in a nonwoven web 30 having a basis weight of between about 10 g/yd2 and about 40 20 g/yd2 (about 12 g/m2 to about 48g/m2), more preferably between about 15 g/yd2and about 25 g/yd2 (about 18g/m2 and about 30glm2). The nonwoven web 30 may comprise fil~m~ntc 36 having similar or different deniers and lengths Further. the nonwoven web 30 may comprise a mixture of fil~mrntc 36 comprisin~ different m~trri~lc Some nonwoven webs cO,llplisillg suitable fii~mentc include the carded25 polypropylene nonwoven web m~nllf~ctllred by the Veratec Nonwoven Group of the Tnt/~m~tional Paper Company, of Walpole, lvl~cc~r~ cetts under the trade name P-11.
the spunbonded polypropylene nonwoven web P-9, and the carded polypropylene nonwoven web P-8. Other suitable nonwoven webs co~ ";!~;r.~ suitable filz~mrntc include COROVON spunbonded polypropylene m~nnf~rt~lred by Corovin GmbH of 30 Germany. and CELES~RA rn~nllf~rt---ed by the Jarnes River Corporation The lengths of the fil~m~ntc 36 in the nonwoven web 30 depend upon the type of process used to make the nonwoven web 30 For inct~nre if a carded nonwoven web is used the fil~m.ontc 36 that comprise such a web can have lengthsthat range from about 0.5 inches to about 5 inches (from about 1 cm. to about 1335 cm.~. In ~ lcd carded nonwoven webs, the fil~n~rntc are between about 1 inch and about 3 inches (between about 2 5 cm. and about 8 cm ) long Alternatively. if a W O 97/25893 PCTr~S97/~0635 spunbonded nonwoven web is used. the filaments36 of such a web will typically becontinuous len~th. (As used herein. the term "continuous" refers to relativelv long filaments that run the entire length of the nonwoven web.~
A ~.er~..ed fi}ament 36 has a length to make at least one complete fibrous element 35. Thus, for example. the fil~m~nt 36 may only have a pair of fixed regions 42 positioned adjacent its ends so that the fibrous element 3~iS forrned of a whole fil~m~r-t 36. More preferably~ the fil~ment 36 has a number of fixed regions 42 positioned along its length to foml a plurality of fibrous elements 35 along each filament 36. If the fi~m~ntc 36 are short. or staple, complete fibrous elements 35 o having two fixed regions 42 and c~tching regions 37 may not be forrned. The resulting incomplete fibrous elements 35 may not be able to securelv engage the hooks ~8 of a complementary hook f~ct~ning material 2~. Thus. the ability of thenonwoven female component 22 to provide a secure closure may be ~limini~h~o~
The amount of inter-fiber bonding between the fil~m~ntc 36 of the nonwoven 13 web 30iS also an illlyO~ factor relevant to the ability of the female co~ on~,llt 2'7 of the present invention to entangle the complementary hook f~ct~nin~ component 24. An excessive number of bond sites created between the fil~m.ont~ 36 in the nonwoven web 30 will tend to i"l~.~.e with the entry of hooks 28 into the nonwoven web 30, thus reducing the shear strength of the f~reninE~ device. (In general. the strength of the f~ctening device will be increased as more hooks are able to enter and engage the nonwoven web.) Altematively, too few inter-fiber bonds 32 may increase the number of fil~n~Pnr~ 36 having loose ~unbonded~ ends, thus reclu~ ing the female component's 22 ability to entangle the hooks 28 of the complementary hook f~ct~ning component 24.
23 In a preferred embodiment of the present invention. the total plan view area of the inter-fiber bonds 32 is between about 1 percent and about 35 percent of the total area of the nonwoven web 30. More particularly, the total plan view area of the inter-fiber bonds is between about 5 percent and about 25 percent of the total area of the nonwoven web. The y~lcellLage of inter-fiber bonding is preferably measured by 5;~ in~ a ~el~.e;,e~ e sample of the nonwoven web under a microscope. The sarnple is viewed from directly above the outwardly-facing surface 21 of the nonwoven web 30. The plan view area of each inter-fiber bond 32 is measured. Thesum of the areas of the bonds is divided by the area of the sample. The result is the p~:~ce~ ge area occupied by the inter-fiber bonds.
33 The pattern of the inter-fiber bonds within the nonwoven web is anotheri"~o~ t factor relating to the strength and overall efficacv of the female W O 97/25893 PCTrUS97/00635 component. The inter-fiber bonds 32 mav be continuous lines or interrnittent areas of bonding. Preferably. the inter-fiber bonds 32 are sufficiently close to~ether that the fil~ment~ 36 of the nonwoven web 30 have relatively few unbonded loose ends.Thus. the t1ict~nre between inter-fiber bonds 37 is preferablv less than the avera~e length of the fil~mentc 36 in the nonwoven web 30~ more preferably, less than about one-half the average length of the fil~mf~ns~ 36 in the nonwoven web 30.
In a ~,ef~".d embodiment of the present invention~ the inter-fiber bonds 32 are arranged in a regular pattern. As used hereim the tenn "regular" refers to bond panerns that are generally similar throughout the area of the nonwoven web 30 when o viewed from directly above the outwardly-facing surface 71 of the nonwoven web30. Suitable inter-fiber bonding patterns include a series of straight or curved lines.
or arrangements of inter-fiber bonds 32 that form grids defining different geome~rical shapes such as squares~ rectangles~ hexagons~ diamonds. and circles.Such regular pa~ ~ will provide the female comyollent 22 with relatively uniform holding characteristics.
One bonding pattern that has been found to work ~cpe~i~lly well in the female component 22 of the present invention is the int~....iLIr..l diarnond-shaped pattern shown in FIGS. I and 2. The "diarnonds" in the diamond-shaped pattern comprise a number of interrnittent inter-fiber bonds 37 regularly arranged in lines 20 that define the edges of generally s~uare shaped regions. (A preferred arrangement of the inter-fiber bonds 32 of the nonwoven web 30 before the fil~mtont~ 36 become shirred is shown on the left side of FIG. 2. A preferred arrangement of the inter-fiber bonds 32 of the nonwoven web 30 after the fil~merltc 36 have become shirred is shown on the left side of FIG. 4.). The pattern is rotated approximately 45 2~ degrees to give the appearance of diamonds. Preferably, the ~1imencions of the pattern should be such that the ~icf~nre between the inter-fiber bonds 32. in at least some portion of the area between the sides of the di~llol1d-shaped areas. is greater than the pro~ected plan view ~iim~nci~nC of the hooks 28 of the comple .-~ . y male component 24. (Plan view ~im~n.cion~ of complc.. l~.y male components are 3~ c~ e~ in greater detail below.) Nonlimiting examples of diamond-shaped bonding p~ c suitable for use in female component 22 of the present invention include p~ rn~ having sides that measure between about 1/2 inch x 1/2 inch (about 1.3 cm. x 1.3 cm.) and about 1/8 in x 1/8 in. ~about 0.3 cm. x 0.3 cm.). more preferably between about 1/4 inch x 1/4 inch (about 0.6 cm. x 0.6 cm.) and about 3/8 3~ inch x 3/8 inch ~about I cm. x 1 cm.). and most preferably about 1/4 inch x 1/4 inch (about 0.6 cm. x 0.6 cm.). A suitable nonwoven web 30 comprising inter-fiber . 15 -bonds 32 arranged in a diamond-shaped pattern is available from the Veratec Nonwoven Group of the International Paper Company. of Walpole. ~Cs~rhncetts under the trade narne P- 11.
The inter-fiber bonds 32 may be produced by any method that is known in s the art In a ~ Ç~...d embodiment. the inter-fiber bonds 32 are produced by passing a nonwoven web 30 through a pair of rollers that have been heated close to the melting point of the fil~mentc 36 comprised in the nonwoven web 30. One of the rollers preferably has a smooth surface; the compl~oml-nt~ry roller has a pattern of pins ,-yten iinsg from its surface in the diaTnond-shaped pattern described above.
10 When the nonwoven web 30 passes between the rollers, the heat and pressure of the rollers causes distinct regions of the fil~mentc 36 to melt producin_ inter-fiber bonds 32 in the preferred diarnond-shaped pattem.
The nonwoven web 30 is p,~lably positioned on and joined with the b~ inE 34 while the backing 34 is in an elongated orientation and while the fil~ml~ntc 36 are in an untensioned condition. While the fil~mentc 36 could conceivably be positioned on the backing 34 in a tensioned or unstable state. such is not ~.~Ç~ d to provide m~ximllm shirring of the fil~mentc 36. Further. while thebacking 34 could be in a relaxed orientation when the fil~mentc 36 are positioned on the b~cl~in~ 34. this is not ~ d because in causing the backing 34 to becomeelor gs~te~l enough fil~mentc 36 may be dislocated, dis~langed. skewed or bonded to the b~kin~ 34 such that the fibrous elements 35 would not be as effective in en~ging the hook r~ ..;"~ component The configuration in which the fil~m~ntc 36 are positioned or laid down on the b~ing 34 ~etermines the size and the ability of the loop f~ctenin~ component22 to provide an effective f~ctPning device While the fil~mentc 36 may be randomly positioned on the b~rkinp 34 such that the fil~mPntc 36 overlap or extend in many di~e.e..l directions, it has been found that the fil~montc 36 should ef~.dbly be positioned generally parallel with each other to provide fibrous elements 35 configured in a uniform direction. In addition. while the fil~mPntc 36 may be positioned lengthwise on the backing 34 in any direction. in order to take advantage of the m~Ximllm shirring effect of the backing 34 to form fibrous cl~ "~ 35 of lll~hllulll height, the fil~mentc 36 are preferably positioned on the - backing 34 in a direction eccenti~lly perpendicular to the path of response of the backing 34. (It has been found. however. that fil~m.ontc 36 positioned eccenti~lly 3~ parallel to the path of response also provide suitable çnt~ngiin~ ability ) The W O 97/25893 PCTAUS97/0~635 16 fil~mcrltc 36 may be positioned or laid down on the backing 34 by any method or means that is known in the art.

. The Backin~
The backing 34 of the present invention is that part of the female f~ctening component 2~ to which the nonwoven web 30 is secured. The b~c~ing 34 is preferably comprised of an elastomeric, pressure sensitive adhesive. so that it may be readily joined to the nonwoven web 30 to form the nonwoven female component 22. As used herein. the term "elastomeric" refers to materials that extend in at least o one direction when a force is applied and return to approximately their original ~l;mçn~ions after the force is removed. Thus. elastomeric materials have an elongated orientation (when force is applied) and a relaxed orientation (when force removed). The term "adhesive" refers to materials which are capable of bonding to another material by sticlcing~ or adhering, to the surface of the other material. A
"pressure sensitive adhesive" is an adhesive that is ~ ollaive to pressure, i.e., is capable of adhering under the infl~enre of pressure alone.
The elastomeric adhesive c(J~ vl;aillg the b~rl~in~ 34 of the present invention may take on a number of different configurations. For example. the backing 34 may comprise a thin film having a uniform or varying thickness. slits. holes.
20 deformations or the like; a l~nnin~te of two or more films; a web of elastomeric adhesive; a single or multiple strands of elastomeric adhesive; discrete regions of elastomeric adhesive formed in random or regular p~tt~n~7 or any combination of the above. In one p.~:r~,.ed embodiment. the b~rkin~ 34 comprises an elastomericadhesive that has been extruded in the form of a thin film of about 0.03 mm. to about 2s 1.0 mm. (about 0.001 in. to about 0.04 in.). In a particularly preferred embo~lim~nt the elastomeric film has a thickness of b~ about 0.025 mm. to about 0.38 mm (about 0.001 in. to about 0.015 in.).
The elastomeric adhesive selected for the b~ in~ 34 may comprise any of a number of di~ elastomeric adhesives as are known in the art. The elastomeric 30 adhesive preferably has an elastic modulus between about I and about 30 PSI and more preferably between about S and about 15 PSI. (The elastic modulus c~ nl~tion is preferably ~i~t~rrnin~?d on the strain interval of about 50% to about 150% elongation of any convenient gage length using the original cross sectionalarea of the sample prior to straining the sarnple to ~et~mirtf~ the elastic modulus.3 35 Further. the elastomeric adhesive should be capable of elongation from about 500 to about 1000 percent in at least one direction without rupture. More preferably. the W O 97/25893 PCTrUS97/00635 elastomeric adhesi-e should be capable of between about 500 percent and about 1000 percent èlongation without rupture. nol exhibit excessi~,e neckinP or thinning when elon~ated. or exhibit excessive hysteresis or ~lel~min~tion upon elongation.
Other characteristics that help define suitable elastomeric adhesives relate to the process in which the present invention is made. As described below. the elastomeric adhesive preferably forms a film that is stretched prior to the application of the nonwoven to the elastomeric adhesive backing. One pl~r~ d method of inducing the stretch is to adhere a portion of the el~ctom~ric adhesive film to tentering belts that diver~e to stretch the film. The overlap between the film and the tentering belts forms a "lap joint". (The term "diverge" is used herein to mean move apart. The term "lap joint" refers to the area where two overlapping materials are joined to~ether.) Preferably. the tensile strength of the film should be less than the lap shear bond stren_th between the film and the tentering belts. (As used herein.
the terrn "tensile strength" refers to the pulling stress re~uired to break a given specimen. The term "lap shear bond stren~th" refers to the force needed to disrupt a lap joint. wherein the force applied is eCcPnti~lly parallel to the surface which adjoins the elastomeric adhesive film and the tentering belts.) Thus. as the tentering belts diver~e and stretch the film. the bond between the film and the tentering belts remains in tact.
. A p~esa~t: sensitive elastomeric adhesive marketed by the Findley Adhesive Corporation of Wauwatosa, Wisconsin under the trade name 198-338. has been found to be particularly well suited for this purpose. However. other suitable elastomeric materials include H2206 and HS2206~ each of which is available from the Findley Adhesive Corporation.
2s 3. The Complc.~ Male Colll~..n~llL
The term "male colll~onc.lL", as used herein, is used to deci~n~t~o the portion of the f~ctening device 20 having eng~ing c~ c.lL~ such as hooks 28. The male component_ 24 used with the nonwoven female culll~onellt 22 of the present invention can be con~.c.lLional, commercially available hook materials. The malet conlpol.ellt 24, however, is not limited to conventional m~teris~lc with flexible, resilient hooks 2~. Suitable male components can have less e~pe"aive~ relatively- inflexible. more brittle hooks. Further, the en~in~ elements may have any shape known in the art such as hooks. "T's", mushrooms. or any other shape. One suitable 3~ male component 24 may comprise a number of shaped eng~in~ elementc projecting from a woven backing such as the collllllc,.;ially available material tlpciEn~ted W O 97/Z5893 PCT~US97/00635 "SCOTCHMATE" brand No. FJ3402 available from Minnesota Mining and ~l~nllf~mring Company. St. Paul. Minnesota. A preferred ma}e component is described in U.S. Patent 4.846.815 entitled "Disposab}e Diaper Having An Improved Fastening Device" which issued to C. L. Scripps on July 11, 1989. Other particular}y preferred male conlponents and methods for making the same are the prongs described in U.S. Patent 5.058.247 entitled "Mechanical F~ctPning Prong"
issued to Thomas et al. on October 22, 1991; U.S. Patent 5,116.563 entitled "Process for Producing a Mechanical Fastener" issued to Thomas et al. on May 26. 1992: U.S.
Patent 5.180.534 entitled "Process of ~f~nllf~tllring A Refastenable Mechanical F~ct~ n;ne System", which issued to Thomas, et al. on January 19, 1993; and U.S.Patent 5.230,851 entitled "Process of Manufacturing a Ref~ctPn~hle Fact~nine System" issued to Thomas on July 27. 1993. Each of these patents are hereby incorporated by reference herein.
The male component 24 may be m~nllf~rt lred from a wide range of ~s m~t.ori~lc. Such suitable m~tf~ri~lc include, but are not limited to. nylon, polyester, polypropylene. or any combination of these or other materials.

Exam~les Of Uses Of The Ref~cten~hle F~stenin~ Device The ~cr;.~ ble (;~ device of the present invention is especially useful as a f~ctenine device for disposable absorbent articles. The term "disposable abs(.lbel.L article", as used herein. refers to articles which absorb and contain body ex~lA~t~c More particularly. the term refers to articles which are placed against or in proximity to the body of the wearer to absorb and contain the various exn~i~tl~sdischar~ed from the body. The terrn "disposable" means that such articles are 2s int.on~ed to be discarded after a single use (i.e., they are not intPnfi~d to be laundered or otherwise be used). Examples of disposable absorbent articles include diapers~
inco~ e~ y,,.. lc sanitary napkins. bandages, and the like.
FIGS. 7 and 8 show an ~oY~rnpl~ry disposable diaper 50 cc,.,.~ ing a f~stPnine system 72 including the nonwoven female f~ctenin~ colllpoll~;llt 22 of the present invention. The diaper 50 preferably co~ .,;cPs a body portion 51 and twowaise regions. a first waist region 56. and a second waist region 58. The body portion 51 ~ bly compric~s a liquid pervious topsheet 64. a liquid impervious b~c~ch~et 68. and an absolb~.lt core 66.
As shown in FIG. 7, t~e f~ctPning system 72 of the diaper 50 comprises the female fz~ctening colllyol1e.lt 22 of the present invention. among other c}c,.nellL~. The f~ctenine system 72 may take on a number of configurations and constructions. In W O 97/25893 PCTr~S97/00635 . 19 one preferred embodiment, the first fastening element 7~a comprises a male component 24. The male com~ol1el1t 24 provides hooks 78 that extend from the tab74 disposed in the second waist region 58. The nonwoven female component 22 of the present invention comprises the second fastening element 72b disposed in thefirst waist region ~6. However, the positions of the components of the f~ctenin~device 20 of the present invention could be reversed so that the first ~ctening element 72a comprises the nonwoven female component 2'7 and the second f~tening element 72b comprises the male co"-pul~e.ll 24.
In an especially preferred embodiment of the disposable diaper 50~ the fil~m~ntc 36 in the nonwoven web 30 of the female cu.llpone.lt 22 are aligned in a single direction. The female component 22 is oriented so that the fi1~mentc 36 in the nonwoven web 30 extend ~cc-onti~lly parallel to the lonEinlriin~l edges 60 of the diaper 50. This orientation aligns the fil~m~n~c 36 generally perp~n~lic~ r to the direction of shear forces applied to the f~ct~ning device 20 during use. In thisconfiguration the fil~m-ontc 36 provide the m~ximum peel and shear force r~Cict~n~e Several examples of well known diaper configurations to which the present invention can be readily adapted are described in U.S. Patents 5,151~092 and 5,221~274 both entitled "Abso.l,~ Article With Dynamic Elastic Waist Feature Having A Predisposed Flexural Hinge", issued to Kenneth B. Buell, et al. on September 29, 1992 and June 22, 1993, l~a~e~ ely; co-pending U.S. Patent Application Serial No. 08/155,048 entitled "Absorbent Article With Multi-Direction~l Fxtencible Side Panels", filed November 19. 1993: and co-pending U.S.
Patent Application Serial No. 08/203,456 entitled "Absu.be~-t Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature" filed on February 2~ 28, 1994. Each of the above mentioned patents and co-pending patent applications are hereby incul~olaLed by reference herein. It should be understood. however. that the r~ ..;..g device of the present invention is not limited to use with any specific diaper structure or configuration.
The female f~ctening component 22 of the present invention may also be used to provide an i~ ~n~i;ve w~ictb~nA or any other elastomeric element ~or a portion thereof) of an abso.l,e--t article, capable of eng~ging the hooks 28 of a complçnnent~ry male r~ co~ o~ 24. (As used herein. the terrn "w~ictb~n~" refers to that portion of an absorbent article that partially or wholly encircles the waist of the wearer.) FIG. 8 shows a diaper 50 having a w~ictb~nd 6 7 3s comprising the female r~ col..pol1c.,.l 22 of the present invention. Further ~Y~mples of diapers suitable for use with the present invention are described in U.S.

W O 97/25893 PCTrUS97/00635 Patent 4~699.62~ entitled "Disposable Diaper Having An Improved Side Closure"
which issued to J. W. Toussant. et al. on October 13. 1987: ~J.S. Patent 5.019.065 entitled "Disposable Absorbent Article With Combination Mechanical and Adhesive Tape Fastener Svstem". issued to Scripps on May 28. 1991: and U.S. Patent 5.242.436 entitled "AbsolL.e-ll Article With F~ct~ning System Providing Dynamic Elasticized W~ictb~n~ Fit". issued to Weil et al.. on September 7. 1993; each of which is hereby incul~olal~d by reference herein.

Method of Makin~ the Female Fastenin ~ Component o The female facIening component 22 of the present invention is made by cont~ting a nonwoven web comprising inter-fiber bonds with an elastomeric pressure sensitive adhesive film. The adhesive film is formed and elongated in at least the cross m~rhine direction before it is brought in contact with the nonwoven web. When the adhesive film and the nonwoven web are brought into contact with each other~ they are joined to form a l~min~te comprising the nonwoven web and an elastomeric adhesive b~kin~ The l~min~t~ is then col.lld~;led such that regions of the nonwoven web become shirred and thus capable of ent~ngiing the hooks of a compl~ c..~ male r;.~,~"i,.g component.
The following is a detailed description of the process for making the female f~ct~nin~ component 22 of the present invention. Although the description refers to the ela~loll,~.;c adhesive backing as an "adhesive film", this terrninology should not be construed to limit the scope of the invention. As mentioned above. the adhesive barking 34 may take on a number of different configurations including films.
Iz~rnin~tec webs. strands. or the like.
The female col~ ol,c.ll 22 of the present invention may be produced on the illustrated apparatus 110, as shown in FIG. 9. The a~l,~dl~ls 110 comprises two separate process m~ es~ process module 111 for the elastomeric adhesive backing 34 (or "adhesive film"), and process module 112 for the nonwoven web 30. The process module 111 co~ ses an extrusion head 116 and a release surface upon which the extruded adhesive is formed. such as the forming belt 117, to forrn the elastomeric adhesive backing film 3$. (In an ~it~rn~tive embodiment, the elastomeric adhesive b~rkin~ could be pre-forrned and supplied to the line from a roll. This would el;min~te the extrusion head 116 and the forming belt 117.) F~minin~ process module 111 in greater detail. the extrusion head 116 has a 3~ slot through which the molten elastic adhesive of the adhesive film 34 is extruded to forrn a thin film of about 0.03 to about 1.0 millimt-ters (about 0.001 in. to about 0.04 WO 97t25893 PCTrUS97/00635 ~1 in.) in thickness. and of any desired width. onto the forming belt 117. An adhesive film 34 having a thickness of about 0.025 to about 0.3.~ millimeters (0.001 - 0.015 inches) is particularly preferred. Generally a thicker adhesive film 34 is preferred as the thickness and stiffness of the nonwoven web 30 increases. It will be a~yal~llL to one skilled in the art that increasing the thickness of the adhesive film 34 will generally provide a ~lopo,lional increase in the ultimate strength of the femalef~c~ening component 2~. An adhesive film 34 of about 8.4 g/cm~ has been found tobe suitable.
The extrusion head 116 extrudes the molten adhesive onto the forming belt o 117 which cools the molten adhesive into an adhesive film 34 suitable for processing and transports the adhesive film 34 to the tentering belts 135. A roll may be utilized in conjunction with the belt 117 to provide additional cooling and a nip for col,lyles~ion of the adhesive film 34. Further, the adhesive film 34 may be seya dLed from the forming belt 117 by a doctor blade (not shown).
After being removed from the forming belt 117~ the application roll 131 guides spaced apart regions of the adhesive film 34 onto the surface of the tentering belts 135. (As used herein. the term "spaced apart" refers to regions of the adhesive film 34 that are spaced apart in the cross machine direction form each other.) The adhesive nature of the adhesive film 34 permits the adhesive film 34 to be secured to 20 the tentering belts 135 without any additional se~ ,.,.cnt means. as are generally used in the art. Preferably, only about 1/4 inch to about 3/4 inch of the edges of the adhesive film 34 should be secured to the working surface of each tentering belt 135.
(It should be noted, however, that the n~ntPrin,, belts could be fiesignecl such that a vacuum assists in holding the film in contact with the tentering belts.) The spaced 25 apart regions of the adhesive film 34 are adhered to the working surfaces of the tentering belts 135 forming continuous lap joints. ~As used herein, the term "continuous" means relatively unbroken or without interruption.) The continuous nature of the lap joint helps to ensure that the adhesive film 34 will be more evenly stretched than films that are elongated by stretching means comprising discrete 30 me~h~nical cl~lly;llg devices.
The tcnterinD belts 135 are spaced apart in the cross m~ehint- direction and diverge as they move in the m~rhin~ direction. The tentering belts 135 preferably comprise a 5~lh5t~nti~11y flat working surface to which the adhesive film 34 is adhered, and members that help provide positive control of the belts in both the35 m~hin.~ and the cross mzlrhine directions. The working surface of each tentering belt 135 iS preferably comprised of any material. such as TEFLON. to which the W O 97/25893 PCTrUS97/00635 adhesive film 34 will adhere sufficiently in shear to stretch the adhesive film 34. and from which the adhesive film 34 can peeled off without ~ ging the adhesive film 3~ when it is removed. One belt with a suitable working surface is available from F. M. Sheppard & Co. of Erlanger? Kentucky. Belt Stvle No. 3W1 1-2A.
Each tentering belt 13~ travels about a pair of pulleys. As shown in FI&. 13, belts 140 and 142 travel about pulleys 141a and 141b. Pulley 141a defines the converging end 146 of the belts 140 and 142 while pulley 141b defines the diverging end 144 of the belts. In one preferred embodiment~ the pulleys 141a and 141b comprise V shaped grooves and the tentering belts 140 and 142 comprise V shaped ~o extensions that ride in the complementary V shaped grooves of the pulleys 141a and 141b. to provide m~r~line direction control ofthe belt in the cross m~rhine direction.
The tentering belts 135 may be driven bv any driving means well known in the art and are preferably not driven by the adhesive film 31. In one pler~..cd embodiment. each tentering belt 135 co~ ises teeth and grooves that coact with the compll ."~ y driving means to provide cross m~rl1in.o directional control of thebelt as it is driven Çu~ lly.
One embodiment of the present invention, as shown in FIG. 10. comprises two tentering belts 135, a first belt 140 and a second belt 142. A first region 159 of the second surface 33 of the adhesive film 34 is adhered to t}~e first belt 140~ and a second region 160 of the second surface 33 of the adhesive film 34 is adhered to the second belt 142. The first belt 140 and the second belt 142 diverge as they move in the m~rhine direction, stretching the adhesive film 34 in the cross machine direction.
(The cross m~- hin-- direction is denoted by the arrow C in FIG. 10.) This configuration is ~ f~ d when it is desired that the adhesive film 34 be evenly 2~ stretched. (Alternative embo-limentc COl~l~vl;sillg more than two tentering belts are fiicCllcce~l below.) As shown in FIG. 9, the ~I~JlIWU~,.l web 30 is taken from the unwind roll 126 and plcr~:~ably passes through the S-wrap tensioning roll 128 to provide for proper tensioning and to prevent puckering or bl-nrhin~ of the nonwoven web 30. Guide 30 roll 130 guides the nonwoven web 30 into the nip between the combining rolls 124.
~f l-~c~c~,..y, a tracking system (not shown) as is commonly utilized and known in the art, may be empioyed in the process module 112 to optimally track and adjust the webs of nonwoven web 30 into the nip between the combining rolls 124. A ~r~,ckinE~ -system m~nnf~rtllred by the Fife Corporation of Oklahoma City. Oklahoma, and 33 sold as Model Op6 LRA may be suitable.

W O 97/25893 PCTrUS97100635 The nip between the combining rolls 124 compresses the nonwoven w-eb 30 into superposing cont~rinP relationship with the elastomeric adhesive backing 34~
causing the pressure sensitive adhesive backing 34 to bond to the nonwoven web 30.
joining the two materials to form the female f~ctening component 22 As used herein. the term "superpose" or "superposing" will refer to one layer of material having a particular geometric shape being laid upon another laver of material having a sl-hsr~nti~lly similar geometric shape such that all like parts of the two layers of material ~ubst~nti~llv coincide.
The combining rolls 124 may take on any number of different configurations o as are known in the art For example, the combining rolls 124 may have smooth surfaces or may have grooves. teeth or any patterns of in-ient~tionS and/or raised areas on their surfaces. Further. the combining rolls 124 mav be identical or may have different surface characteristics. as described above.
Once the nonwoven web 30 and the elastomeric adhesive b~cking 34 have been joined to form the female f~ctening component 22. the l~min~t~ 90 is returned to a relaxed condition In this configuration. the nonwoven web 30 will become gathered in at least the direction parallel to the path of response of the adhesive film 34, which will form ridges, wrinkles, or furrows ext~nriing outwardly from the first surface 31 of the female component 22 capable of entzlnglinçr the hooks 28 of a complement~ry male f~c~ning comporlent24. The elastomeric l~min~te 90 will be el~cti~liy extensible in the direction parallel to the path of ~.a~onse of the adhesive film 34 Up to about the free length of the nonwoven web 30.
Co..l,~ g the i~min~te 90 to a relaxed condition can be accomplished in a number of ways, including simply removing the ~ AI~' 90 from the tentering belts135 and allowing it to contract More preferably. however. as shown in FIG. 13, the l~min~te 90 can remain adhered to the belts 140 and 142 as they travel from the diverging end 144 towards the converging end 146 of their cycle. As the belts 140 and 142 travel from the diverging end 144 toward the converging end 146, the belts 140 and 142 converge, and thus contract the i~min,.te 90. (As used herein, the terms "converge" and "converging" mean to move closer together.) Alternatively~ as shown in FIG. 11, the l ~min~te 90 may be removed from the belts 140 and 142 andtransported to a separate configuration of converging belts 158. Although the converging belts 158 may take on a number of different configurations. a detailed description of one l,.e~lled embodiment of the converging belts is described in the co-pending U S. Application Serial No. ~8/254,812, entitled "A~d~s For CoMinuously Stretching or Continuously P~ele~cing Stretching Forces From A Web W O 97125893 PCTrUS97100635 Usin_ Two Pairs of Opposing ~ion-Planar Belts". filed on June 6. 1994. in the names of L John Viltro. et al. which is incorporated herein by reference.
After the l~min~te 90 is contracted. it is removed from either the tentering belts 135 or the converging belts 158. Ieaving e~posed the pressure sensitive adhesive of the second surface 33 of the adhesive b~king 34 The exposed surface may be used to bond the female f~t~ning component 22 to an absorbent article or any other desired article. or may be deactivated by blocking as is commonly known in the art so that the adhesive of the e~astomeric adhesive backing 34 does not bond to other materials through the Ple~ U1~ sensitive ~.lupe,Lies of the elastomericadhesive bacl~ing 34 Blocking is accomplished by an adhesive deactivation system(not shown~ applying a powder of resin to the exposed face of the elastomeric adhesive backing 34 Suitable resin powders include talcum powder. polyolefinic powders. and preferably a resin similar to that used for the nonwoven web 30 Alternatively, the e?cposed face of the ela~lu.l,~,.c a&esive backing 34 may be deactivated by applying a non-adhesive elastomeric film. nonwoven. foam or any other suitable non-adhesive material thereto. An exarnple of one suitable non-adhesive elastomeric film is H2901 m~nllf~t--red by Findley Adhesives Corporation of Wauwatosa, Wisconsin.
One preferred alternative embodiment of the present invention provides regions of differential stretch throughout the adhesive film 34. as shown in FIG. I l.
comprises three tentering belts. a first belt 140a~ a second belt l42a. and a third belt 143a As ~ cucced above, spaced apart regions of the second surface 33 of the adhesive 34 are adhered to each of the tentering belts In this particular embodiment. a first region 159a of the adhesive film 34 is adhered to the first belt 2~ 140a, a second region 160a of the adhesive film 34 is adhered to the second belt 142a and a third region 161a of the adhesive film is adhered to the third belt 143a.
As the belts move in the m~hinf~ direction, the first belt 140a and the second belt 142a diverge at a rate different from the rate at which the second belt 142a and the third belt 143a diverge, thus producing two regions of differential stretch in the adhesive film 34.
Another p.~;r~ ,d alternative embc!~lim~n~ as shown in FIG. 12, co,ll~lises a first pair 180 of tentering belts colllpliseS belts 182 and 184, and a second pair 18~
of tentering belts comprises belts 187 and 189 Each of said belts contacts a different spaced apart region of the second surface 33 of the adhesive film 34. As 3~ the pairs of belts move in the m~hine direction, they diverge at dirr~ rates producing areas of differential stretch throughout the adhesive film 34 (Of course W O 97/2S893 PCT~US97/00635 the first pair 180 could comprise tentering belts 184 and 187 and the second pair 185 couid comprise the tentering belts 182 and 189.) Further. numerous other confi~urations are contemplated wherein some of the tenterin_ belts diverge and others run parallel to each other. thus producing an adhesive film 34 having portions that are stretched between the diverging belts and other portions that are left unstretched between the parallel belts. (Although some preferred embodiments have been discussed. it should be noted that any number of tentering belts mav be used to produce any combination of stretched and relaxed regions throughout the adhesivefilm 34.) o Yet another alternative embodiment of the present invention provides a female f~crtoninP component 27 with multi-directional stretch. In this embodiment.
the adhesive film 3~ may be drawn through the nip formed between a pair of tensioning rolls. The tensioning rolls provide for m~rhine direction stretching the adhesive film 34 prior to being applied to the tentering belts 135. this provides a 5 l~min~te which is elastically extensible in two directions, i.ethe m~hine direction and the cross m~rhin~ direction. A l~min~t~ which is eiastically extensible in the machine direction and methods of forming such a l~min~e are described in greaterdetail in U.S. Patent 5.032,120, entitled "Disposable Absorbent Article Having Improved r eg Cuffs", issued July 16. 1991, to Mary E. Freeland and Patrick J.
20 Allen: which is incul~u.a~ed herein by ,efc.~.lce.

Method of Makin~ a ~ri-l~min~t~ Embodiment The above-described method of producing a female f~ctening component comprising a single nonwoven web 30 joined to the first surface , I of the ~s elastomeric adhesive film 34 can also be used to produce a tri-l~min~te female r;.~ P CC~ pullc:l~t con~ g a nonwoven web 30. ioined to the first surface 31 of the backing 34 and a second lamina 80 joined to the second surface 33 of the backing 34. As described above. the nonwoven web 30 and the backing 34 are joined to form the l~min~te 90. However. when the l~min~te 90 exits the nip 30 between combining rolls 124, the exposed face of the adhesive b~king 34 is not deactivated as described above. Rather. as sho~,vn in FIG. 14. the l~min~te 90 is allowed to remain on the tentering belts 135 as the tentering belts 135 move from the diverging end 144 of their cycle toward the converging end 146 of their cvcle.
~Itern~tively~ as is shown in FIG. IS, the l~min~te 90 may be transported to the35 separate converging belts 158. In either case. the l~min~t~ 90 mav be partiallv or fully relaxed prior to application of a second lamina 80.

W O97/25893 PCTrUS97/00635 The second lamina 80 is provided by the additional process modu}e 1 13. as is sho~n in FIGS. 14 and 1~. The second lamina 80 is taken from the unwind roll 150and preferably passes through the S-wrap tensioning roll 152 to provide for proper tensioning and prevent puckering or bunching of the lamina 80. Guide roll 156 guides the second lamina 80 into the combining rolls 16Z. If n~ce~ry. a trackingsystem. not shown. as is comrnonly utilized and known in the art~ may be employed in the process module 113 to optimally track and adjust the second larnina 80 into the combining rolls 162.
After the l~m;n~t~ 90 CO~ liaillg the nonwoven 30 and the elastomeric o adhesive backing 3~ exits the converging belts 158. the second surface 33 of the adhesive backing 34 is brought into contact with the second larnina 80. The l~min~te 90 and the second lamina 80 are passed through the nip of combining rolls 162 under sufficient plesaLI.~ for the adhesive 34 to adhere to the lamina 80. thus forming the tri-l~min~t~ female f~ctenin~ CGnll~Ollent 100.
In a preferred embodiment, the second lamina 80 is joined to the adhesive b~rl~ing 34 after the l~min~te 90 has been at least partially, yet not fully relaxed.
(This creates a tri-lz3min~t~ with the characteristics and benefits described above with respect to one ~itern~tive embodiment of the present invention as shown in FIG. 6.
Preferably~ the second lamina 80 is joined to the adhesive backing 34 after the 20 l~min~tto 90 has been relaxed such that the lateral ~limen~ion5 of the l~min~te 90, after converging, is between about 90% and about 50% of the lateral dimensions of the larnina 22 when fully stretched. In an ~speri~lly yleç~ d emboc~im~nt the second larnina 80 is joined to the adhesive b~rl~ing 34 after the l~min~te 90 has been relaxed such that the lateral ~iimen~ions of the l~minzit~ 90. after converging. is about ~s 70% of the lateral rlim~n~ions of the l~min~te 90 when fully stretched. However.
emborlimPntc are co..~ .lated wherein the second lamina 80 is joined after the klmin~tt? 90 is co.,~ ly relaxed, or while the l~min~te 90 is fully alle~ched.
After the tri-l~min~te 100 has been formed, as described above, the tri-l~min~te 100 may be adhered to an abso-l.~ nL article or any other desired object.
The process of forming the tri-l~min~te 100 leaves exposed the portions of the second surface 33 that were adhered to the tentering belts 35. Thus, the portions of the second surface 33 of the adhesive film that were adhered to the tentering belts 35 can be used to join the tri-l~min~te 100 to any desired object without the use of any additional adhesive.
3s While particu}ar embo-lim~nt~ of the present invention have been illustrated and described. it would be obvious to those skilled in the art that various other W O 97/25893 27 PCTrUS97/00635 chan~es and modifications can be made without departing from the spirit and scope ~ of the invention. It is therefore inten~led to cover in the appended Claims all such chan~es and modifications that are within the scope of this invention.

WE~AT IS CLAIMED IS:

Claims (10)

1. A female component of a refastenable fastening device capable of engaging a complementary hook fastening component, said female component characterized in that said female component comprises:

an elastomeric adhesive backing having an elongated orientation, a relaxed orientation, a path of response along which said material contracts from said elongated orientation to said relaxed orientation and at least two regions of differential elongation; and a nonwoven web in contact with, and thereby secured to said elastomeric adhesive backing, said nonwoven web being secured to said elastomeric adhesive backing while said backing is in said elongated orientation, said nonwoven web comprising a multiplicity of fibrous elements comprising filaments that are joined together with inter-fiber bonds at spaced, fixed regions along the length of each of said filaments to define between each pair of fixed regions an unsecured catching region, wherein said fibrous elements comprise those filaments that are shirred when said backing contracts to said relaxed orientation.

2. A female component for a refastenable fastening device capable of engaging a complementary hook fastening component, said female component characterized in that said female component comprises:

an elastomeric adhesive backing having a first surface, a second surface, an elongated orientation, a relaxed orientation, and a path of response along which said material contracts from said elongated orientation to said relaxed orientation;

a nonwoven web in contact with, and thereby secured to, said first surface of said elastomeric adhesive backing, said nonwoven web being secured to said elastomeric adhesive backing while said backing is in said elongated orientation, said nonwoven web comprising a multiplicity of fibrous elements comprising filaments that are joined together with inter-fiber bonds at spaced, fixed regions along the length of each of said filaments to define between each pair of fixed regions an unsecured catching region, wherein said fibrous elements comprise those filaments that are shirred when said backing contracts to said relaxed orientation; and a second lamina in contact with, and thereby joined to, said second surface of said elastomeric adhesive backing.

3. The female component of Claim 2 wherein said second lamina is joined with said elastomeric adhesive backing while said backing is in said elongated orientation, or said second lamina is joined with said elastomeric adhesive backing after said backing has been partially relaxed.

4. The female component of Claims 2 or 3 wherein said elastomeric adhesive backing comprises regions of differential elongation.

5. The female component of Claim 2, 3, or 4 wherein said second lamina comprises a second nonwoven web comprising a multiplicity of fibrous elements preferably positioned on said backing essentially perpendicular to said path of response of said elastomeric adhesive backing, said fibrous elements comprising filaments that are joined together with inter-fiber bonds at spaced, fixed regions along the length of each of said filaments to define between each pair of fixed regions an unsecured catching region, wherein said fibrous elements comprise those filaments that are shirred when said backing contracts to said relaxed orientation, said inter-fiber bonds preferably being arranged in a diamond-shaped pattern.

6. The female fastening component of any of the preceding Claims wherein said filaments are positioned on said backing essentially perpendicular or essentially parallel to said path of response of said elastomeric adhesive backing, or randomly positioned on said elastomeric adhesive backing.

7. The female fastening component of any of the preceding Claims wherein said nonwoven web comprises carded polypropylene filaments.

8. The female fastening component of any of the preceding Claims wherein said inter-fiber bonds are arranged in a diamond-shaped pattern.

9. A disposable absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet joined with said topsheet, an absorbent core positioned between said topsheet and said backsheet, and a fastening system for fastening said disposable absorbent article about a wearer, wherein said fastening system comprises the female fastening component of any of the preceding Claims.

10. The disposable absorbent article of Claim 9 further comprising a waistband, wherein said waistband comprises the female fastening component of any of the preceding Claims.