CN1694804A

CN1694804A - Extensible laminate of nonwoven and elastomeric materials and process for making the same

Info

Publication number: CN1694804A
Application number: CNA03825008XA
Authority: CN
Inventors: M·T·莫尔曼; P·S·波特尼斯; G·T·苏杜思; L·W·科利尔四世; D·M·马特拉; R·J·帕尔默; S·－P·L·康耶尔; C·J·莫雷尔; R·W·Z·圭尔圭斯
Original assignee: Kimberly Clark Worldwide Inc
Current assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Priority date: 2002-11-27
Filing date: 2003-07-24
Publication date: 2005-11-09
Also published as: US20040102125A1; MXPA05005010A; AU2003256685A1; EP1567329A1; BR0316276A; WO2004050348A1; KR20050086535A

Abstract

An extensible laminate includes a sheet of an extensible nonwoven material that has a fabric side and a film side, a sheet of an elastomeric film, and an adhesive. The adhesive is applied to at least a portion of the film side of the extensible nonwoven material. The extensible nonwoven material is selectively attached to the elastomeric film by a plurality of intermittent adhesive bonds. The extensible nonwoven material is further selectively attached to the elastomeric film by a plurality of thermal point bonds. The intermittent adhesive bonds cover a greater percentage of an interfacial plane between the extensible nonwoven material and the elastomeric film material than the thermal point bonds. A process for making the extensible laminate is also disclosed.

Description

The laminate and the manufacture method thereof of extending non-woven and elastomeric material

Technical field

The present invention relates to take intermittent adhesive bonds and thermal point bond and with the bonding extensible nonwoven material and the laminate of elastomeric material, wherein between bonding covering extensible nonwoven material of adhesive and the elastomeric material percentage of interfacial plane greater than heat bonding.Compare with the laminate that elastomeric material is bonded on the extensible nonwoven material fully, the extensible of making shows the transverse elasticity of raising.In addition, the laminate of making is owing to the decorative pattern that thermal point bond forms shows desirable surface aesthetic.Also disclose a kind of method of making extensible, it provides big flexibility in manufacture process.

Background technology

The composite one of elasticity and non-elastic material to be by with elastomeric material to allow whole composite and elongate or the mode of elongation is bonded on the non-elastic material and makes.This type of composite is often used in dress materials, pad, diaper, adult-incontinence articles and the feminine care.A kind of this type of composite or laminate comprise the extensible nonwoven material that is bonded on the elastomer sheet.

Elongation of this type of laminate and the ability of replying are subjected between elastomer sheet and the extensible nonwoven material bonding or link the influence of degree.Generally speaking, the binding degree is big more between elastomer sheet and the extensible nonwoven material, and the extending force of laminate and permanent deformation are just big more and retraction force/extension force ratio is just low more.Yet the bondability between non-woven material and the elastomer sheet must be enough to provide cohesive force to laminate, and each layer is unlikely during use to be peeled off or be separated from each other so that make.

Each of laminate layer can adopt various technology to be bonded together, and comprises heat bonding, adhesive is bonding and it is bonding to put, and the latter also can utilize heat effect.The heat bonding technology comprises molten elastomeric material is expressed on the extensible nonwoven web with form of film.Film and non-woven material are bonded together two-layer by smooth calendered subsequently.The heat bonding technology also comprises sent the dress rolling ray machine roller of heating to realize bonding with extensible nonwoven material web cast elastomeric film or meltblown elastomeric web.Yet in both cases, thereby elastomeric material all is substantially fully bonded to and has increased extending force and permanent deformation on the non-woven fabric and reduced retraction force/extension force ratio.In addition, in the heat bonding technology, must be during elongation and/or calendering processing extremely carefully to avoid making laminate overheated.Degraded and/or fusion take place in overheated elastomeric material and the extensible nonwoven material of causing, thereby cause fault and the inefficacy of laminate between the operating period in laminate.

The result that the adhesive adhering technique obtains is similar.In general, a kind of adhesive is generally hot melt or molten type adhesive or Pressuresensitive Adhesive, is applied to the surface of elastomer sheet or extending non-woven fabric.Subsequently, each layer accepted calendering together to reach bonding.Each layer of the laminate that forms can link fully each other or optionally link.

The point adhering technique can be to rely on heat effect, also can be used to each layer of binder couse condensation material.The point adhering technique relates generally to force each zone that the various piece of one deck enters the second layer so that the each several part of ground floor is absorbed in the second layer with mechanical force, thereby makes two-layer being bonded together.It is desirable in the production of extensible nonwoven composites, elastomeric material is in fusion or near molten condition, so that reach effectively bonding between each layer of material.Elastomeric material also can soften by heating texturing and/or smooth calender roll.The example that the non-woven material point is adhered to the method on the elastomer sheet is disclosed in the United States Patent (USP) 6,001,460 of authorizing people such as Morman, receives its disclosure for referencial use at this.

Being commonly used to link in the middle of the adhering technique of each layer of extensible, put bonding generation pleasant surface detail the most attractive in appearance and the function between each layer and link.Except the performance characteristic of laminate, appearance usually is the key factor that leading consumer more favors with respect to another kind a kind of product.Yet the flexibility that relies on heat to reach aspect the material type that bonding adhering technique allows to use in speed of production with in each layer is limited.

Adhesive is bonded in the manufacturing process aspect big flexibility is provided, and is for example non-resilient, elastomeric, pressure-sensitive, melt and spray or hot-melt adhesive because the kind of adhesive is varied, all can be used to bonding various material.In addition, compare with heat bonding, adhesive is bonding may cost benefit better, to the restriction of technology and material still less.Moreover adhesive can apply into the pattern of varied imitation point bonding patterns and not need to use expensive calender or patterns for calender rolls.This feature also makes it change the adhesive bond pattern fast at production period, so that obtain different decorative patterns and/or the bonding level of coverage of adhesive during single production is criticized.

In sum, need or require a kind of extensible that improved elasticity has the surface detail attractive in appearance of hope again that has.

The features and advantages of the present invention just be to provide a kind of can be at a relatively high speed and the big flexibility extensible of producing.The features and advantages of the present invention also are to provide a kind of extensible of producing under the condition of thermal degradation and/or fusion of not taking place at nonwoven web.

Definition

Term " extending " be meant a kind of material can elongate at least 50% along at least one direction (to its original unstretched length at least 150%) and do not rupture, aptly at least 100% (to its original unstretched length at least 200%).For example, originally unstretched length is that 3 inches extensible materials can be stretched at least 4.5 inches tensile elongation and do not rupture along at least one direction.This term comprises elastomeric material, also comprise can elongating but the remarkable material of retraction not, for example necked nonwoven and itself with regard to tensile non-woven material as bonding carded web.

Here employed term " flexible " and " elastomeric " are meant a kind of material, it is after being applied in a unbalanced force, extending unbalanced length to a certain elongation, this length for its lax unstretched length at least about 150%, and after the unbalanced force that stretches is removed, in about 1min, will reply at least 55% of its elongation.

Term as used herein " answer " is meant the retraction of the material that is stretched when stopping this unbalanced force after with material extending by applying unbalanced force.For example, make width reach 1.5 inches if lax, unbalanced width is 1 inch a material by having prolonged 50% along laterally being stretched, then this material has been elongated 50% (0.5 inch), thereby its stretched width is 150% of its lax width.If this exemplary expanded material is in that to be disengaged lack of balance and tensile force later on lax and be returned to 1.1 inches width, then this material will have been replied 80% (0.4 inch) of its 0.5 inch elongation.Answer can be expressed as [(maximum stretched dimension-final sample size)/(maximum stretched dimension-original sample size)] * 100.

Term " twin shaft can stretch " is meant a kind of material, it can stretch at least about 50% along two directions of being perpendicular to one another (for example can be longitudinally and laterally, perhaps longitudinally from front to back and along laterally from a side to opposite side).But this term comprises twin shaft tensile layer condensation material, for example is disclosed in the United States Patent (USP) 5,114,781 and 5,116 of authorizing people such as Morman, and those in 662 are for referencial use in these receipts.

Here employed term " vertically " or " MD " are meant the length of material along its direction of producing.Term " laterally " or " CD " are meant the width (for example being generally perpendicular to direction longitudinally) of material.

Here employed term " polymer " " generally comprise but be not limited to: homopolymers, copolymer such as block, grafting, random and alternate copolymer, terpolymer etc. and blend and various modified form.And, unless otherwise specifically limited, term " polymer " " should contain all possible geometric configuration of this material.These configurations include but not limited to: isotaxy, syndiotaxy and atactic symmetries.

Here employed term " elastomer sheet " and " elastomeric web " are meant by the elastomer thin film of extruding, curtain coating or other method well known in the art forms, and elastomeric nonwoven fabric, meltblown elastomeric web for example, as be disclosed in the United States Patent (USP) 4 of authorizing people such as Wisneski, 663, in 220, at this that its disclosure receipts are for referencial use, and the elastomer foam plastics.

Term as used herein " metallocene " is meant the polyolefin by the preparation of metallocene catalyst polymerisation.This type of catalyst is reported in " metalloscene catalyst has been started synthetic new era of polymer ", Ann M.Thayer, Chemical ﹠amp; Engineering News, 1995-09-11, P.15.

Term as used herein " nonwoven web " or " non-woven material " are meant a kind of material, and it has the structure that is interweaved and constituted by each fiber or silk, but is not with identifiable repetitive mode.Nonwoven web can adopt several different methods to form, as meltblown, spun-bond process, air lay process, its method of forming and bonded carded web process.

Here employed term " side surface of thin film " is meant can link, adhere to or be adhered on the elastomer sheet with the nonwoven web of formation laminate or the surface of material when referring to nonwoven web or non-woven material.The term " fabric " side " when referring to nonwoven web or material, be meant that surface opposite with film side.

Here employed term " microfibre " is meant that average diameter is not more than about 100 μ m, and for example diameter is the small diameter fibers of about 0.5 μ m～about 50 μ m, and more particularly the average diameter of microfibre also can be about 4 μ m～about 40 μ m.

Here employed term " bonded carded web " is meant the fibre web of being made by short fiber, and short fiber was sent combing or carding apparatus, and this device separately also comes into line short fiber along the longitudinal, thereby forms the fibrous nonwoven fibre web that roughly longitudinally is orientated.This kind fiber is bought with can becoming bag usually, and is placed on opener and on/blender or scutcher fiber is separated, and then sends into carding apparatus.Fibre web is in case form, and uses in the middle of several known adhesive bonding methods a kind or multiple that it is bonding subsequently.One of this type of adhesive bonding method is a powder-stuck, and wherein powdery adhesive is distributed in the whole fibre web, activates then, and the general using hot-air is realized the way of fibre web and adhesive heating.Another kind of suitable adhesive bonding method is that decorative pattern is bonding, and wherein patterns for calender rolls or the ultrasonic bonds equipment with heating is bonded together fiber, and bonding generally only limiting in the local bond pattern is though wish that fibre web also can carry out bonding along its whole surface.Another kind of suitable and known adhesive bonding method, particularly when the employing two-component staple fiber, it is bonding to penetrate air exactly.

Here employed term " meltblown fibers " is meant the fiber that is shaped as follows: molten thermoplastic is expressed in the high velocity air (for example air stream) with fusion tow or long filament from a plurality of die capillaries (diecapillary) very thin, that be generally circle, air-flow is with the drawing-down of molten thermoplastic tow, diameter diminishes, may little diameter range to microfibre.Then, meltblown fibers is being carried secretly and is being deposited on by high velocity air and collecting on the surface, forms the fibre web of the meltblown fibers of random dispersion.These class methods for example are disclosed in the United States Patent (USP) 3,849,241 of authorizing Butin, receive its disclosure for referencial use at this.

Here employed term " spun-bonded fibre " is meant small diameter fibers, it forms by molten thermoplastic is generally the circular capillary to extrude with long filament from spinning plate a plurality of very thin, and the diameter of the long filament of extruding stretches or other known spunbond mechanism and reducing fast by for example spraying subsequently.The production of spunbond nonwoven web is described in the United States Patent (USP) 4,340,563 of for example authorizing people such as Appel and authorizes in people's such as Dorschner the United States Patent (USP) 3,692,618, receives its disclosure for referencial use at this.

Here employed term " inter-fibre-bond " is meant by the heat bonding between the single non woven fibre or tangles to form bonding that the bonding fibre net structure produces.Fibre matting be meltblowing method intrinsic but can be by producing such as water thorn or acupuncture or strengthening.In the manufacturing process of most of spun-bonded fibres, adopt a step or a multistep heat bonding step.Alternatively and/or additionally, it is desired bonding and keep the construction bonds of fibre web to adopt adhesive to strengthen.For example, can adopt powdery adhesive and chemical solvent bonding.

Here employed term " extensible nonwoven material own " is meant, not need such as constriction or wrinkling further processing just can be along stretch at least 50% non-woven material of at least one direction.

Here employed term " neckable material " be meant any once by such as stretch or shirred processing by the material that shrank along at least one direction.

Here employed term " but neckable material " be meant any can be by the material of constriction.

Here employed term " reversible neckable material " is meant a kind of material of constriction, once at its constriction state it was handled to give its memory, during size before the power that applies is stretched to its constriction with this material, this constriction and the part handled will be returned to the size of its constriction usually after this external force is removed.A kind of processing form is heating.Say that generally the elongation of the material of reversible constriction is limited in the elongation of the size before its constriction basically.Therefore, unless material is flexible, surpass the destruction that the preceding too much elongation of size of its constriction will cause material.Reversible neckable material can comprise more than one layer, the for example spunbond fibre web of multilayer, multilayer melt spray fibre web, multilayer bonded carded web or their any other suitable combination or mixture are as the United States Patent (USP) 4,965 of authorizing Morman, 122 is described, for referencial use in these receipts.

Here employed term " constriction percentage " is meant the ratio of determining like this: but measure the preceding size (width) of constriction of neckable material and the difference between the constriction size (width), but then divided by size * 100 before the neckable material constriction.

Here employed term " extensible " is meant a kind of material, and it has (for example, the extensible of single vermicelli) that is connected at least two places on the extensible materials.Elastomer sheet can be attached at interrupted point on the extensible materials or can be fully thereon bonding.Binding is to finish under elastomer sheet and extensible materials are in the situation of overlapping configuration.Extensible can comprise the layer more than 2.For example, thus elastomer sheet can have the extensible materials that is attached at its two sides forms a kind of three layers of extensible (for example, two vermicelli extensible) with extensible materials/elastomer sheet/extensible materials structure.Can add additional elasticity or elastomer sheet, necked material layers and/or extensible materials own such as bonded carded web.The combination of other elastomer sheet and extensible materials also can be adopted, for example as the United States Patent (USP) 5,114,781 and 5,116,662 that transfers Morman jointly and authorize people such as Morman 5,336,545 in point out, for referencial use in these receipts.

Here employed term " interfacial plane " is meant between 2 adjacent sheet in single vermicelli extensible, fibre web or the layer by the width dimensions of laminate and the two dimensional surface of length dimension regulation, perhaps comprise 3 or 2 outside sheet materials, fibre web or layers of two vermicelli extensible of more a plurality of sheet material, fibre web or layer between the two dimensional surface stipulated by the width dimensions and the length dimension of laminate.

Here employed term " cyclic test " is meant a kind of method, it adopts elongation constant speed cupping machine for example by the (Cary of Sintech company, North Carolina) Gong Ying Sintech 2, model 3397-139 measures the transverse elasticity of extensible.Specifically, the sample of extensible is cut into 4.5 * 3 inches size, and wherein 4.5 inches is lateral dimension.These 3 inches long samples are clamped between 2 groups of air-actuated jaws, make nominal length (spacings of anchor clamps) equal 2 inches, and draw direction transversely.Draw speed is 20 inch per minute clocks.Test was finished 2 extension/retraction cycle periods.Sample at first is stretched to 100% elongation (4-inch spacing jig), and is returned (retracted) to initial nominal length immediately.Repeat this elongation-retraction circulation then.At last, sample being stretched to always fracture just stops.Power and elongation are measured by suitable load cell and other sensor.Data are by computer program record and analysis.The load (power) that sample is measured during with first circulation elongation (stretchings) cycle period 30% elongation and during second loops back compressed mode during 30% elongation the load of mensuration characterize.The elasticity measurement result is with the ratio value representation of retraction force/extension force.

Here employed term " transverse elasticity " and " DE value " are meant according to the retraction force of cyclic test mensuration and the ratio between the extending force.

Here employed term " bond coverage " and " bonding covering percentage " are meant by the size of the interfacial plane of intermittent adhesive bonds and/or thermal point bonds covering.

Here employed term " intermittent bonds " or " intermittently bonding " be meant 2 or more a plurality of material layer between the discontinuity zone of linking portion.Each layer maintenance in the intermittent bonds peripheral region do not link basically each other, thereby allows each layer independently to move.

Here employed term " intermittent adhesive bonds " is meant by the each several part at first fabric, film or fibrous material sheet material and applies adhesive discontinuous or the random patterns form, and sent two roll gaps between the smooth nip rolls with first sheet material and second fabric, film or fibrous material sheet material, the intermittent bonds that forms thereby go up in each zone that makes the various piece of first sheet material optionally stick to second sheet material.The intermittent adhesive bonds level of coverage depends on the binder amount that applies at least in part and applies pattern.

Here employed term " thermal point bond " is meant intermittently bonding by what use heat and/or pressure to form.For example, thermal point bond can adopt the heating patterned calender roll that the various piece of first fabric, film or fibrous material sheet material is pressed in second fabric, film or the fibrous material sheet material, makes the various piece of second sheet material wrap each zone of first sheet material and bonding with it and form.Alternatively, thermal point bond can adopt decorative pattern ultrasonic bonds head generation local heat zone to be shaped, so that make when treating that jointing material was sent between ultrasonic bonds head and the ultrasonic bonds anvil roller, the synergy of heating and pressurization makes and forms discontinuous bounding point between the material.Thermal point bond can have various shape.Thermal point bond can be discontinuity point, and is for example circular or oval-shaped, perhaps can be star, animal shape, line segment shape or other shape.A kind of thermal point bond pattern of the combinable formation of various thermal point bond shapes, for example wire weave, H﹠amp; P and Ramisch pattern.The degree that thermal point bond covers depends on the size and the quantity of thermal point bonds at least in part.

Here term " specially " and " largely " contained in employed term " optionally ".

Here employed term " substantially by ... form " do not get rid of the additional materials that requires characteristic of given composition of not appreciable impact or product or the existence of processing step.This type of exemplary materials will include but not limited to that pigment, antioxidant, stabilizing agent, surfactant, wax, flow improver additive, solvent, particle and adding are to improve the material of composition processability.

Here employed term " comprises " makes claim contain described additional materials or processing step in addition openly.

These terms may illustrate in the remainder at this and be defined with additional language.

Summary of the invention

The present invention relates to the extensible that transverse elasticity is improved.This extensible comprises intermittent adhesive bonds and the thermal point bond that has the zone that does not link therebetween.Thereby the non-connecting area between the bounding point is keeping the elasticity maximization that the independent mobility of each layer of laminate makes extensible.It is desirable to, extensible of the present invention has the DE value greater than about 0.22 retraction force/extension force ratio.By the also usefulness of intermittent adhesive bonds and thermal point bond, can make the extensible of surface aesthetic quickly with hope, peel strength and cohesive force remain unchanged simultaneously.

In one embodiment of the present invention, extensible comprises extensible nonwoven material sheet, elastomeric material sheet material and adhesive.Adhesive application is at least a portion side surface of thin film of extensible nonwoven material, so that this extensible nonwoven material is optionally sticked on the elastomer sheet by a large amount of intermittent adhesive bonds.Extensible nonwoven material further optionally sticks on the elastomer sheet by a large amount of thermal point bonds again, so that intermittent adhesive bonds covers the percentage of interfacial plane between bigger extensible nonwoven material and the elastomer sheet than focus bounding point.

In another embodiment, extensible comprises first extensible nonwoven material sheet, second extensible nonwoven material sheet and the elastomeric material sheet material between first and second extensible nonwoven material sheet.On at least a portion side surface of thin film of first extensible nonwoven material sheet and/or second extensible nonwoven material sheet, win extensible nonwoven material sheet and/or second sheet material are optionally sticked on the elastomeric material sheet material by a large amount of intermittent adhesive bonds adhesive application.First and/or second extensible nonwoven material sheet relies on a large amount of thermal point bonds further optionally to stick on the elastomeric material sheet material, so that intermittent adhesive bonds covers the percentage of interfacial plane between first and second bigger necked nonwoven sheet material than focus bounding point.Hope neither contains intermittent adhesive at least about 50% interfacial plane and does not also contain thermal point bonds.

The method of making extensible comprises the following steps: to provide the fibre web of extensible nonwoven material; The fibre web of elastomeric material is provided; With discontinuous or random patterns with adhesive application at least a portion side surface of thin film of extensible nonwoven web; Optionally stick to extensible nonwoven web on the elastomeric web by a large amount of intermittent adhesive bonds; And optionally stick on the elastomeric web by a large amount of thermal point bond extensible nonwoven web of naming a person for a particular job, intermittent adhesive bonds covers the percentage of interfacial plane between bigger extensible nonwoven web and the elastomeric web than focus bounding point thus.

In another embodiment, the method for making extensible comprises the following steps: to provide the fibre web of first extensible nonwoven material with side surface of thin film and fabric side; With discontinuous pattern with the side surface of thin film of adhesive application in first extensible nonwoven material web; The fibre web of elastomeric material is provided; Optionally stick to first extensible nonwoven web on the elastomeric web by a large amount of intermittent adhesive bonds; The fibre web of second extensible nonwoven material is provided; And optionally stick on the elastomeric web by a large amount of thermal point bond second extensible nonwoven web of naming a person for a particular job, intermittent adhesive bonds covers the percentage of interfacial plane between first and second bigger extending non-woven material fibre web than focus bounding point thus.

The accompanying drawing summary

Fig. 1 is the detail drawing of the single vermicelli extensible of the present invention.

Fig. 2 is the detail drawing of intermittent adhesive bonds pattern.

Fig. 3 is the detail drawing of thermal point bond pattern.

Fig. 4 is the detail drawing of intermittent adhesive and thermal point bond pattern.

Fig. 5 and 6 is detail drawings of the two vermicelli extensible of the present invention.

Fig. 7,8 and 9 is schematic diagrames of making the method for extensible of the present invention.

DESCRIPTION OF THE PREFERRED

The invention provides a kind of extensible with the discontinuous interrupted adhesion area of interlayer and non-adhesion area.Utilize intermittent adhesive bonds and thermal point bond one or more extensible nonwoven layers of naming a person for a particular job optionally to stick on the elastomer layer simultaneously.But intermittent adhesive bonds is than the percentage of interfacial plane between bigger extensible nonwoven layers of the bonding covering of focus and the elastomer layer.Thermal point bond gives the laminate surface aesthetic pleasant pattern.The method of making extensible also is provided.

The use of uniting of intermittent adhesive bonds and thermal point bond not only provides bigger manufacturing flexibility but also improved transverse elasticity is provided.It is found that thermal point bond is the effective means that links each layer of extensible with cross-directional extensibility.Yet under industrial production speed, the texturing calender rolls of heating need be heated to higher temperature could produce the bonding of desirability.Regrettably, this higher temperature is to the softness of extensible nonwoven layers and fluffyly have a negative effect, and therefore the extensible of producing is unsatisfactory.

Have now found that high production speed can be issued in the situation of not negative effect extensible.By intermittent adhesive bonds and thermal point bond and usefulness, the texturing cotton gin roller of heating can maintain and not destroy or this extensible nonwoven layers of degrading is kept the temperature of desired peel strength of the extensible of making and cohesive force simultaneously again, and reason is that intermittent adhesive bonds has remedied thermal point bond.

Generally speaking, interfacial intermittent adhesive bonds should cover in the whole interfacial plane area than interface thermal point bonds big at least 5%.For example, if between thermal point bond cover film and the non-woven layer 20% of the area of plane, then intermittent adhesive bonds should cover at least 25% of interface plane.Aptly, intermittent adhesive bonds should cover in the interface plane than bonding big 10% the area of focus at least.So-called " interfacial adhesion point ", what refer to only is the bounding point of interlayer, does not comprise interfibrous bounding point in the nonwoven web.

In a kind of embodiment shown in Figure 1, extensible 10 comprises first extensible nonwoven material sheet 12 and the second elastomeric material sheet material 14.Extensible nonwoven sheet 12 has side surface of thin film 16 and the fabric side 18 that faces elastomer sheet 14.Adhesive application is at least a portion side surface of thin film 16 of extensible nonwoven sheet 12, and a large amount of thus intermittent adhesive bonds 20 optionally stick to extensible nonwoven sheet 12 on the elastomer sheet 14.Extensible nonwoven sheet 12 further optionally sticks on the elastomer sheet 14 by a large amount of thermal point bonds 24.Intermittent adhesive bonds 20 covers the percentage of interface plane 22 between bigger extensible nonwoven sheet 12 and the elastomer sheet 14 than focus bounding point 24.Intermittent adhesive bonds 20 can overlap with thermal point bonds 24, but this kind overlaps and be nonessential.

Extensible is owing to the influence of extensible nonwoven material has cross-directional extensibility.When transverse extension power is removed, because the influencing laminate and will get back to the configuration of its manufacturing basically of elastomeric material.As shown in Figure 1, extensible nonwoven sheet 12 is not being sticked on the elastomer sheet 14 basically by interface plane part 22 places of intermittent adhesive bonds 20 and/or thermal point bonds 24 coverings.Because extensible nonwoven sheet 12 allows elastomer sheet 14 less constraint ground to stretch with independently moving of elastomer sheet 14 and replys between

bounding point

20 and 24, causes laminate to have improved transverse elasticity.

It is desirable to, the DE value of laminate 10 along horizontal 26 is the retraction force/extension force ratio greater than about 0.22.The method that the elasticity of laminate 10 is described in " definition " of transverse elasticity according to the front is measured.

Aptly, extensible nonwoven material 12 can be extensible nonwoven material own, and for example the crimp bicomponent spunbonded materials is disclosed as the United States Patent (USP) 5,418,045 that transfers people such as Pike jointly, and is for referencial use in these receipts, perhaps Qu Xiang adhesion fiber web.

Other suitable extensible nonwoven material comprises twin shaft extensible nonwoven material, for example neck stretched/creped spunbond.The vertical and horizontal extensible nonwoven material can cause it to provide along horizontal constriction (and extensibility) by drawing of fiber nonwoven web longitudinally.Alternatively, non-woven material can be along horizontal discontinuous bonding very loose fiber collection, so that this material can be along cross directional stretch.Thereby the same material that is endowed transverse elongation can longitudinally curl or wrinkling its vertical extensibility that causes.

Extensible nonwoven material 12 also can be a necked nonwoven, for example the spunbond fibre web of constriction, constriction melt spray fibre web or examples of neck-bonded carded web.If necked nonwoven is the fibre web of meltblown fibers, then it can comprise melt-blown micro-fiber.Necked nonwoven can be made by any material, if it can be by tensioning constriction, and after being subjected to making the external force effect of its elongation, be stretched to the preceding size of its constriction.Some polymer, for example polyolefin, polyester and polyamide can be accepted heat treatment under proper condition and obtain this kind memory.Exemplary polyolefins comprises one or more that polyethylene, polypropylene, polybutene, ethylene copolymer, propylene copolymer and butylene copolymer are central.Found that useful polypropylene comprises for example by the (Wilmington of Himont company, the Delaware) polypropylene of supplying with trade name PF-304, by (the Baytown of Exxon-Mobil chemical company, the Texas) polypropylene of supplying with registration mark ESCORENE PD-3445, with the polypropylene of supplying with trade name DX 5A09 by shell chemical company (Houston, Texas).Also polyethylene be can use, ASPUN 6811A and 2553 linear low density polyethylene (LLDPE)s comprised, by Dow Chemical (Midland, Michigan) supply, and various high density polyethylene (HDPE).The chemical characteristic of these materials can be obtained by manufacturer place separately.

In one embodiment of the present invention, extensible nonwoven material 12 can be a multilayer material, and for example having, at least one spunbond web layer is attached on the layer of at least one melt spray fibre web, bonded carded web or other suitable material.For example, extensible nonwoven material 12 can be a kind of multilayer material, comprise that basic weight melts and sprays polyolefin layer and the basic weight second spunbond polyolefin layer between about 0.2～about 8osy (about 6.8～about 271.3gsm) between the first spunbond polyolefin layer of about 0.2～about 8 ounces every square yard (osy) (about 6.8～about 271.3 grams every square metre (gsm)), basic weight between about 0.1～about 4osy (about 3.4～about 113.4gsm).

Alternatively, extensible nonwoven material 12 can be the homogenous material layer, and for example basic weight is between the spunbond fibre web of about 0.2～about 10osy (about 6.8～about 339.1gsm), and perhaps basic weight is between the melt spray fibre web of about 0.2～about 8osy (about 6.8～about 271.3gsm).Aptly, extensible nonwoven material 12 can have about constriction percentage of 15%～about 75%.It is desirable to, extensible nonwoven material 12 can have about constriction percentage of 25%～about 70%.

Extensible nonwoven material 12 also can comprise by two or the composite made of the mixture of more kinds of mixture of different fibers or fiber and particle.This type of mixture can form by following method: fiber and/or particle are joined in the air-flow of carrying meltblown fibers secretly so that make meltblown fibers and other material (for example wood pulp, short fiber or particle, superabsorbent material for example) interlacing of closely tangling, fiber is collected in and forms the meltblown fibers of random dispersion and the adhesion fiber web of other material on the gathering-device then, for example be disclosed in the United States Patent (USP) 4 of authorizing people such as Anderson, 100, in 324, for referencial use in these receipts.

The fiber of extensible nonwoven material 12 can utilize in adhesive bonding method of describing in " definition " bonding between previous fibre one or more to combine by inter-fibre-bond.

Elastomer sheet 14 can be by any material manufacturing that manufactures sheet-form.Elastomer sheet 14 can be non-woven elastomeric web.For example, nonwoven elastomeric web can be shaped so that nonwoven elastomeric web to be provided by the blend that melts and sprays suitable resin or comprise this resin.The object lesson of nonwoven elastomeric web is disclosed in the United States Patent (USP) 4,663,220 of authorizing people such as Wisneski, and is for referencial use in these receipts.

Alternatively, elastomer sheet 14 can be an elastomer thin film, and the method for the extruding of resin by any suitable formed film or resin blend, curtain coating and so on is shaped.For example, elastomer thin film can be made by the elastic block copolymer with general formula A-B-A ', wherein A and A ' are thermoplastic polymer end blocks, comprise styrene part as poly-(vinyl-arene) and wherein B be block such as conjugated diene or lower alkanols alkene polymer in the chain of elastomer polymer.Elastomer thin film can be shaped with (polystyrene/poly-(ethylene butene)/polystyrene) block copolymer that registration mark KRATON G provides by for example KRATON Polymers company (Houston, Texas).A kind of this based block copolymer can be KRATON G-1657 for example.The suitable blend of block copolymer containing comprises for example KRATON G-2755, KRATON G-2760, KRATON MD6659 and KRATON RP6578.

Other spendable exemplary materials comprises polyurethane elastomer material, for example by Noveon company (Cleveland, the Ohio) with those of registration mark ESTANE supply, the polyamide elastomer material, for example by ATOFINA chemical company (Philadelphia, Pennsylvania) with those of registration mark PEBAX supply, and polyester elastomer materials, for example by E.I.Du Pont Company (Wilmington, Delaware) with those of registration mark HYTREL supply.Technology by polyester elastomeric material shaped resilient sheet material is disclosed in the United States Patent (USP) 4,741,949 of for example authorizing people such as Morman, and is for referencial use in these receipts.

Elastomer thin film can be elastomer polymer and the blend with polymer of finite elasticity.For example, elastomer polymer can with " metallocene " polyblend of the polymer of single-site catalyzed as producing according to the metallocene method.Term " polymer of metallocene catalyst " is used for comprising those in this article by adopting metallocene or control geometric configuration catalyst, and promptly a class metal-organic complex is as polymerization catalyst ethene and the polymeric material produced at least.For example, common metallocene is a ferrocene, a kind of complex compound of being made up of metal of two cyclopentadienyl groups (Cp) part therebetween.The metallocene process catalyst comprises two (n-butyl cyclopentadienyl) titanium chloride, two (n-butyl cyclopentadienyl) zirconium dichloride, two (cyclopentadienyl group) scandium chloride, two (indenyl) zirconium dichloride, two (methyl cyclopentadienyl) titanium chloride, two (methyl cyclopentadienyl) zirconium dichloride, cobaltocene, the cyclopentadienyl group titanium trichloride, ferrocene, the dichloride hafnocene, isopropyl (cyclopentadienyl group-1-fluorenyl) zirconium dichloride, dichloride two luxuriant molybdenums, dicyclopentadienyl nickel, dichloride two luxuriant niobiums, ruthenocene, titanocene dichloride, zirconocene hydrogen chloride, zirconocene dichloride and the like.The more detailed list of this compounds is disclosed in United States Patent (USP) 5,374, in 696, authorizes people such as Rosen, and transfers Dow Chemical.This compounds is also discussed in people such as authorizing Stevens also transfers the United States Patent (USP) 5,064,802 of Dow Chemical.

It is desirable to, metallocene polymers is selected from the copolymer and the combination thereof of copolymer, ethene and 1-octene of copolymer, ethene and the 1-hexene of ethene and 1-butylene.This type of metallocene polymers is represented the EXXPOL of polypropylene base polymer by Exxon-Mobil chemical company (Baytwon, Texas) with registration mark and is represented the EXACT supply of polyvinyl polymer.Du Pont-Tao Shi elastomer company (Wilmington, Delaware) is with registration mark ENGAGE available commercial polymer.Metallocene polymers is also supplied with registration mark AFFINITY by Dow Chemical (Midland, Michigan).The metallocene polymers that is fit to the present invention's use comprises for example ENGAGE EG8200 and AFFINITY XUS58380.01L.

Comprise independent polypropylene or also be suitable for forming elastomer thin film with the elastomer polymer of the combination of the low material of other elastomer polymer or elasticity.For example, elastomer thin film can be made up by polypropylene elastomer homopolymers, polypropylene elastomer copolymer or its and form.

Polyolefin can be used for separately forming extending film or can with the elastomer polymer blend to improve the processability of film composite.Polyolefin can be can extrude separately or with the blending form when time under the appropriate combination that is in high temperature and high pressure.Useful polyolefine material comprises for example polyethylene, polypropylene and polybutene, comprising ethylene copolymer, propylene copolymer and butylene copolymer.A kind of useful especially polyethylene can be buied with registration mark PETROTHENE NA601 from U.S.I. chemical company.Can use two or more kinds of polyolefin.Elastomer polymer and the polyolefinic blend of extruding are disclosed in the United States Patent (USP) 4,663,220 of for example authorizing people such as Wisneski, and be for referencial use in these receipts.

Elastomer thin film also can be a multilayer material, and in other words, it can comprise two or more a plurality of bonding fibre web or sheet material.In addition, elastomer thin film can be such multilayer material, and wherein one or more layers comprise the mixture of elasticity and non-elastic fiber or particle.The example of the one type of elastic web in back is disclosed in the United States Patent (USP) 4,209,563 of authorizing Sisson, and for referencial use in these receipts, wherein elastomer and inelastic body fiber interlacing form by the fibrous single bonding fibre web of random dispersion together.

Be used for exemplary elastomeric films of the present invention and comprise (poly-/poly-(ethylene butene)/polystyrene) block copolymer, metallocene derived polymers and polyolefinic blend.For example, elastomer thin film can be made by about 15%～polyolefin that about 75% metallocene is derived, the blend of about 10%～about 60% (polystyrene/poly-(ethylene butene)/polystyrene) block copolymer and 0～about 15% low density polyethylene (LDPE).

On the other hand, elastomer sheet 14 can be the elastomer foam plastics.A kind of suitable elastomer foam plastics are elastomeric polyurethane foam plastics.

Elastomer sheet 14 can be by any formation in the known method traditionally in a large number, includes but not limited to that flat die is extruded, inflation film (tubulose) method, curtain coating, melts and sprays etc.It is desirable to, elastomer sheet 14 is to be shaped on chill roll, be laminated to extensible nonwoven material 12 get on before substantially the cooling.This can be avoided extra and undesirable bonding between extensible nonwoven material 12 and elastomer sheet 14, the bonding retraction force/extension force ratio that may reduce extensible 10 of this kind.Aptly, the basic weight of elastomer sheet 14 can be between about 5～about 100g/m ², about preferablyly 25～about 60g/m ²

Point out that as top extensible nonwoven material 12 optionally sticks on the elastomer sheet 14 by a large amount of intermittent adhesive bonds 20.Adopt non-resilient and/or elastic adhesive all is fit to the present invention.The example of suitable binders is the meltblown adhesive that contains following ingredients: about 54.5%～about 57.5wt% petroleum hydrocarbon resin; The mixture of several mineral oil of about 18.5%～about 21.5wt%; About 22.5%～about 27.5wt% SBS; About 0.1%～about 0.9wt% polyethylene and ethylene vinyl acetate; And about 0.2%～about 1.8wt% antioxidant and stabilizing agent.The object lesson that is suitable for adhesive of the present invention is NS34-5610, is supplied by national starch chemical company (National Starch and ChemicalCompany of Bridgewater, New Jersey).

Adhesive can side surface of thin film 16 by any method paint extensible nonwoven material 12 well known in the art on, include but not limited to meltblowing method, spraying, interrupted sealing coating, combing and/or the printing of decorative pattern intaglio plate cylinder.Alternatively or additionally, but at least a portion on adhesive paint elastomer sheet 14 surfaces.It is desirable for adhesive applies with fusion or liquid state.Aptly, the adhesive that applies with molten condition should not make extensible nonwoven material 12 that thermal degradation and/or fusion take place.Alternatively, single single thread, long filament or line that adhesive can be used as solid or semi-solid form apply, and realize bonding thereby activate them by heating and/or pressurization.

Adhesive can change along with adhesive type, method of application, the bond coverage that applies decorative pattern, requirement, elastomer thin film type and extensible nonwoven material type in the side surface of thin film 16 and/or the applied amounts on elastomer sheet 14 of extensible nonwoven material 12.For example, adhesive can adopt meltblowing method with about 2g/m ²～about 10g/m ²Applied amounts apply, to reach to 22 about 10%～about 70% the bond coverage of the interface plane between extensible nonwoven material sheet 12 and the elastomer thin film 14.

Wish that adhesive applies with random and/or discontinuous pattern form.Wish that more adhesive is to apply along horizontal 26 discontinuous pattern forms.As shown in Figure 1, wish that adhesive is to apply along horizontal 26 and vertical 28 all discontinuous patterns most.

Referring to Fig. 2, a kind of discontinuous pattern of suitable adhesive application comprises a large amount of a single points 30.Satisfying is that the diameter of these points is between about 1mm～about 2mm, and area is between about 0.8mm ²～about 3.1mm ²More but heart is, as shown in Figure 2, point 30 is arranged in chequer on the side surface of thin film 16 of extensible nonwoven material 12.Aptly, point 30 each other spacing d press center to center mensuration between about 5mm～about 8mm, and provide and be of a size of about 25mm ²～about 64mm ²Grid.This kind pattern can provide about bond coverage of 1.25%～about 12.5% (calculating according to [some area/lattice area] * 100).

Advantageously, if adhesive is stiff, then intermittent adhesive bonds 20 can cover about 10%～about 50% of interfacial plane 22 between extensible nonwoven material sheet 12 and the elastomer thin film 14.More advantageously, inelastic intermittent adhesive bonds 20 can cover about 10%～about 40% of interfacial plane 22.Satisfying is, interface plane 22 do not have inelastic intermittent adhesive bonds 20 at least about 50%～about 90%.

Aptly, if adhesive is elastomeric, then intermittent adhesive bonds 20 can cover about 10%～about 70% of interfacial plane 22.Ground preferably, elastomeric intermittent adhesive bonds 20 can cover about 10%～about 65% of interfacial plane 22.Optimum ground, elastomeric intermittent adhesive bonds 20 can cover about 10%～about 50% of interfacial plane 22.Ideally, interfacial plane does not have elastomeric intermittent adhesive bonds at least about 30%～about 70%.

As shown in Figure 1, extensible nonwoven material sheet 12 also relies on a large amount of thermal point bonds 24 further optionally to stick on the elastomer sheet 14.Thermal point bonds 24 can and be pressurizeed by heating and be entered into each zone of elastomer sheet 14 with the each several part that forces extensible nonwoven material sheet 12, makes the various piece of extensible nonwoven material sheet 12 be wrapped up and form by the various piece of elastomer sheet 14.

This kind thermal point bond was generally by sending the roll gap between a pair of laminating roll to form two material sheets.Laminating roll one of at least has texturing, it is had be pressed between roller along with sheet material and form a little bonding projection or needle pattern.Another laminate can be smooth, perhaps also can be texturing.If second roller is texturing, then its pattern can cause the thermal point bonds on each face of laminate to overlap each other with the pattern match of first roller.Alternatively, two patterns can be setovered, and cause the two sides of laminate to demonstrate different bonding patterns.These two rollers also can have spiral pattern, and its opposite pitch is so that make these two screw threads only just take place bonding in the intersection.

In an alternative embodiment, thermal point bonds 24 can adopt the bonding or solder technology formation of ultrasonic wave.Generally speaking, this type thermal point bond is by two material sheets being sent the gap between ultrasonic wave binding head and the bonding anvil roller of ultrasonic wave form.Binding head and anvil roller one of at least are texturing or patterned, so that it has and manyly accepts the ultrasonic wave effect along with sheet material and form the projection of thermal point bonds.

Thermal point bond coverage can multiply by dial by the pin density that shows with unit are pin numerical table and amass and calculate.For example, one comprises that a large amount of areas are 0.01cm ²The pin of/pin also has 30 pins/cm ²The engraved roll of pin density 0.30 or 30% thermal point bond coverage will be provided.

Thermal point bonds 24 can the intermittent adhesive bonds 20 in interfacial plane between.Alternatively, as shown in Figure 1, at least a portion thermal point bonds 24 can overlap at least a portion intermittent adhesive bonds 20.Aptly, thermal point bonds 24 can cover about 5%～about 50% of interfacial plane.Ground preferably, thermal point bonds 24 can cover about 10%～about 40% of interfacial plane 22.Advantageously, do not have thermal point bonds 24 at least about 50% interfacial plane 22.

In another embodiment, intermittent adhesive bonds 20 and thermal point bonds 24 can be the thermal point bonds alternately and the striped or the band of intermittent adhesive bonds as shown in Figure 4 in interfacial plane 22.These stripeds or band can be along diagonal or other suitable pattern orientation horizontal, vertical, that interfacial plane is striden on the edge.Single striped or band can have identical or different size such as length and/or width.In addition, single bonding striped or band can be each other at a distance of a non-bonding striped or bands that is positioned at interfacial plane 22.Striped or band can any suitable pattern configurations, and the bond coverage of requirement is provided.

Referring to Fig. 1, intermittent adhesive bonds 20 covers the percentage of bigger interfacial plane 22 than focus bounding point 24.Interfacial plane at least about 30%, do not have inelastic intermittent adhesive bonds and thermal point bonds (when adhesive when being stiff) at least about 50% aptly.Preferablyly, interfacial plane does not have inelastic intermittent adhesive bonds and thermal point bonds at least about 60%.It is desirable to, interfacial plane do not have elasticity intermittent adhesive bonds and thermal point bonds (when adhesive when being flexible) at least about 30%.Better is, interfacial plane do not have elasticity intermittent adhesive bonds and thermal point bonds at least about 35%.It would be desirable, interfacial plane do not have elasticity intermittent adhesive bonds and thermal point bonds at least about 50%.When adopting the combination of elasticity and inelastic adhesives, interfacial plane 22 should not have any adhesive bounding point and thermal bond points at least about 30%.

Except peel strength and interior bonding contribution to extensible, thermal point bonds 24 is also given fabric side 18 certain aesthetic pleasant surface details of extensible nonwoven material 12.Bond pattern can be evenly or is applied to unevenly on the fabric side 18 of extensible nonwoven material 12.The bond pattern that evenly applies contributes to the more uniform material property in the whole surface of the extensible after making, and the inhomogeneous decorative pattern that applies then may influence the performance such as the level of retractive force of material.

Developed various decorative pattern that is used for roll.Just as understood by those skilled in the art, the bond coverage that needs be roughly or with regard to scope because bonding pin normally taper and wear away as time passes.Understand that as those skilled in the art term " pin number/square inch " or " bonding counting/square inch " are general sometimes, because pin will cause bounding point in base material, its size is the same on roller with surface relationships and pin.There are many discontinuous bond pattern to use.For example, for referencial use in these receipts referring to the United States Patent (USP) 4,041,203 of authorizing people such as Brock.A kind of example of decorative pattern is Hansen Pennings or " H﹠amp; P " pattern, 200 bounding points of having an appointment per square inch, as the United States Patent (USP) 3,855 of authorizing Hansen and Pennings, described in 046.H﹠amp; The P decorative pattern has the point or the needle-like bonding zone of box-shaped, and wherein the side dimension of each pin is 0.038 inch (0.965mm), and for example the decorative pattern of Xing Chenging has about 30% bond coverage.Another kind of typical some bond pattern is extended pattern Hansen and Pennings, or " EHP " bonding patterns, for example it can produce about bond coverage of 15%～about 18%, and its box-shaped pin side dimension is 0.037 inch (0.94mm), pin density be about 100 pins per square inch.Other decorative pattern commonly used comprises " Ramisch " Argyle with repetition rhombus, its bond coverage is between about 8%～about 14%, 52 pins per square inch, and " S " undulations, be described in the United States Patent (USP) 5 that transfers people such as McCormack jointly, in 964,742, for referencial use in these receipts.Other decorative pattern comprises for example x wire, vertical line or other extensible pattern well known in the art.This type of extensible pattern that a kind of suitable the present invention uses is called " wire weave ", bond coverage between about 15%～about 20%, 302 pins per square inch.As shown in Figure 3, wire weave bond pattern 32 comprises producing and looks the Argyle element that looks like decorative pattern like the window screening.Each pattern element can be by 4 elliptical point bounding points, 34 regulations.

In another embodiment, as shown in Figure 5, extensible 10 comprises first extensible nonwoven material sheet 12 with side surface of thin film 16 and fabric side 18, second extensible nonwoven material sheet 36 with side surface of thin film 38 and fabric side 40, and has first surface 17 and second surface 37 and the elastomeric material sheet material 14 between extensible nonwoven material sheet 12 and 36.First adhesive is applied at least a portion first surface 17 of at least a portion side surface of thin film 16 of first extensible nonwoven material sheet 12 and/or elastomer sheet 14 (not shown)s, causes first extensible nonwoven material sheet 12 optionally to be sticked on the elastomer sheet 14 by a large amount of intermittent adhesive bonds 20.Second adhesive is applied at least a portion second surface 37 of at least a portion side surface of thin film 38 of the second necked nonwoven sheet material 36 and/or elastomer sheet 14 (not shown)s, causes second extensible nonwoven material sheet 36 by a large amount of intermittent adhesive bonds 20 ' optionally stick on the elastomer sheet 14.First extensible nonwoven material sheet 12 and the second necked nonwoven sheet material 36 are optionally sticked on the elastomer sheet 14 by a large amount of thermal point bonds 24 and 24 ' further again.Intermittent adhesive bonds 20 and 20 ' covers the first bigger extensible nonwoven material sheet 12 and the percentage of the interfacial plane 42 between second extensible nonwoven material sheet 36 than the bounding point 24 and 24 ' of making an inventory.

First extensible nonwoven material sheet 12 and second extensible nonwoven material sheet 36 can be same materials or can be different materials.For example, first sheet material 12 can be spunbond fibre web, and second sheet material 36 can be spunbond fibre web, melt spray fibre web, bonded carded web or its multilayer materials.In addition, first sheet material 12 can be the extensible nonwoven material with certain basic weight, and second sheet material 36 can be the extensible nonwoven material with identical or different basic weight.

Similarly, first and second adhesives can be identical or different.For example, first and second adhesives can be meltblown adhesive, and are for example described above.Alternatively, first adhesive can be a meltblown adhesive, and second adhesive can be the hot melt spraying binder, for example a kind of styrene-isoprene-phenylethene based adhesive, supply with trade name Findley 2525A by Ato-Findley adhesive company (Wauwatosa, Wisconsin).In addition, first and second adhesives can apply by identical or different discontinuous and/or random patterns.

Another embodiment as shown in Figure 6.Extensible 10 comprises first extensible nonwoven material sheet 12, second extensible nonwoven material sheet 36 with side surface of thin film 16 and fabric side 18 and the elastomeric material sheet material 14 with first surface 17.Elastomer sheet 14 is between extensible nonwoven material first sheet material 12 and second sheet material 36.Adhesive application causes first extensible nonwoven material sheet 12 optionally to be sticked on the elastomer sheet 14 by a large amount of intermittent adhesive bonds 20 at least a portion first surface 17 of at least a portion side surface of thin film 16 of first extensible nonwoven material sheet 12 and/or elastomer sheet 14 (not shown)s.Second extensible nonwoven material sheet 36 is optionally sticked on the elastomer sheet 14 by a large amount of thermal point bonds 24.Intermittent adhesive bonds 20 covers the first bigger extensible nonwoven material sheet 12 and the percentage of the interfacial plane 42 between second extensible nonwoven material sheet 36 than focus bounding point 24.

Extensible laminate 10 of the present invention can be attached in any suitable absorbent article.The example that can comprise the absorbent article of extensible 10 comprises absorbent garment, and for example training pants, diaper, urine trousers, feminine hygiene products, swimsuit, incontinence article, other personal nursing or health care clothes comprise medical garment etc.Here employed term " incontinence article " comprises that children are with absorbent pants, the children with special requirement or Young Adults such as unsociable and eccentric children or because physical disabilities cause having bladder/absorbent garment of other human of large intestine control problem and even the absorbent garment that the incontinence old man uses.

The method of making extensible laminate 10 is described among Fig. 7.This method comprises the following steps: to provide the extensible nonwoven web 12 with side surface of thin film 16 and fabric side 18; And provide elastomeric web 14.Adhesive 44 is at least a portion side surface of thin film 16 of discontinuous decorative pattern paint extensible nonwoven web 12.Alternatively or additionally, but on the first surface 17 of adhesive paint elastomeric web 14 (not shown)s.Extensible nonwoven material web 12 is optionally sticked on the elastomeric web 14 by a large amount of intermittent adhesive bonds 20 (not shown)s.Intermittent adhesive bonds 20 is by fibre web being sent first roll gap 46 between the first smooth nip rolls 48 and the second smooth nip rolls 50 form.Extensible nonwoven material web 12 is also optionally sticked on the elastomeric web 14 by a large amount of thermal point bonds 24 (not shown)s.Thermal point bonds 24 is to form by second roll gap 52 between the patterned calender roll 56 of extensible nonwoven material web 12 and elastomeric web 14 being sent smooth anvil roller 54 and heating.It is desirable to, the fabric side 18 of extensible nonwoven material web 12 faces patterned calender roll 56 orientations of heating, causes thermal point bonds 24 to produce a kind of aesthetic pleasant pattern on the extensible nonwovens surface of extensible 10.

The patterned calender roll 56 of heating has a large amount of each intervals on its surface projection or pin 58.Projection 58 is commonly referred to as embossed spots.The fabric side 18 of projection 58 contact extensible nonwoven material web 12, and optionally force elastomeric film web 14 to enter into the fibre structure of the side surface of thin film 16 of extensible nonwoven web 12, thereby extensible nonwoven web 12 is wrapped up and is adhered on the elastomeric film web 14 in the part one by one of a large amount of thermal bond points 24.Zone between thermal point bonds 24 and intermittent adhesive bonds 20, extensible nonwoven web 12 and elastomeric web 14 are not bonded to each other, and can move independently of one another.The structure of leaving second roll gap 52 is extensible 10 of the present invention at this moment, and can be wound on the takers-in to store or to transport further to process.Thereby the fabric side 18 of the patterned calender roll of this heating 56 contact extensible nonwoven web 12 prevents that elastomeric web 14 from sticking on the projection 58.Yet, under some situation, may wish the patterned calender roll 52 contact resilient body fibre webs 14 that heat.

Patterned calender roll 56 heated temperature depend on the character of elastomeric web 14 and/or extensible nonwoven web 12, but generally between about 100 °F～about 275 °F (about 38 ℃～about 135 ℃).Adhesion characteristic partly depends on multiple factor, and existence, elastomer sheet 14 and the extensible nonwoven material 12 of composition, wetting agent that includes but not limited to fibre web 12 and 14 is in the temperature of the patterned calender roll 56 of the light anvil roller 54 of the temperature at thermal bond points 24 places, heating and heating etc.In addition, the sample of projection 58 and structure will influence bonding.This type of factor includes but not limited to height, geometry, density, width and the pattern of projection 58, the size of second roll gap 52 etc.

Randomly, can be shaped online in production period elastomeric web 14.For example, the first smooth nip rolls 48 can be a chill roll, thereby elastomer polymer or blend polymer are expressed into formation cast elastomeric film fibre web on it, are laminated on the extensible nonwoven web by adhesive immediately.

Know that 2 above material layers can be laminated together and form extensible of the present invention, such as but not limited to, spunbond-elastomer-the spunbond layer condensation material, spunbond-elastomer-meltblown layer condensation material etc.Fig. 8 and 9 has shown substituting of the method that forms extensible of the present invention

Embodiment.

Fig. 8 shows the method for making the extensible of the present invention that comprises two extensible nonwoven material layers.This method may further comprise the steps: first extensible nonwoven material web 12 with side surface of thin film 16 and fabric side 18 is provided; On at least a portion side surface of thin film 16 of first extensible nonwoven material web 12, apply adhesive 44 along discontinuous pattern; Elastomeric material fibre web 14 is provided; With by a large amount of intermittent adhesive bonds 20 (not shown)s first extensible nonwoven web 12 is optionally sticked on the elastomeric web 14.Intermittent adhesive bonds 20 is by fibre web 12 and 14 being sent first roll gap 46 between the first smooth nip rolls 48 and the second smooth nip rolls 50 form.Second extensible nonwoven material web 36 with side surface of thin film 38 and fabric side 40 is provided.Second extensible nonwoven web 36 is optionally sticked on the elastomeric web 14 by a large amount of thermal point bonds 24 (not shown)s.Thermal point bonds 24 is to form by second roll gap 52 between the patterned calender roll 56 of first extensible nonwoven web, elastomeric web and second extensible nonwoven web being sent light anvil roller 54 and heating, and wherein Jia Re patterned calender roll is positioned at fabric side 40 position adjacent with second extensible nonwoven web 36.

Randomly, this method can comprise following additional step: along discontinuous pattern with adhesive application to the side surface of thin film 38 of second extensible nonwoven web 36, optionally stick on the elastomeric web 14 and/or by a large amount of thermal point bonds 24 ' first extensible nonwoven web 12 is optionally sticked on the elastomeric web 14 by a large amount of intermittent adhesive bonds 20 ' with second extensible nonwoven web 36.In addition, also can at least a portion of the first surface 17 of elastomeric web 14 and/or second surface 37, apply adhesive.

Fig. 9 shows the another kind of method that forms the extensible that comprises two extensible nonwoven material web.This method comprises the following steps: to provide first extensible nonwoven material web 12; On the side surface of thin film 16 of first extensible nonwoven web 12, apply adhesive 44 along discontinuous pattern; Elastomeric web 14 is provided; Thereby and rely on a large amount of intermittent adhesive bonds 20 (not shown)s that first extensible nonwoven material web 12 is optionally sticked to form first composite 60 on the elastomeric web 14.Intermittent adhesive bonds 20 is to send first roll gap 46 between the first smooth nip rolls 48 and the second smooth nip rolls 50 to form together by first extensible nonwoven web 12 and the elastomeric web 14 of the side surface of thin film 16 that will have the elastomeric web of facing 14 orientations.This method also comprises provides second extensible nonwoven material web 36 with side surface of thin film 38 and fabric side 40; Along discontinuous pattern on the side surface of thin film 38 of second extensible nonwoven web 36, apply adhesive 44 '; And second extensible nonwoven web 36 is optionally sticked on the elastomeric web 14, thereby form second composite 62 by a large amount of intermittent adhesive bonds 20 ' (not shown)s.Intermittent adhesive bonds 20 ' be was by sending second roll gap 64 between second nip rolls 50 and the 3rd nip rolls 66 to form together in first composite 60 and second extensible nonwoven web 36, and wherein fibre web 36 has the side surface of thin film 38 of elastic web 14 orientations that face first composite 60.This method also comprises by a large amount of thermal point bonds 24 (not shown)s first extensible nonwoven web 12 is optionally sticked on the elastomeric web 14, and by a large amount of thermal point bonds 24 ' (not shown)s second extensible nonwoven web optionally sticked on the elastomeric web 14.It is to form by the roll gap 52 between the patterned calender roll 56 of second composite 62 being sent the first smooth anvil roller 54 adjacent with second extensible nonwoven web 36 and first heating adjacent with first extensible nonwoven web 12 that first extensible nonwoven web 12 is sticked to thermal point bonds 24 on the elastomeric web 14.Second extensible nonwoven web 36 is sticked to thermal point bonds 24 on the elastomeric web 14 ' be to be formed by the roll gap 68 between the patterned calender roll 72 of second composite 62 being sent the second smooth anvil roller 70 adjacent with first extensible nonwoven web 12 and second heating adjacent with second extensible nonwoven web 36.

Alternatively, in Fig. 7,8 and 9, light anvil roller 52 and/or 70 can be the bonding anvil roller of ultrasonic wave, and the patterned calender roll 56 and/or 72 of heating can be a texturing ultrasonic wave binding head.

Though just a few exemplary of the present invention is described in detail in the above, but those skilled in the art are easy to find out, also can make many modifications to exemplary under the condition that does not depart from innovation concept of the present invention and advantage basically.Therefore, all these type of modifications all should be included in as in the scope of the invention that limits in the following claim.

It is to be noted that any patent quoted or publication are received for referencial use without exception in full here.

Claims

1. extensible comprises:

Sheet material with extensible nonwoven material of side surface of thin film and fabric side;

The sheet material of elastomer thin film; And

Adhesive, it is applied at least a portion side surface of thin film of extensible nonwoven material, causes the sheet material of extensible nonwoven material optionally to stick on the elastomer thin film sheet material by a large amount of intermittent adhesive bonds,

Wherein extensible nonwoven material sheet also optionally sticks on the elastomer thin film sheet material by a large amount of thermal point bonds, and intermittent adhesive bonds covers the percentage of interfacial plane between bigger extensible nonwoven material sheet and the elastomer thin film sheet material than focus bounding point.

2. the extensible of claim 1 does not wherein stick on the elastomer thin film sheet material in the part interfacial plane of extensible nonwoven material sheet between intermittent adhesive bonds and thermal point bonds basically.

3. the extensible of claim 1, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered 5% interfacial plane.

4. the extensible of claim 1, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered 10% interfacial plane.

5. the extensible of claim 1, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered 20% interfacial plane.

6. the extensible of claim 1, wherein laminate has the DE value greater than about 0.22 retraction force/extension force ratio.

7. the extensible of claim 1, wherein thermal point bonds in interfacial plane between intermittent adhesive bonds.

8. the extensible of claim 1, wherein at least a portion thermal point bonds overlaps at least a portion intermittent adhesive bonds.

9. the extensible of claim 1, wherein adhesive is an inelastic adhesives.

10. the extensible of claim 9, wherein intermittent adhesive bonds covers about 5%～about 50% of interfacial plane.

11. the extensible of claim 1, wherein adhesive is an elastomeric adhesive.

12. the extensible of claim 11, wherein intermittent adhesive bonds covers the highest by about 70% of interfacial plane.

13. comprise the absorbent article of the extensible of claim 1.

14. an extensible comprises:

First extensible nonwoven material sheet with side surface of thin film and fabric side;

The sheet material of elastomer thin film; And

First adhesive, it is applied in the side surface of thin film of first extensible nonwoven material sheet along discontinuous pattern, causes first extensible nonwoven material sheet optionally to stick on the elastomer thin film sheet material by first a large amount of intermittent adhesive bonds,

Wherein first extensible nonwoven material sheet also optionally sticks on the elastomer thin film sheet material by first calorimetric point bounding point, cause intermittent adhesive bonds to cover the percentage of interfacial plane between first bigger extensible nonwoven material sheet and the elastomer thin film sheet material, and do not have intermittent adhesive bonds at least about 50% interfacial plane than focus bounding point.

15. the extensible of claim 14, wherein laminate has the DE value greater than about 0.22 retraction force/extension force ratio.

16. the extensible of claim 14 does not wherein have intermittent adhesive bonds and thermal point bonds at least about 50% interfacial plane.

17. the extensible of claim 14 also comprises:

Second extensible nonwoven material sheet with side surface of thin film and fabric side; With

Second adhesive, it is applied in the side surface of thin film of second extensible nonwoven material sheet along discontinuous pattern, causes second extensible nonwoven material sheet optionally to stick on the elastomer thin film sheet material by second a large amount of intermittent adhesive bonds,

Wherein first and second a large amount of intermittent adhesive bonds cover the percentage of interfacial plane between the first and second bigger extensible nonwoven material sheet than focus bounding point.

18. the extensible of claim 17, wherein second extensible nonwoven material sheet also optionally sticks on the elastomer thin film sheet material by second largest calorimetric point bounding point, causes first and second a large amount of intermittent adhesive bonds to cover the percentage of interfacial plane between the first and second bigger extensible nonwoven material sheet than focus bounding point.

19. an extensible comprises:

The sheet material of elastomer thin film;

Adhesive, it is applied in the side surface of thin film of first extensible nonwoven material sheet along discontinuous pattern, causes first extensible nonwoven material sheet optionally to stick on the elastomer thin film sheet material by a large amount of intermittent adhesive bonds; And

Second extensible nonwoven material sheet, it optionally sticks to by a large amount of thermal point bonds on the sheet material of elastomer thin film,

Wherein intermittent adhesive bonds covers the percentage of interfacial plane between the first and second bigger extensible nonwoven material sheet than focus bounding point, and do not have intermittent adhesive bonds and thermal point bonds at least about 50% interfacial plane, and laminate has the DE value greater than about 0.22 retraction force/extension force ratio.

20. a method of making extensible comprises the following steps:

The fibre web of the extensible nonwoven material with side surface of thin film and fabric side is provided;

The fibre web of elastomer thin film is provided;

Apply adhesive along discontinuous pattern at the side surface of thin film of extensible nonwoven material web;

Optionally stick to extensible nonwoven material web on the elastomeric film web by a large amount of intermittent adhesive bonds; And

Optionally stick on the elastomeric film web by the name a person for a particular job fibre web of extensible nonwoven material of a large amount of thermal point bond,

Wherein intermittent adhesive bonds covers the percentage of interfacial plane between bigger extensible nonwoven material web and the elastomeric film web than focus bounding point.

21. the method for claim 20, wherein laminate has the DE value greater than about 0.22 retraction force/extension force ratio.

22. the method for claim 20, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered about 5% interfacial plane.

23. the method for claim 20, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered about 10% interfacial plane.

24. the method for claim 20, wherein intermittent adhesive bonds at least than the focus bounding point more and is covered about 20% interfacial plane.

25. the method for claim 20, wherein thermal point bonds was by sending extensible nonwoven material web and elastomeric film web roll gap between light anvil roller and heating, the patterned calender roll to form.

26. the method for claim 20, wherein thermal point bonds is by sending the gap between bonding anvil roller of ultrasonic wave and the texturing ultrasonic wave binding head to form extensible nonwoven material web and elastomeric film web.

27. the method for claim 20, wherein adhesive is that form with a large amount of a single points applies.

28. the method for claim 27, wherein the diameter of a single point is about 1mm～about 2mm.

29. the method for claim 28, wherein a single point constitutes chequer.

30. the method for claim 29, wherein a single point spacing each other is about 5mm～about 8mm, presses center to center and measures.

31. a method of making extensible comprises the following steps:

The fibre web of first extensible nonwoven material with side surface of thin film and fabric side is provided;

Apply adhesive along discontinuous pattern at the side surface of thin film of first extensible nonwoven material web;

Elastomeric film web is provided;

Optionally stick to the fibre web of first extensible nonwoven material on the elastomeric film web by a large amount of intermittent adhesive bonds;

The fibre web of second extensible nonwoven material with side surface of thin film and fabric side is provided;

Optionally stick on the elastomeric film web by the name a person for a particular job fibre web of second extensible nonwoven material of a large amount of thermal point bond,

Wherein intermittent adhesive bonds covers the percentage of interfacial plane between first and second bigger extensible nonwoven material web than focus bounding point.

32. the method for claim 31 also comprises by a large amount of thermal point bond first extensible nonwoven material web of naming a person for a particular job and sticks to step on the elastomeric film web.

33. the method for claim 31 also comprises the following step: apply adhesive at the side surface of thin film of second extensible nonwoven material web along discontinuous pattern; And second extensible nonwoven material web is optionally sticked on the elastomeric film web by a large amount of intermittent adhesive bonds.

34. the method for claim 32 also comprises the following step: apply adhesive at the side surface of thin film of second extensible nonwoven material web along discontinuous pattern; And second extensible nonwoven material web is bonded on the elastomeric film web by a large amount of intermittent adhesive bonds.