JPS6228456A - Nonwoven elastic web with gather - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The field of the invention includes composite nonwoven elastic webs including nonwoven elastic webs bonded to nonwoven geared webs and methods of forming such composite nonwoven elastic webs. . The field of the invention also relates to a method of forming an elastic geared nonwoven web by separating the geared web from a nonwoven elastic web after the gearing is effected by contraction of the nonwoven elastic J-F. include.

Background of the invention Diapers and sanitary napkins (hereinafter simply referred to as napkins)
In the field of manufacturing, it is considered desirable to provide napkins with an outer cover. Such an outer cover is
(1) provides elasticity throughout (tight yet comfortable fit); (2) is water repellent (retains fluids within the napkin); (3) is breathable (allows vapor to flow through the napkin material). (4) softness (improved wearing comfort); and (5) low cost.

Unfortunately, known composite nonwoven materials currently available on the market lack one or more of the above properties. Furthermore, these composite elastic nonwoven materials are not formed utilizing the novel and economical method of the present invention.

For example, Wade U.S. Pat. No. 2,957.5
A method of making a composite elastic sheet material disclosed in No. 12 involves bonding a crepe or wrinkled flexible sheet material to, for example, an elastic meltblown material. Column 5, pages 39-48 of this patent states that a fibrous web of elastomeric material may be stretched and bonded to a wrinkled web at one spaced point or area. It is described that when Stomerve is relaxed, this complex has the structure shown in Figure 7.

Another method of forming composite elastic fabrics is disclosed in Pufahl, US Pat. No. 3,316,136. A preferred method of manufacturing this fabric utilizes an adhesive that is first applied to the elastic backing in the desired pattern and then the elastic backing is stretched. While the elastic backing is in a stretched state, the overlay is placed thereon and the overlay is brought into pressure engagement with the elastic backing for a period of time sufficient to ensure bonding of the two layers. After the applied adhesive dries, the tension on the elastic backing is released and the overlay fabric is geared in the areas marked with adhesive.

Example 56 of U.S. Pat. No. 3,485,706 to Evans discloses the production of a stretchable nonwoven reverberant pattern structure with unidirectional elasticity from an initial layered material. The structure consists of two polyester stable fibers with a web of spandex yarn between them.
The web roars. The webs are bonded together by using jets of water to entangle the fibers of one web with the fibers of an adjacent web. During the entanglement stage, the spandex yarn stretches 200 percent.

U.S. Pat. No. 3,673,026 to Brown discloses a method for making laminated fabrics, and in particular, a method for making nonwoven laminate fabrics with controlled loft. in this way,
Loose webs of nonwoven materials, such as crepe tissue or bonded synthetic fibers, are elastically stretched at different elongation rates and laminated adhesively to one another while remaining in these different elongation states. The bonded webs are then relaxed, causing each web to undergo varying degrees of shrinkage, and then separated in the unbonded areas to control the bulk of the laminate. The patent states that various types of stretching include situations in which only one web is actually stretched while the other web is maintained at or near a relaxed condition.

U.S. Pat. No. 3,687,797 to W.I.D.A.M.A. describes a method for producing resilient cellulosic wadding products by laminating a low cellulose wadding web to a pre-stretched polyurethane foam web. Disclosed. In this method, adhesive is applied to either web in the desired pattern and the batted web is first laminated to a pre-stretched polyurethane foam web. During this lamination step, the polyurethane foam web is maintained in tension. After laminating the two webs, the tension on the pre-stretched polyurethane foam web is released, causing shrinkage of the foam web. The adhesive holds the wadding and foam together and provides bulk in the areas between the adhesive areas.

Any stress remaining in the product after shrinkage can be further released by wetting.

U.S. Pat. No. 3,842,832 to W.I.D.E.M.A.N. is directed to disposable elastic products such as bandages and methods of manufacturing the same. This product is manufactured by applying adhesive to one side of a nonwoven material stretched longitudinally on rollers. at the same time,
The polyurethane web is longitudinally stretched under heat and then bonded to the nonwoven material. A second nonwoven material is then adhered to the other side of the polyurethane web to form a laminate consisting of an inner stretched polyurethane core and an outer unstretched nonwoven layer adhesively adhered to the core. next,
The laminate is passed through a water heater to loosen the engagement between the nonwoven outer layer and the adhesive bonding the expanded polyurethane core layer to it. Thus, the stretched polyurethane layer can return to approximately its original length, and the outer nonwoven layer will shrink or become wavy or wrinkled.

U.S. Pat. No. 4,104,170 to Nedza discloses a liquid filter having an improved expanded polypropylene element. The polypropylene element is manufactured by forming a nonwoven underlayer of continuous polypropylene fibers bonded together in a random pattern. A top layer of short male polypropylene elements is then attached to the bottom layer, for example, by melt spraying the top layer onto a stretch sheet of the bottom layer.

A method of making an elastic fabric structure comprising relatively elastic synthetic organic polymer fibers and relatively inelastic synthetic organic stretchable polymer fibers is disclosed in U.S. Pat. No. 4,209 to 5isson.
, No. 563. In this method, relatively elastic Fa fibers and extensible or relatively inelastic fibers are placed in a sufficient amount M on the porous surface of a nonwoven web having random ta-a intersections. It includes the steps to proceed in. Thereafter, at least some portions of the fiber intersections are adhered to form a cohesively bonded fabric, which is stretched to elongate some of the fibers in at least one direction and then loosened to form a web of relatively elastic fibers. Forms loops and punches relatively inelastic fibers that can be used by shrinking and stretching. Advancement of the fibers relative to the porous forming surface is positively controlled, and this positive control is described in column 7, paragraph 19 of this U.S. patent.
Contrasted with transporting the TA fibers using an air stream in lines ~33. Further, in column 9, line 44 and below of this patent, it is stated that an embossing pattern or a roll nip with a smooth head can be used to bond filaments to form a cohesive fabric.

U.S. Pat. No. 4,296,163 to Emi et al. (A)
It is a mesh structure consisting of a mixture of synthetic elastomer polymers, in which individual TA males randomly interlace in an irregular relationship.
interconnected to form a number of differently sized and shaped meshes, the mesh structure of which after elongation by 10% of at least 70% in two randomly chosen directions mutually perpendicular to the plane of the mesh; (B) a sheet-like mesh structure having a recovery rate; and (B) a mat-like, web-like, or sheet-like fiber structure consisting of short or long fibers,
50% in at least one randomly chosen direction
A fibrous composite having a cohesive assembly with a fibrous structure having a post-elongation recovery of less than 10% is disclosed. The US patent states that the elastic composite material is suitable as a variety of clothing base materials and industrial materials such as filter cloths, absorbent materials, and insulation materials. Methods for forming this composite are described in column 6, lines 64 et seq., and these methods involve binderless bonding as described in column 9, lines 15-41.

DesMarais, US Pat. No. 4,323,534, discloses a method for extruding thermoplastic resin compositions for thermoplastic resins having exceptional strength and good elasticity. In column 8 of this U.S. patent, the subtitle rF i ber
- Under Forming J, 79.13% KRAT
ON G-1652, 19.78% stearic acid, 0.98% + 17) titanium dioxide, 0.1% I
Melt blown operations of blended resins containing rganox 1010 antioxidant are disclosed. It is also stated that individual fibers were extruded from a melt blown mold.

Jones, U.S. Pat. No. 4,355,452, discloses a panty and method of assembling the same that has a built-in elastic system that minimizes gathers and provides a comfortable fit. Here, meltblown KRATO
It is stated that materials made of N rubber are well suited for panty fabric materials. In addition, melt blown KRAT
A method for making ON fabrics is disclosed and is shown schematically in Figure 8 of this US patent.

A possible method utilizing KRAT6N G-1652 is discussed in column 4, line 67 et seq. of this US patent.

W a h 1 q u i s t U.S. Patent 4,3
No. 79°192 discloses a method of forming an impermeable absorbent Basoya fabric using a film and a fibrous web, in which prebonding of continuous filaments is performed using one or more melt-blown molds. Small-diameter discontinuous fibers are melt-blown into a mat directly onto the web. Column 3, lines 35-40 of this U.S. patent states that the primary bond between the nanofibers and the continuous filaments is created by forming a microscopic ta# mat directly on the child bonded continuous filament web. It is described that the microfiber pine 1- is produced and attached to a continuous filament web.

Likhyani, U.S. Pat. No. 4,426,420, discloses a hydraulically entangled spunlace fabric consisting of at least two types of stable fibers and an elastomeric fiber that behaves as ordinary stable fibers until heat treated to improve the fabric. A method for imparting stretchability and elasticity is disclosed. The method includes stretching the latent elastomer edge fibers and relaxing them between the stretching and winding stages.

Romaink U.S. Patent No. 4,446°1
No. 89 includes at least one layer of nonwoven textile fabric attached to an elastic layer by needle punching, the nonwoven textile fabric layer being permanently stretched when the elastic device is stretched within its elastic limits. A nonwoven textile fabric laminate is disclosed. When the elastic layer is loosened and returned to its substantially unstretched state, the nonwoven fabric layer simultaneously relaxes, thereby increasing its bulk. It is also described that this non-woven textile fabric laminate can be used to make clothing items with increased freedom of movement.

The abstract of Japanese document number 47-43150 is
(a) uniaxially stretching a sheet or film made of a mixture of incompatible polymers; (b) superimposing the sheet or film on a sheet of foamed polymer; and (C) perpendicular to the direction of stretching of the base layer. This disclosure discloses a method for producing a highly adhesive nonwoven fabric by stretching the laminate in (d) and then stretching in the stretching direction of the base layer. Preferred polymers are stated to include polyamides, linear polyesters, and polyolefins. Preferably the upper layer is polypropylene foam.

5hell titled “rKRATON Thermoplastic Rubber”
The Chemical Company's brochure describes thermoplastic KRATON materials. This booklet is rSC: 19B-83printed in
It has the codes U, S, A, and 7/83 SMJ.

Although the various publications mentioned above may disclose products and methods having some of the features or method steps of the present invention, it is not possible to obtain the claimed method or product from these methods. It does not disclose or suggest anything.

DEFINITIONS The terms ``elastic'' and ``elastomer'' refer to an elastomer that is capable of being stretched to a stretched bias length of at least 125 percent (approximately 1% of the relaxed unbiased length) when applied with a tension stress and capable of resolving stretching forces. Used interchangeably to mean any material that recovers at least about 40 percent of its elongation when used. A hypothetical example/example that would satisfy this definition for an elastomeric material is that it can stretch to at least 1.25 inches, and when stretched to 1.25 inches and then relaxed, it can stretch to 1.25 inches.
There are 1 inch samples of material that recover to lengths of less than 15 inches. Many elastic materials can be stretched significantly more than 25 percent of their relaxed length, and
Many of them will recover to approximately their original relaxed length when the stretching force is released. This latter class of materials is generally preferred for purposes of the present invention.

As used herein, the term "recovery" refers to the shrinkage of a material when a piascar is applied and the material is stretched and then the piascar is removed. For example, if a material with a relaxed unbiased length of 1 inch is stretched 50 percent by stretching it to a length of 1.5 inches, the material will have a stretched length of 150 percent of its relaxed length. If, after the bias tension force is removed, the stretched material contracts or recovers to a length of 1.1 inches, then the material has recovered 80 barsen (0.4 inches) of its elongation.

As used herein, the term "inelastic" or "non-elastomer" refers to the term "elastic" or "elastomer."
means materials not included in the term .

As used herein, the term "meltblown microfibers" refers to average diameters not exceeding about 100 microns, preferably from about 0.5 microns to about 50 microns, and more preferably from about 4 microns to about 40 microns. small diameter fibers having an average diameter, extruding a molten thermoplastic material into a molten thread or filament through a plurality of fine, usually circular die capillaries into a high velocity gas (e.g., air) stream;
This term refers to small diameter fibers made by thinning filaments of molten thermoplastic material with this high velocity gas stream to reduce the diameter to the above range. Thereafter, the high velocity gas stream carries the meltblown nanofibers to a collection surface where they are deposited to form a randomly distributed web of meltblown nanofibers. This process can be performed, for example, in Buti
No. 3,849,241 to N., the disclosure of which is hereby incorporated by reference.

As used herein, the term "binderless bonded microfibers" refers to diameters not exceeding about 100 microns, preferably from about 10 microns to about 50 microns, and preferably from about 12 microns to about Small diameter fibers having a diameter of up to 30 microns are produced by extruding the molten heat-absorbing material into filaments through a plurality of narrow, usually circular capillaries in a spinneret, and adjusting the diameter of the extruded filaments by, for example, drawing or pultrusion processing or other well-known methods. refers to small diameter fibers made by rapid reduction, such as by a binder-free bonding mechanism. The manufacture of binder-free bonded nonwoven webs is described in U.S. Pat. No. 4,340, A.P.E.
No. 563, the disclosure of which is also incorporated herein by reference.

As used herein, the term "nonwoven web" includes a web of any material formed without the use of a textile method that provides a structure made of individual fibers woven together in an identifiable repeating manner. .

Specific examples of nonwoven webs include, but are not limited to, meltblown nonwoven webs, bonded nonwoven webs without binders, porous films, microporous webs, and carded webs of stable fibers. These nonwoven webs are 1
Having an average basis weight of about 300 grams per square meter or less, preferably the nonwoven web has an average basis weight of about 5 grams per square meter to about 100 grams per square meter. More preferably, the nonwoven web has an average basis weight of about 10 grams per square meter to about 75 grams per square meter.

As used herein, the expression "consisting essentially of" does not exclude the presence of additional materials that have no appreciable effect on the elastomeric and other properties of a given composition. Such materials include pigments, acid inhibitors, stabilizers, surfactants, waxes, flow enhancers, solid solvents, particles, and materials added to enhance the processability of the composition.

The term "styrene component" used here is CH□-
It means a monomer unit represented by CI.

Unless specifically defined or otherwise limited, the terms "polymer" or "polymer resin" as used herein are intended to be used in a broad and non-limiting sense, including monopolymers,
Copolymers (e.g. block, graft, random,
(alternating copolymers, terpolymers, etc.) and blends and modified products thereof. Furthermore, unless otherwise specified, "polymer"
, the term "polymeric resin" shall include all possible geometric molecular shapes of the material. These molecular shapes include, but are not limited to, isotactic, syndiotactic, and random symmetries.

OBJECTS OF THE INVENTION It is an overall object of the present invention to provide a new method of forming a composite nonwoven elastic web consisting of a nonwoven elastic web and a fibrous nonwoven geared web bonded thereto.

Another object of the present invention is a composite nonwoven elastic web comprising a nonwoven elastic web bonded to a fibrous nonwoven geared web, the fibrous elastic web being directly gatherable on the surface of the nonwoven elastic web. Forming the nonwoven geared web results in forming a composite nonwoven elastic web in which the arts nonwoven geared web is geared and the nonwoven elastic web is maintained in an elongated bias state, and then the nonwoven elastic The object of the present invention is to provide a new method for relaxing a web from its stretched biased state or length to a relaxed unbiased state or length.

Another object of the invention includes a nonwoven elastic web bonded to a fibrous nonwoven geared web, the fibrous nonwoven geared web being formed in a gatherable manner on a surface of the nonwoven elastic web. The aim is to provide a composite non-woven elastic web that is bonded thereto at the same time.

Yet another object of the present invention is to provide a composite non-fibrous elastic web formed by the method of the present invention.

Another object of the present invention is to provide a new method for forming elastic geared nonwoven webs solely from non-elastic materials.

Another object of the present invention is a novel method for forming a geared nonwoven elastic web, the method comprising forming a nonwoven gatherable web directly on the surface of the nonwoven elastic web and stretching the nonwoven elastic web. releasably bonding the gatherable web to the nonwoven elastic web while maintaining the nonwoven elastic web in a relaxed state or length, and then relaxing the nonwoven elastic web from its stretched biased state or length to its relaxed unbiased state or length. A method is provided that includes the steps of attaching gears to a gatherable web and separating the geared web from an elastic web to form an elastically compensating geared web.

Still another object of the present invention is a novel method for forming a geared nonwoven elastic web, the method comprising forming a gatherable web directly on a stretchable porous forming surface and placing the forming surface in a stretched state. retracting the forming surface to gear the gatherable web, and thereafter separating the geared web from the forming surface. and forming a geared web having elasticity.

Yet another object of the present invention is to provide a resilient geared nonwoven web formed by the method of the present invention.

Further objects and wide applicability of the invention will become apparent to those skilled in the art from the details set forth below; however, the detailed description of the presently preferred embodiments of the invention is by way of example only, and It will be obvious to those skilled in the art that various changes and modifications can be made from the following detailed description within the spirit and scope of the invention.

SUMMARY OF THE INVENTION The present invention is directed to a method of making a composite nonwoven elastic web consisting of a nonwoven elastic web bonded to a 1a# quality nonwoven geared web. In particular, the method of the present invention provides a method for flexing a geared nonwoven fibrous web bonded to a nonwoven elastic web in a relaxed, unstretched state, such that the nonwoven elastic web relaxes from a stretched bias length to a relaxed unbiased unstretched length. To produce a composite nonwoven elastic web in which gears are attached to a fibrous nonwoven geared web when the gears are applied. An important feature of the method of the present invention is that the Fa Iga nonwoven gatherable web is formed directly on the surface of the nonwoven elastic web, while the nonwoven elastic web is maintained in a stretched biased state.

Nonwoven elastic webs can be formed, for example, by melt blown processes or any other method of forming nonwoven elastic webs. For example, the nonwoven elastic web may be a porous web of a different elastic film than a meltblown fibrous nonwoven elastic web. The nonwoven elastic web thus formed has a normal, relaxed, unstretched, unbiased length. Thereafter, the nonwoven elastic web is stretched by stretching it to a stretch bias length.

The next step in the process - the C,R male fibrous nonwoven gatherable web is prepared, for example, by either the Mel-Blown method or the binder-free bonding method, or the nonwoven elastic web is bonded to its elongated bias. Any other method of forming a fibrous nonwoven gatherable web directly on the surface of a nonwoven elastic web while maintaining its length can be used.

During formation of the fibrous nonwoven gatherable web of fibers, the nonwoven elastic web is maintained at an elongated length of at least 125 percent, ie, at least about 1 degree of the relaxed, unbiased length of the nonwoven elastic web. For example, the stretch bias length of the nonwoven elastic web is maintained in a range from at least about 125 percent of the relaxation valve bias length of the nonwoven elastic web to about 700 percent or more of the relaxation valve bias length of the nonwoven elastic web. You can get it.

While the nonwoven gatherable web is bonded to the nonwoven elastic web, the nonwoven elastic web is maintained at an extended stretched bias length. This results in the formation of a composite nonwoven elastic web that includes a nonwoven elastic web bonded to a fibrous nonwoven gatherable web of fibers. At this stage of the method, the nonwoven gatherable web of TA fibers is formed directly onto the surface of the nonwoven elastic web, while the nonwoven elastic web is maintained in its stretched bias length. The woven elastic web is in a stretched, elongated bias state.

The fibrous nonwoven gatherable web of fibers is not geared but is in a gatherable condition.

In one embodiment of the invention, the bonding of the fibrous nonwoven gatherable web to the nonwoven elastic web is accomplished by thermal bonding, which fuses the two webs together. Thermal bonding may be performed from 50° C. below the melting temperature of at least one material utilized to form at least one web to about the melting temperature of at least one material utilized to form at least one web. It can be carried out within a temperature range. At high processing speeds, thermal bonding may be performed at or above the melting temperature of the material or materials utilized to form the web. Thermal bonding may also be carried out under suitable normal pressure conditions. If desired, conventional sonic bonding techniques may be used in place of thermal bonding.

In another embodiment of the present invention, the bonding of the fibrous nonwoven gatherable web to the stretched nonwoven elastic web during the formation of the fibrous nonwoven gatherable web on the surface of the elastic web. is achieved only by intertwining the individual fibers of the fibrous nonwoven gatherable web of taIs with a nonwoven elastic web. If the nonwoven elastic web is a fibrous nonwoven elastic web formed, for example, by meltblowing, the intertwining of the fibers of the fibrous nonwoven gatherable web with the fibrous nonwoven elastic web will cause the fibrous nonwoven elastic web to This is accomplished by intertwining the individual fibers of the woven gatherable web with the individual r-fibers of the fibrous elastic web. When the nonwoven elastic web is a porous film, bonding of the fibrous nonwoven web to the film is accomplished by entangling individual wtm of the fibrous gatherable web into the pores of the film.

In yet another embodiment, the bonding of the two webs to each other is accomplished by making the nonwoven elastic web from a tacky elastic material.

In any of the embodiments of the method of the present invention, the bonding of the two webs to each other can be further enhanced by applying pressure to the two webs after forming the gatherable web on the surface of the elastic web. Also, in either embodiment, the bonding of the two webs may be further improved by applying an adhesive to the top surface of the nonwoven elastic web prior to forming the fibrous nonwoven gatherable web of fibers.

After the two webs are bonded together to form a composite elastic web, the pie scar is removed from the composite non-woven elastic web and the composite elastic web is allowed to relax to its normal relaxation valve bias length. A fibrous nonwoven gatherable web of fibers is bonded to a nonwoven elastic web while the nonwoven elastic web is stretched so that relaxation of the composite nonwoven elastic web causes the nonwoven elastic web to contract and gather. Possible gears can be attached to the web.

After the nonwoven elastic web is geared by reducing the tension applied to the composite nonwoven elastic web, the composite nonwoven elastic web can be wound into rolls and prepared for storage and transportation. The composite non-woven elastic web can then be utilized to form a wide range of products, such as outer covers for diapers.

Alternatively, the geared nonwoven web may be separated from the nonwoven elastic web after it has been geared by shrinkage of the nonwoven elastic web; in this embodiment, the geared nonwoven web can be used alone or in combination with various other It can be utilized with web or film materials to form a variety of products. Interestingly, the separated geared nonwoven web retains a significant degree of geared configuration and is elastic. The geared nonwoven web, as described above, can be formed into a nonwoven elastic web that can be stretched and gathered directly onto its surface.

During formation to the surface of the nonwoven elastic web, a fibrous nonwoven gatherable web of fibers is separably bonded to the nonwoven elastic web while maintaining the nonwoven elastic web in its extended elongated bias length. . The result is a composite nonwoven elastic web that includes a nonwoven elastic web and a ma fibrous nonwoven gatherable web separably bonded to the nonwoven elastic web. At this stage of the method, the nonwoven elastic web is used to form a fibrous nonwoven gatherable web of fibers directly onto the surface of the nonwoven elastic web without maintaining the nonwoven elastic web in its stretched bias length. The elastic web is biased in a stretched state and the fibrous nonwoven gatherable web of fibers is ungeared but in a gatherable state.

The separable bonding of the fibrous nonwoven gatherable web to the stretched nonwoven elastic web involves the formation of a fibrous nonwoven gatherable web of #I fibers to the surface of the nonwoven elastic web. Individual F of fibrous nonwoven gatherable web
This is done by intertwining a, II & with a non-woven elastic web. If the nonwoven elastic web is a fibrous nonwoven elastic web formed, for example, by Norl-Blown, the separable bond of the fibrous nonwoven gatherable web of fibers to the fibrous nonwoven elastic web is , by intertwining the individual fibers of the fibrous gatherable web with the individual fibers of the fibrous nonwoven elastic web. When the nonwoven elastic web is a porous film, the separable bond of the fibrous nonwoven web with the nonwoven elastic web is m! ! This is done by intertwining the individual fibers of the gatherable web with the pores of the porous film.

After releasably bonding the two webs to each other to form a composite elastic web, the composite non-woven elastic web is freed of the pie scars and the composite non-woven elastic web is contracted to its normal contraction valve bias length. The fibrous nonwoven gatherable web of fibers is separably bonded to the nonwoven elastic web while the nonwoven elastic web is in tension so that it can be gathered when the composite nonwoven elastic web contracts. The web is dragged by the shrinkage of the nonwoven elastic web, resulting in the formation of gathers on its surface.

After gearing of the #a Iga nonwoven gatherable web is carried out by reducing the tension scar applied to the composite nonwoven elastic web, the geared MA nonwoven web is separated from the nonwoven elastic web. Separated, the geared web is wound into a roll for storage, for example. After separation of the fibrous nonwoven geared web from the nonwoven elastic web, the nonwoven elastic web can be reused as a forming surface.

Upon separation from the nonwoven elastic web, the fibrous nonwoven geared web remains in the geared form, and upon application of a stretched piascus in the geared direction of the fibrous nonwoven gatherable web, the geared web It is important to note that when the stretched piascus is removed, the stretched nonwoven geared web substantially shrinks to the geared form and length, which is the difference between the composite nonwoven elastic web and the stretched nonwoven geared web. It takes the form it has after separation. That is, the fibrous nonwoven geared web has elasticity. The fact that the geared web retains its geared configuration upon separation from the nonwoven elastic web is surprising.

However, it is even more surprising that the separated fibrous nonwoven geared web has such resiliency that when stretched to its stretched length, it recovers at least about 40 percent of its stretched length. That is, the fibrous nonwoven web after separation has elastic or elastomeric properties as defined herein. In fact, R fibrous nonwoven geared webs have been found to be elastic even when made from non-elastic materials such as polypropylene.

Preferably, the fibrous nonwoven gatherable web of fibers includes at least one meltblown fibrous nonwoven web. Other methods that may be utilized in forming a fibrous nonwoven gatherable web of fibers include binderless bonding or any other method capable of forming a fibrous nonwoven gatherable web of fibers. The geared fibrous nonwoven web is made entirely of one type of inelastic material or two types of non-elastic material.
It can be formed from a blend of two or more non-elastic materials. However, the geared nonwoven web may be made of a blend of one or more non-elastic materials and one or more elastomeric materials or one or more elastomeric materials. The non-elastic material forming the fibrous nonwoven gatherable web of fibers may include a non-elastic polyester material, a non-elastic polyolefin material, or one or more of the following types of non-elastic polyester materials and 1.
There are blends of one or more non-elastic polyolefin materials. An example of a non-elastic polyester material is polyethylene terephthalate. An example of a non-elastic polyolefin is non-elastic polypropylene sold under the trade name PF301.

Alternatively, the need for a nonwoven elastic web may be eliminated by forming a geared nonwoven web that can be gathered directly onto a stretchable surface, such as a stretchable mesh screen.

In a particular embodiment of the method of the invention, adhesive H & fibrous nonwoven elastic webs, such as adhesive elastic materials such as A-B-A' block copolymers or such A
- Formed by melt blown microfibers of a blend of B-A' block copolymer and poly(alpha-methylstyrene). where A and A' are thermoplastic polystyrene, polystyrene homolog end blocks, and B is a resilient polyisoprene intermediate block. In some embodiments, A may be the same thermoplastic polystyrene or polystyrene homologue endblock as A'. The tacky fibrous nonwoven elastic web is then stretched to its stretched length, and the fibrous fibrous nonwoven gatherable web is, for example, stretched to this stretched length while the tacky fibrous nonwoven elastic web is maintained at its stretched length. It is formed by melt-blown or binder-free bonding of a fibrous nonwoven gatherable web of fibers directly to the surface of a woven elastic web. As a result of the fact that the fibrous nonwoven elastic web is tacky, the fibrous nonwoven gatherable web of fibers is formed and adhered to the surface of the tacky fibrous nonwoven elastic web. In this example, a composite non-woven elastic web is formed having a non-geared fibrous non-woven gatherable web adhered to a cohesive fibrous non-woven elastic web;
Bonding of the two webs to each other is accomplished by adhesion that occurs during formation of the fibrous nonwoven gatherable web of fibers to the surface of the fibrous nonwoven elastic web. The adhesion of the 22 webs to each other can be enhanced by applying pressure to the composite non-fibrous elastic web by passing the composite non-fibrous elastic web through a nip between rollers. These rollers do not need to be heated after forming the composite nonwoven elastic web and before relaxing the sticky Ha male nonwoven elastic web. Adhesion can be further enhanced by applying an adhesive to the surface of the tacky fibrous nonwoven elastic web prior to forming the gatherable web.

The composite non-woven elastic web is then relaxed to its normal relaxed, unbiased length. Because the fibrous nonwoven gatherable web of fibers was bonded to the tacky fibrous nonwoven elastic web while keeping the tacky w1 Iiga nonwoven elastic web in tension, the composite nonwoven elastic web, and therefore the tacky mra
When the fibrous nonwoven elastic web is relaxed, the gatherable web is pulled and gathered by the contracting fibrous nonwoven elastic web.

After the fibrous nonwoven gatherable web of fibers has been gathered, the composite nonwoven elastic web may be wound into a roll for storage and transportation, upon winding of the composite nonwoven elastic web. Applying a second fibrous nonwoven gatherable web to the exposed side of the tacky fibrous nonwoven elastic web prior to the gathering step to avoid adhesion of the exposed side of the tacky fibrous nonwoven elastic web. preferable. or,
Either before or after gearing, beef wrapping paper may be applied to the exposed sticky side of the adhesive fibrous nonwoven elastic web and removed before utilizing the composite nonwoven elastic web; Elastic webs can be utilized to form a wide range of products.

The present invention is also directed to a composite nonwoven elastic web comprising a nonwoven elastic web bonded to a fibrous nonwoven gatherable web of geared fibers, which composite nonwoven elastic web is formed by any method of the embodiments. In particular, the composite nonwoven elastic web, in its relaxed, unstretched state, has ta fibers that are geared as a result of relaxing the nonwoven elastic web from a stretched stretched bias length to a relaxed unbiased unstretched length. Consists of a nonwoven elastic web bonded to a nonwoven geared web. Examples of elastomeric materials that can be used to form fibrous nonwoven elastic webs include polyester elastomeric materials, polyurethane elastomeric materials, and polyamide elastomeric materials. Other elastomeric materials that can be used to form fibrous nonwoven elastic webs include (a) A-B;
- A' block copolymer (where A and A' are each a thermoplastic polymer end block containing a styrene component, A may be the same thermoplastic polymer end block as A', and B is an elastomeric polymer such as a conjugated diene or lower alkene), (b)
or more types of polyolefins or poly(alpha-methylstyrene) and A-B-A' block copolymerization'#- (where A and A' are each a thermoplastic polymer endpropolymer containing a styrene component). Tsuku and A
may be the same thermoplastic polymer endblock as A', for example poly(vinyl arene), and B is an elastomeric polymer midblock such as a conjugated diene or lower alkene). The A and A' end diblocks may be selected from the group including polystyrene, polystyrene homologs, and the B midblock may be selected from the group including polyisoprene, polybutadiene, poly(ethylene-butylene), A and When A' is selected from the group containing polystyrene or polystyrene homologues, and B is poly(ethylene-butylene), the substances that can be blended with these block copolymers are ethylene,
Polymers containing propylene, butene and other lower alkenes, or copolymers of one or more of these substances. If A and A' are selected from the group containing polystyrene or polystyrene homologs, and B is a polyisoprene midblock, a material that can be blended with this type of block copolymer is poly(alpha-methylstyrene).

Preferably, the gatherable web includes at least one fibrous nonwoven web, which fibrous nonwoven web is melt blown, binderless bonded, or formed into a fibrous nonwoven gatherable web of fibers. Inelastic fibers may be formed by any other method that may be used. Preferred materials capable of forming the gatherable web include polyester materials, polyolefin materials, or
Comprising blends of one or more polyester materials and one or more polyolefin materials. An example of a polyester material is polyethylene terephthalate. An example of a polyolefin material is polypropylene.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, in particular FIG.
910 is the melt blown ultra-fine sheet formed by roller 1.
8.20 is collected onto a porous collection screen 14 moving as shown by arrow 16. The materials used to form the null 1 to blown ultrafine fibers 10 are as follows:
For reasons that will become clear later, it is an elastomeric material.

The porous collection screen 14 is attached to a rotating roller 18.
20, and these rollers are driven by a conventional drive (not shown). Also, although not shown for the sake of brevity.

A punch-through vacuum polyx is placed between the rollers 18, 20 and under the underside of the upper portion of the screen 14. The vacuum polyx serves to hold the microfibers 10 on the top surface of the screen 14. As the melt-blown superfluorescent material 610 is deposited on the moving collection screen 14, it entangles with each other and clumps together to create a cohesive fibrous bottom R elastic web 2.
form 2. The intertwined and cohesive fibrous nonwoven elastic web 22 is conveyed by the porous collection screen 14 to a nib or gap 24 between rotating rollers 20 and rotating nip rollers 26 . This nip or gap 24 is adjusted so that the rollers 20.26 tightly engage the fibrous nonwoven elastic web 22 without adversely affecting it. The rotational speed of roller 20.26 is adjusted so that the circumferential speed of roller 20.26 is approximately the same as the speed of moving porous collection screen 14. Melt blown ultra-fine when placed on the surface of the porous screen 14! 110 is insufficient to form a cohesive web 22 that is capable of performing the stretching and relaxation steps described below without adverse effects (e.g., the web separates and loses integrity when a stretching force is applied). In order to improve the mutual agglomeration of the nanofibers 10, the rollers 26 may be heated to a suitable high temperature (depending on the desired degree of agglomeration and the nature of the material used to form the nanofibers 10). The microfibers IO may be thermally bonded to each other by maintaining the nanofibers IO at different temperatures. Typical 8 bonding temperature ranges range from 50° C. below the melting temperature of at least one of the materials utilized to form web 22 to the melting temperature of at least one of the materials utilized to form web 22. . However, at high throughputs, temperatures above the melting temperature of the material may be used. After passing through the nip 24, the nonwoven elastic web 22 is moved between a rotating roller 30 and a second rotating nip roller 3 by the action of rollers 20.26.
2 into and through the second nip or gap 28 formed between the two. By adjusting the rotation of rollers 30 and 32, the circumferential speed of rollers 30 and 32 is equal to that of roller 2.
The surface velocity should be greater than 0.26. The nip 28 between the two rollers 30.32 is adjusted so that the rollers 30.32 tightly engage the fibrous nonwoven elastic web 22 without adversely affecting it. As a result of increasing the circumferential speed of roller 30.32 compared to the circumferential surface drive of roller 20.26, the fibrous/nonwoven elastic web 22 is subjected to a high shear in the longitudinal direction, or machine direction (MD), and in this direction, It can be stretched to the extended tension bias length. Roller 2o, 26 and roller 30, '32
The degree of stretching of the fibrous nonwoven elastic web 22 that occurs in the region 34 between can be varied, for example, by varying the circumferential speed of the rollers 3o, 32 relative to the circumferential speed of the rollers 20.26. For example, if the circumferential speed of rollers 3o, 32 is twice that of roller 20.26, #
The male nonwoven elastic web 22 will stretch to a stretched length of about twice its original relaxed unstretched unbiased length, or about 200 percent. In particular, it is preferred that the nonwoven elastic web 22 stretches from at least about 150 percent to about 700 percent or more of its relaxed, unbiased length.

After the fibrous nonwoven elastic web 22 has been stretched by the combined action of rollers 20.26 and 30.32, the web 22
is moved to a second porous collection screen 36, which is moving in the direction of arrow 38 in FIG. This second porous collection screen 36 moves around and is driven by the rotating roller 40, which rotates in unison with the roller 30. The rotating rollers 30, 40 are common drive devices (not shown)
Driven by. This drive device is a rotating roller 18
．． It may be the same device that drives 20. Although not shown for simplicity, 1. A conventional vacuum polyx is installed between the rollers 30, 40 and under the underside of the upper portion of the screen 36. This vacuum polyx is screen 3
6 to help hold the web 22 on top of the web 22. Stretched m! The non-woven elastic web 2z fills the nip or gap 42 formed between the rotating roller 40 and the third rotating nip roller 44 by the second porous collection screen 36.
carried to. The rotation of rotating roller 40 and nip roller 44 is adjusted so that the circumferential speed of the two rollers 40.44 is approximately the same as the circumferential speed of roller 30.32.

The circumferential speed of rollers 40, 44 is kept approximately the same as that of rollers 30, 32, and nip 42 is adjusted to
．． 44 is adapted to firmly hold the nonwoven elastic web 22 so that the stretched state of the fibrous nonwoven elastic web 22 is maintained while it is being conveyed by the second porous collection screen 36. be done.

Meltblown microfibers 4 formed in a conventional meltblown mold 48 while being conveyed by a stretched fibrous nonwoven elastic web 22 or a second porous collection screen 36
6 is melt-blown directly on the upper surface of the stretched nonwoven elastic web 22 to form a fibrous nonwoven gathered usable web 50 of cohesive fibers located on the upper surface of the stretched fibrous nonwoven elastic web 22. Here, melt blown mold 48
Note that the distance between the mold tip of the melt blown mold 48 and the elastic web 22 as well as the speed at which the elastic web 22 passes under the mold tip of the melt blown mold 48 is adjusted. Elastic web 2
It has been found that if these adjustments, which vary depending on the material or composition of materials forming 2, are not made correctly, the hot air present at the mold tip can cause the elastic web 22 to melt. As the meltblown microfibers 46 collect on the top surface of the fibrous nonwoven elastic web 22, they intertwine and aggregate to form a fibrous nonwoven gatherable web 50 of cohesive g&fibers. Form. Depending on the distance between the mold tip of the meltblown painter 48 and the stretched fibrous nonwoven elastic web z2, the meltblown microfibers 46 may also become mechanically entangled with the y-fibers of the elastic web 22.

Broadly speaking, as the distance between the mold tip of melt blown mold 48 and the upper surface of stretched fibrous nonwoven elastic web 22 increases, the fiA of fibers of web 50 and fiA of web 22 increases.
The rate at which males become mechanically entangled is reduced. To ensure mechanical intertwining between the fibers of web 50 and the #l fibers of web 22, the die tips of melt-blown die 48 and the #1 fibers of web 22 are
The distance from the top surface of 2 should not be greater than approximately 25 inches. Preferably, this distance should be in the range of about 6 inches to about 16 inches. Depending on the material utilized to form the webs 22, 50 and the distance between the mold tip of the melt blown mold 48 and the top surface of the web 22, the elastic web 22, 50
Adhesion of the fibers of the gatherable web 50 to the fibers of the gatherable web 50 may also occur. Suitable materials for use in forming the fibrous nonwoven elastic web 22 are preferably selected from materials to be utilized in forming the Fi&fibrous nonwoven gatherable web 50. Select after reading.

In particular, the material selected to form the fibrous nonwoven gatherable web 50 should be one that will form the web 50 that can be gathered by the contraction forces of the fibrous nonwoven elastic web 22.

Because the retraction forces of web 22 vary depending on the material chosen to form it, the material chosen to form web 22 must be selected such that the gathering force of web 22 is capable of gearing web 50. Must be. Examples of materials utilized in forming web 22.50 are discussed below.

Depending on the desired properties of the final product, the materials utilized to form the gUm constituting the webs 22.50 and the process steps/conditions used therein, the two cohesive webs 22.50 can be joined together in a variety of ways. . For example, if a relatively weak bond between the two webs 22.50 is desired, a fibrous nonwoven gatherable web 50 of fibers may be formed on the stretched surface of the fibrous nonwoven elastic web 22. Fibrous nonwoven gearing allows the individual melt blown fibers of web 50 to be assembled into fibrous nonwoven elastic web 22.
The two webs 22.50 may be interconnected only by intertwining with the individual meltblown fibers of the webs 22.50. In this embodiment, the two webs 22.50 can be separated from each other upon application of a relatively small force, such as a jerking or rubbing force applied by a person's fingers. 2
If it is desired to bond the two cohesive webs 22.50 more strongly to each other, the bonding of the fibrous nonwoven gatherable web 50 of TA fibers to the fibrous nonwoven elastic web 22 can be performed in 2-) of the webs 22.50. By thermally bonding So to each other, m
It is preferable to carry out this process while maintaining the M1 nonwoven elastic web 22 at its stretched length. This thermal bonding can be applied, for example, to the web 2
2.50 between rollers 40.44,
4 by arranging the two webs 22.50 to apply appropriate thermal bonding temperatures and pressures. For example, the bonding of the fibrous non-woven gatherable web 50 to the fibrous non-woven elastic web 22 is performed by rollers 40.4.
4. A temperature range from 50° C. below the melting point of at least one of the materials used to form the web 22.50 to the melting temperature of at least one of the materials used to form the web 22.50. However, at high processing rates, the two webs 22.50 are exposed to high temperatures for short periods of time. As such, thermal bonding may be performed at a temperature above the melting point of one or both of the materials utilized to form web 22.50. By adjusting the nip 42, pressure heat bonding of the two webs 22.50 to each other may be effected with any suitable bonding pressure. Other methods of thermally bonding the two webs 22.50 to each other may also be used, for example instead of the two thermal bonding devices 40.44 a conventional sonic bonding device (
(not shown) may also be used. Here, two webs 2
2.50 mutual joints to nip 42 web 22.50
Note that there is some improvement just by passing the . This is because passing through the nip places pressure on the two webs 22.50, increasing the entanglement of the individual fibers of the two webs 22.50.

The fibrous non-woven elastic web 22 can be bonded (separable or non-separable depending on the desired end product) to the web 50 to form a composite non-woven elastic material. After forming the web 52, magnetic! The pie scar added to the A-quality nonwoven elastic web 22 is loosened. This may include, for example, a nip formed by a pair of rotating nip rollers 56,58 over a composite nonwoven elastic web 52 that includes both a Yuga nonwoven elastic web 22 and a fibrous nonwoven gatherable web 50; That is, by passing it through the gap 54. Adjust the nip 54 and remove the roller 56.5.
8 to firmly engage the composite non-fibrous elastic web 52 without adversely affecting it. Nip roller 56.58
The rotation of the nip rollers 56,58 is adjusted such that the peripheral velocity of the nip rollers 56, 58 causes the composite non-woven elastic web 52 to relax and contract to a relaxed, unbiased length due to its elasticity. Relaxation and contraction of the composite nonwoven elastic web 52 to its relaxed, unbiased length causes the fibrous nonwoven gatherable web 50 of fibers bonded to the fibrous nonwoven elastic web 22 to move together;
That is, the fibrous nonwoven elastic web 2 shrinks and shrinks.
Gearing is done on the upper surface of 2.

After relaxing and contracting the composite non-fibrous elastic web 52, the composite non-fibrous elastic web 52 is transferred to a feeding roller 60 for storage and transportation.
is wound up. The composite non-woven elastic web 52 can then be utilized to manufacture a variety of products, such as outer covering materials for diapers and other clothing.

Alternatively, if the geared nonwoven web 50 is intended to be separated from the nonwoven elastic web 22, in this example the fibrous nonwoven geared web 50 is separated from the nip 64 between two rotating nip rollers 64, 66. The nonwoven elastic web 22 is passed through two rotating nip rollers 70,72.
The two webs 22.
50 separate from each other. The nips 62,68 are adjusted so that the rollers 64,66 engage the web 50 without adversely affecting it, and the rollers 70,72 engage the web 22 without adversely affecting it. After separation of the two webs 22.50, these webs 22.5
0 onto storage rolls 74 and 76, respectively. When winding the fibrous nonwoven geared web 50, care should be taken not to store it under high tension or without gears under a pie skirt.
If the web 50 is stored in a wound state without tensioned gears, it is possible that the web 50 will lose its ability to hold its gears. When the web 50 loses its gathers, the web 50 loses its elasticity.

Therefore, in order to maintain the web in its geared condition while being stored, the rotation of the storage roll 76 may be adjusted.
The circumferential speed of the roll 76 is approximately equal to or only slightly greater than the circumferential speed of the rollers 64,66.

Upon separation from the nonwoven elastic web 22, the geared fibrous nonwoven web 50 assumes a creped or geared appearance. Thus, upon application of a stretching force in the machine direction (i.e., a direction approximately perpendicular to the line of the gears), the web 50 will remain approximately flat to the extent that the gears permit, e.g. Surprisingly, the geared web 50 exhibits the elasticity defined herein when the stretching force on the gears is removed.

The web 50 is made of a non-elastic material, e.g.
Geared web 50 exhibited elasticity even when made from polypropylene sold under the trade designation PF301 by T.T. Corporation.

ta fibrous nonwoven elastic web 22 of composite nonwoven elastic web 52
The portion may be formed of any elastomeric material from which it may be formed. Examples of elastomeric materials that can be used to form the fibrous nonwoven elastic web 22 include, for example, E, I.

DuPont DeNemours & Co.

B.

Product name Es from F. Goodrich & Co.
There are polyurethane elastomeric materials available under the trade name Pebax, such as those available from the Rilsan Company under the trade name Pebax. Other elastomeric materials used to form the fibrous nonwoven elastic web 22 include (
a) Elastomeric A-B-A' block copolymer (where A and A' are each a thermoplastic polymer end block containing a styrene component, and A is the same thermoplastic polymer end block as A') (b) one or more elastomeric polymer midblocks such as conjugated dienes or lower alkenes), for example, poly(vinyl arene), B is an elastomeric polymer midblock such as a conjugated diene or lower alkene, Polyolefin or poly(alpha-methylstyrene) and elastomer A-B-A' block copolymer end blocks (
Here, A and A' are each a thermoplastic polymer end block containing a styrene component, and A may be the same thermoplastic polymer end block as A', for example, poly(
B is a conjugated diene or an elastomeric polymer midblock such as a lower alkene). The A, A' materials may be selected from the group of materials including polystyrene or polystyrene homologs, and the B material may be selected from the group of materials including polyisoprene, polybutadiene, poly(ethylene-styrene). This common type of material is D
es Marais U.S. Patent No. 4,323,534
No. 4,355,425 to Jones, supra, the 5hell booklet. Saturated or nearly saturated poly(ethylene-phthylene) intermediate block
Commercially available elastomer A-B-A' with
The block copolymer has the following chemical formula where x, y and n
is a positive integer. The polystyrene end blocks A and A' are represented by the following chemical formula.

Here, n is a positive integer that may be the same or different for A and A'. Sometimes called 5-EB-S block copolymer, it is manufactured by 5hell Chemical Company under the trade name KRATON G.
KRATON G is commercially available from y.
1 6 5 0, KRATON G
There are 1652 and KRATONGX 1657.

Other elastomeric resins that may be used are A-B-A' block copolymer subpolymers, where A, A' are polystyrene end-floes, and "B" is a polyphtadiene intermediate block having the formula:

-(-C1(2-CH-C1(-C1(2+-where,
n is a positive integer. This material is sometimes called 5-B-S block copolymer and is manufactured by 5hell Chemica
l Company under the trade name KRATON D, for example, KRATON D 1101, K
RATOND 1102, KRATOND 1
It is commercially available as 116. Another 5-BS block copolymer is Ph1llips PetroleumCo
Product name 5olprene41 from mpany
It can be obtained as 8. Another elastomeric resin is an A-B-A' block copolymer, where A and A' are polystyrene end blocks, as described above, and B is a polyisoprene intermediate block; is represented by the following chemical formula.

CH.

Here, n is a positive integer. These Flo-Tsuku copolymers are sometimes called s-r-s block copolymers and are 5he
ll Chemical Company under the trade name KRATON D, e.g. KRATON D
1107, KRATOND 1111, KRAT
ON D 1112, KRATON D 11
It is commercially available under 17.

KRATON D and K above at 74F
A summary of typical properties of RATON G resin is shown in Table 1 and Table 1I below.

No. 1 KRATON D Coarse--1D-1101D-1+02 D-1107 Tensile strength (psi)' 4600246002310022
9002300$ Modulus Cpsi)' 400 400
1 (IQ Zo.

Elongation ($)' 880 880 1:lOO1
200 Residual strain at break (:) 10 10 10 1.
0 hardness (shihea 8) 71 71
37 52 ratio 0-94
0.94 [), 92 0.93 Bruckfield viscosity (toluene solution) cps 77°F 4000' 1200
″ 1600 pieces 131110:l Melt viscosity Melt index condition G gm5/10mln, 1 6 9 Plasticizer oil component zw o o
o.

Styrene/j muro ratio 31159 28/72
14/86 21/79 Physical KRATON D Characteristics D-11120-1116D-1117
Tensile strength (psi) '1500'4600'1
2002300z Modulus (psi)” 70 350
．． 60 Elongation (X)' 1400 900
1300 Residual strain at break (X) 20 10 15 Hardness (Shore A) 34 65
32 specific gravity 0.92 0.94 0
．． 92 Bruckfield viscosity (toluene solution) cps 77F 900' 9000
3 500' Melt viscosity Melt index condition G Bs/10mln, - Plasticizer oil Component $w 0 0
0 styrene/rubber 6 ratio 14/86 zl
/79 17/83 Physical form 0tsuto 9" Beret No. ■ Table KRATON G Characteristics G-1650G-1652G-1657
Tensile strength (psi)' 5000245002340023
00z modulus (psi)' 800
700 350 Elongation ($)” 500
500 750 Residual strain at break ($) --- Hardness (Shore A) 75
75 65 specific gravity 0.91'
0.91 0.90 Flushfield viscosity (toluene solution) cps 77F 1500'
550'1200' Melt viscosity Melt index condition G gm5/10mln, - Plasticizer oil Component $W 0 0
0 Styrene/Rubber 6 ratio 28/72
29/71 14/86 Physical form Small piece Small piece Herrett I A
STM Method D412 - Tensile Test, Show Separation Rate, 10 in,/min.

2 Typical properties determined for films cast from toluene solution 3 Net polymer concentration, 25% W 4 Net polymer concentration, 20% W 5 Components measured on stretched film cast from toluene solution Property 6 determined by extrapolation with respect to zero Ratio of the sum of the molecular weights of the end blocks (A+A'') to the amount of the B middle blocks. For example, KRATON G
-1650, the molecular weight of the end block (A+A') is 28 percent of the molecular weight of the A-B-A' block copolymer.

Null 1 Hegelone molding of 5-EB-3KRATON G block copolymer in pure form, i.e., in net form, has a temperature of at least about 550F to about 6
It has been found difficult to do so at temperatures up to 25F, except at throughputs lower than at least about 0.14 grams per wood capillary per minute. To avoid such high temperature and low throughput conditions, different types of K
It has been found that blending with some of the RATON G materials provides a satisfactory melt blown material. For example, a polyolefin material consisting of 5-
Blends of EB-S block copolymers resulted in null l-blown moldable materials. In particular, polyolefin is KR
If desired to be blended with the ATON GS-EB-S block copolymer, the polyolefin may include a copolymer of ethylene, propylene, phthene or other low alkenes, or a blend of one or more of these materials. Polymers are preferred. A particularly preferred polyolefin for blending with the KR, ATONGS-EB-S block copolymer is polyethylene, and a preferred polyethylene is available under the trade name Petr.

thene Na601 (here, PENa601
or N a 601) and tJ.

S-1, ChemiCals Company.

U, S, 1. According to information obtained from the Chemicals Company, Na 601 is a low molecular weight, low density polyethylene for use in the field of melt adhesives and coatings. U,S.

1. Chemicals C+company also states that Na601 has the following nominal value: (j)Fultzfield viscosity cp is 150 when measured according to ASTM D3236.
8500 at ℃, 3300 at 190℃, (2) AS
Density is 0°90 when measured according to TMD1505
3 grams per cubic centimeter and (3) ASTM
When measured according to D1238, the conductive mel index is 2000 grams/10 minutes, and (4) A
It has a ring and ball softening point of 102°C when measured according to STM E28 (s) and a tensile strength of 850 pounds per square inch when measured according to AsTxt D63B (6) as measured according to ASTM D 638. When I did this, the elongation was 90%, (
7) The rigidity TF at -34°C is 45,000.

(8) The hardness of gold at 77'F is 3.6.

Na60J has a number average molecular weight (Mn) of about 4600,
Weight average molecular weight (M w ) of about 22,400 and about 83
It is believed to have a Z average molecular weight (M z ) of 300. Polydispersity of Na601 (M w / M n )
is approximately 4,87.

Here, Mn is calculated using the following formula.

Mw is calculated using the following formula.

Mz is calculated using the following formula.

where MW = various molecular weights of individual molecules in the sample, n = number of molecules in a given sample with a given molecular weight of MW.

Melt blown blends of polyolefins and S I-3,5-B-S block copolymers were found to be unsatisfactory due to incompatibilities. However, a good material that can be blended with the 5-I-S block copolymer is poly(alpha-methylstyrene), and the preferred poly(alpha-methylstyrene) is commercially available under the trade name 18-210.
Available from o.

Preferably, M&fibrous nonwoven gearable web 5 of composite nonwoven elastic web 52 formed by the method of the present invention.
The zero section can be formed from any gatherable material that can be formed. For example, the fibrous nonwoven gatherable web 50 of fibers may be a blend of non-elastic and elastic materials, one or more non-elastic materials, or one or more elastic materials and two. It can be formed from a blend of one or more types of non-elastic materials. Preferably, the fibrous nonwoven gatherable web 50 of fibers is formed from a non-elastic gatherable material that can be fiber-formed, melt blown, or bonded without a binder. Examples of fiber-forming materials that can be used to form the 5 mm fibrous nonwoven gatherable web include polyester materials, polyolefin materials, one or more polyester materials and one or more polyester materials. There are formulations of different types of polyolefin materials. An example of a polyester M&fiber forming material is polyethylene terephthalate. An example of a fiber-forming polyolefin material is polypropylene. A preferred polypropylene material is trade name PC973, PF3.
01 from Himont Company.

Himont PC-973 Polypropylene Him
The typical characteristics of ont are ASTM D
a density of approximately 0°900 grams per cubic centimeter as measured according to ATEM D1238, a conditional melt flow rate of 35 grams 710 minutes as measured according to ATEM D1238, and a conditional melt flow rate of approximately 4300 as measured according to ATEM D638.
Tensile strength in bond/square inch (psi) and ASTM
Flexural modulus of approximately 182,000 as measured in accordance with D 790,B and 9 as measured in accordance with ASTM D785A
It has an R scale Rockwell hardness of 3. PC-
973 has a number average molecular weight (Mn) of about 40,100 and a
It is believed to have a weight average molecular weight of 72,000 and a two-average molecular weight of about 674,000.

The polydispersity (Mw/Mn) of PC-973 is approximately 4°29.

If the fibrous nonwoven gatherable web 50 of fibers is desired to be separated from the nonwoven elastic web 22 after gearing, one fibrous nonwoven gatherable web 50 may be separated from the nonwoven elastic web 22 by It is preferable to be able to return to a substantially attached state. In most embodiments, the geared condition (e.g., configuration) that FG 50 has upon separation from web 22 is less than the same amount of length of web 50 when web 50 is releasably coupled to elastic web 22. It is currently believed that the material is somewhat longer in the gathering direction (ie, one machine direction). In other words, web 50 will stretch somewhat in the gathering direction after separation from web 22. Therefore, the geared relief valve bias length of one separate web 50 will be somewhat greater than or equal to the geared relief valve bias length of the same amount of web 50 when coupled to elastic web 22.

In a particular embodiment of the invention, the composite nonwoven elastic web 52 is a fibrous nonwoven gatherable web 50 of fibers.
It consists of a non-woven elastic web 22 of Ha debris bonded to. The composite non-fibrous elastic web 52 of this embodiment differs from the composite non-fibrous elastic web 52 of the above-described embodiments in the following points. That is, two webs 22.50 of the composite non-woven elastic web 52
The bonding is performed without the application of heat or pressure or both during the bonding step, and the U & fibers of the web 50 are bonded during the formation of the fibrous nonwoven gatherable web 50 onto the nonwoven elastic web 22. This bond is stronger than that obtained by intertwining the fibers of web 22.

In this particular embodiment, a fibrous nonwoven elastic web 2
2 is made of a tacky elastomeric material, and once formed, the fibrous nonwoven elastic web 22 becomes tacky. The tacky fibrous nonwoven elastic web 22 is formed by melt-blowing onto the porous collection screen 14 . Alternatively, an adhesive nonwoven elastic porous film (not shown) may be used in place of the adhesive Faiga nonwoven elastic web 22. Thereafter, the adhesive fibrous nonwoven elastic web 22
at least about 13A of relaxed unbiased length by the combined action of rollers 20.26 and 30.32;
That is, it is stretched to an elongated length of at least about 150 percent. In particular, it is preferred that the adhesive fibrous nonwoven elastic web 22 be stretched to a length of from about 150 percent to about 700 percent of its relaxed, unbiased length.

After stretching the tacky fibrous nonwoven elastic web 22, the fibrous nonwoven elastic web 22 is stretched to the nip or gap 42 between rotating rollers 40 and rotating nip rollers 44.
is conveyed by a second porous collection screen 36. A yitm fibrous nonwoven gatherable web 50 is formed directly on top of the adhesive fibrous nonwoven elastic web 22 while the web 22 is conveyed by the second porous collection screen 36 . This can be done by any conventional melt blown or binderless bonding method, or by using a non-woven gatherable web 5.
Any other conventional method available for forming the 0 may be used, such as conventional carding equipment to form a card web. Similar to the previously described embodiments, the adhesive fibrous nonwoven elastic quench 22 is applied to the rollers 30, 32 when forming the fibrous nonwoven gatherable web 50 on the surface of the web 22. Roller 4 relative to circumferential speed
The extended bias length is maintained by appropriately adjusting the circumferential velocity of 0.44. Due to the fact that the nonwoven elastic web 22 is tacky during its formation, the two webs 20,50 are separated during the formation of the fibrous nonwoven gatherable web 50 onto the top surface of the nonwoven elastic web 22. The adhesion of the webs to each other improves their bonding (compared to the bonding of the webs only by entanglement). The result is a 5B22 fibrous nonwoven gatherable web 50 of fibers.
Formation and bonding occur simultaneously. Although any adhesive elastomeric material can be used to form the adhesive fibrous nonwoven elastic quench 22 of this example, a preferred adhesive elastomeric material includes an elastomeric A-B-A' block copolymer. where A and A' are each thermoplastic polystyrene end blocks and B is a polyisoprene midblock. This type of triblock copolymer material is sometimes called a 5-rs block copolymer,
Product name KRATON D, for example, K
RATON D1107. KRATONDllll,
KRATON D 1 1 1 2.

Shell Chemic with KRATON D1117
Al, Company is Ichihara. Alternatively, blends of S-I-S block copolymers and poly(alpha-methylstyrene) may be utilized.

The materials that may be used to form the fibrous nonwoven elastic web 50 of this embodiment may be any of those previously described with respect to the fibrous nonwoven gatherable web 50 of fibers. That is, the #R male fibrous nonwoven gatherable web can be formed of any gatherable material that can be formed into the visceral nonwoven gatherable web 50.

For example, a fibrous nonwoven gatherable web 5 of fiber a
0 is a blend of an inelastic material and an elastic material, one or more inelastic materials, or a blend of one or more elastic materials and two or more inelastic materials. Can be formed from objects. Preferably, the fibrous nonwoven gatherable web 50 is made from a melt blown process for forming fibers or from a binderless bondable non-elastic gatherable material.

However, the fibrous nonwoven gatherable web 50 of fibers can be used to attach a carded web to the side of the 5B 22 or to form the fibrous nonwoven gatherable web 50 on the side of the web 22. It can be formed by any other method. Examples of u & fiber-forming materials that may be used to form the fibrous nonwoven gatherable quench 50 include polyester materials, polyolefin materials, or one or more polyester materials and one or more types. is a blend of polyolefin materials. An example of a material for forming polyester TA fibers is polyethylene terephthalate. An example of a fiber-forming polyolefin material is polypropylene. A preferred polypropylene material is commercially available from Himont Company under the trade name PC973, PF301.

In certain situations, it may be desirable to include loose particles of one or more types of solid material in one or both of the webs 22.50 during formation of the webs 22.50. For example, it may be desirable to include one or more types of fibers or other particles, such as cotton fibers, wood pulp fibers, polyester fibers, in one or both of the webs 22.50 during formation. This can be accomplished using conventional secondary molding equipment in conjunction with melt blown molding equipment or binderless bonding equipment 12 and/or 48. Such sub-forming equipment is well known to manufacturers, and AHderso
The device disclosed in U.S. Pat. No. 4,100,432 to No.

Fibrous nonwoven gatherable web 50 of fibers adhesive j@,! After being formed and simultaneously bonded to the upper surface of the i-quality nonwoven elastic web 22, the composite nonwoven elastic web 52 is moved to the roller 40.
, 44. These rollers do not require heating or any additional pressure on the composite non-fibrous elastic web 52 for the reasons discussed above. after that,
The stretching tension applied to the adhesive nonwoven elastic web 22 is reduced, and the composite nonwoven elastic web 52 is relaxed. The fibrous non-woven gathered usable web 50 has adhesiveness H.
&As the composite nonwoven elastic web 52 relaxes and contracts because it is bonded to the nonwoven elastic web 22 while the fibrous nonwoven elastic web 22 is in a stretched state, the tan fibrous nonwoven gathers. The flexible webs 50 are constricted together and geared to form a soft wad-like or mat-like web 50 bonded to the surface of the elastic web 22.

Examples Evolistyrene A, A' end blocks and poly(ethylene-phthylene) "B" intermediate blocks (trade name KRATO
N GX1657She 11Chemical
A-B-A' block copolymer 6-PE Na601 with U. S. 1. Chemica]
A preformed fibrous nonwoven elastic web was prepared in roll form by melt-blowing a 40 weight percent formulation (obtained from A. Company).

Melt blown molding of the fibrous nonwoven elastic web was accomplished by extruding the material formulation through a melt blown mold having 30 extrusion capillaries per linear inch of mold tip. The diameter of each capillary is approximately 0.

0.145 inches and approximately 0.113 inches long. The formulation is approximately 0 per capillary per minute at a temperature of approximately 595°F.
．． A rate of 52 crumbs was extruded through a capillary tube. The pressure at which the formulation was extruded was 73 bonds/square inch gauge at the capillary. The mold tip configuration is adjusted to be recessed approximately 0.090 inch inward from the plane containing the outer surface of the air plate forming the molding air gear tube on each side of the extruded capillary. The two molding air gaps were adjusted to form an air gap of about 0.06 inches. Molding air for melt-blowing the formulation was supplied to the air gap at a temperature of about 600 liters and a pressure of about 4 bonds per square inch gauge. The melt blown taH thus formed was blown onto the mold screen approximately 15 inches from the mold tip.

The thus formed fibrous nonwoven elastic web is unwound and stretched by applying tension in the machine direction (MD), i.e., a pie scar, to maintain the fibrous nonwoven elastic web at its stretched length. The top surface of the web is made of polypropylene (product name PC973 manufactured by Himont Compa).
A tFtM nonwoven geared web was formed by melt-blowing a tFtM nonwoven geared web (commercially available from NY) into lfim fibrils. - Melt blown molding of the FM m fibrous nonwoven gatherable web was performed by extruding polypropylene through a melt blown mold having 30 extrusion capillaries per linear inch of mold tip. The diameter of each capillary is approximately 0
．． 0.145 inch, and the length was approximately 0.113 inch. Polypropylene was extruded through the capillary tubes at a rate of about 0.38 grams per capillary per minute at a temperature of about 590F. The extrusion pressure applied to the polypropylene was 29 bonds/square inch gauge at the capillary.

The mold tip configuration was adjusted to lie approximately flush with the plane containing the outer surface of the air plate forming the molding air gap on each side of the capillary. The air plates were adjusted to create two forming air gaps, one on each side of the extrusion capillary, creating an air gap of approximately 0.015 inch. The molding air required for melt blow molding polypropylene is approximately 600
The air gear was supplied at a temperature of F and a pressure of approximately 4 bonds per square inch gauge. The melt-blown polypropylene ultrafine fibers thus formed were approximately 16 mm thick from the mold tip.
H & fiber quality located at the inch! & Melt blown molding directly onto the top surface of the elastic web.

Because of these processing conditions, the viscosity of the polypropylene was about 20 voise, forming very small diameter polypropylene microfibers on the surface of the fibrous nonwoven elastic woofer.

The stretch tension was then reduced, the tamer nonwoven elastic web was shrunken, and the meltblown polypropylene web was geared in the machine direction. The composite nonfibrous elastic web thus formed has interlayer bonding properties that clearly result from the intertwining of the individual fibers of these webs, even though the two webs are not bonded by adhesive or thermal bonding. It was off.

'A sample of the fibrous nonwoven elastic web itself and a sample of the composite nonwoven elastic web were stretched in an Irxstron tensile tester model 1122 to obtain an elongation of 100 percent for each sample, that is, twice the unstretched length. The sample was returned to the unstretched state. This procedure was repeated three times before each sample was stretched to break point. Each sample was 2 inches wide and 5 inches long, and the initial jaw separation on the tester was set at 1 inch. The sample was placed lengthwise in the testing machine and stretched at a speed of 5 inches per minute. Machine direction data was obtained from samples having a machine direction length of 5 inches and a cross direction width of 2 inches. Transverse measurements were taken from samples having a length of 5 inches in the lateral force direction and a width of 2 inches in the machine direction. The data obtained for the nonwoven elastic webs are shown in Table 2 below, and the data obtained for the composite nonwoven elastic webs are shown in Table 2 below.

Table M-R Fibrous Nonwoven Elastic Web Peak TEA Peak Load Peak Elongation Number ~ ((,/
Meunier Z upper] -Ω (English knee - (inch) 100$
Ill 8vg” 1.94
．． 9744. 9968Std Dev”
'''', 40.197.000
9], OOX tZ, Avg 1.3
8. 9303. 9870Std
Dev, 29. 188
．． 0006100% $3 Avg
1.30. 9074. 9
873SLd Dev, 28
．． 181. 000810D$ Wei 4
Avg 1.24. 890
3, 'J873Std Dev
, 25. 178. 0005
Break 15 Avg 10.08 1.4488
3.1:194Std Dev 3.1
4. 2982. 5181 Lateral measurement value Peak TEA''' Peak load
Peak Growth/Regression Number (inch-
bond) (pound) (inch) 100
X 11 Avg” 1.50
．． 7811-9974Std Dev”
', 12. 0593. 0017
100% 112 Avg 1.0
8. 7459,! 1866St
d Dev, 08. 0568
, f10091011% +13 Av
g +, 01. 7251.
9870Std Dev, 07
, (1542,0007100$ I Av
g, 96. 7107.
9863Std De'v, 07
．． 05'13. 0008 broken! lIi! 5
Avg 10.4] 1.295
3.644Std Dev 1.24
．． 095. 268 Table ■ - Composite nonwoven elastic web elongation peak TEA” peak load
Peak i request (+p +i number (inch-bond) (bond) (inch)
100% JI Avg” 2.04
1.2606. 9976Std D
ev"", 17. 0793
．． 0009100% B Avg
1.37 1.2056. 9866S
td Dev, 12. 081
0. 0012100% 13 Avg
1.29 1.1798
．． 9874Std Dcv,il
, 0773. 0011100$
114 Avg 1.24 1
．． 161. 9876Std Dev
, 11' , 0792
．． 0012 Break 15 Avg 9,65 2
．． 5134 2.281Std Dev
1.87. 1659. 224:1
Transverse direction measurement value (peak TEA) peak load peak (
Inch-Bond) (Bond) (Inch) 100% II Avg” 2.28
1.277. 9009Std D
ev"", 48. 1593
．． 0900100% ”2 Avg
, 70], 077. 985
3Std Dev, 09. 2
206. 0002100% 83 A
vg, 58 1.022
．． 9874Std Dev, 08
．． 2139. 0013100$
II4 Avg, 5:l
, 9846. 9873Std De
v, 08. 2148
．． 0012 Fyr15 Avg""", 88
1.159 1.0865Std Dev
, 21. 2220. 0120
Tables 1 and 2 are total absorbed energy (inch-bond),
Peak (maximum) load (bond) occurring at each repetition, 100
Each peak elongation (in inches) is disclosed as the sample is stretched in each iteration of the percent elongation procedure and as the sample is stretched to break. As can be seen, the total energy required to stretch a sample 100 percent in the machine direction at peak load is approximately the same for the fibrous nonwoven elastic web and the composite nonwoven elastic web. This is believed to be because the melt blown polypropylene web is geared in the machine direction and requires less energy to stretch in the machine direction. During elongation at break,
The peak load for the composite nonwoven elastic web increased by over 70 percent. This is indicative of the strength of the melt blown polypropylene web or the composite non-woven elastic web.

In the transverse direction (TD)' (melt blown polypropylene is not geared), the peak load for initial strength of the composite nonwoven elastic web is more than 60 percent greater than the peak load for the fibrous nonwoven elastic web. This indicates that even the low elongation of the melt blown polypropylene web contributes to the strength of the composite non-woven elastic web. Furthermore, the peak total absorbed energy for the composite nonwoven elastic web is shown to be increased by 50 percent over that of the congested nonwoven elastic web at initial stretch. In subsequent decompression stages this value actually decreases. This indicates that the melt blown polypropylene web has significantly fractured or torn during the initial stretch and is no longer contributing to the total energy of the composite non-woven elastic web.

Here, it was observed that the "air permeability" of the composite nonwoven elastic web was still better than the "air permeability" of the fibrous nonwoven elastic web. Additionally, the water repellency of polypropylene is further enhanced due to the thin web of melt blown polypropylene microfibers affixed to the surface of the fibrous nonwoven elastic web. Furthermore, by attaching a thin web of melt-blown ultrafine A-fibers to the surface of the melt-blown FB, the rubber-like feel of the nonwoven elastic web was changed to a soft and desirable feel.

Examples ■ Polystyrene A, A' end blocks and poly(ethylene-phthylene) "B" intermediate blocks (trade name KRATON
GX1657 Shell Chemical C
A-B-A' block copolymer 6-claw PE Na601 with 6-claw PE Na601 (obtained from U.S. company) S. 1. ChemicaI
A preformed amorphous nonwoven elastic web was prepared in roll form by melt blowing a 40 ta=% formulation (obtained from A. Company).

Melt blown molding of the fibrous nonwoven elastic web was accomplished by extruding the material formulation through a melt blown mold having 30 extrusion capillaries per linear inch of mold tip. The diameter of each capillary is approximately 0.

0.145 inches and approximately 0.113 inches long. The formulation is approximately 0.5 mm per capillary per minute at a temperature of approximately 570F.
It was extruded through a capillary tube at a rate of 50 grams. The pressure at which the formulation was extruded was 144 bonds/square inch gauge at the capillary. However, it is now believed that this measurement was inaccurate due to a malfunction of the pressure probe.

The shape of the mold and the tubes were adjusted so that the molding air gear tubes were formed on both sides of the capillary tube and were recessed approximately 0.110 inches inward from the plane containing the outer surface of the through air plate. The air plates were adjusted to create two forming air gaps, one on each side of the extrusion capillary, or an air gap of about 0.110 inch. Molding air for melt blowing the formulation was supplied to the air gap at a temperature of about 614F and a pressure of about 4 bonds/square gauge. The meltblown fibers were formed into a mold screen that was believed to be approximately 16 inches from the mold tip. This distance measurement was not performed accurately.

The thus formed fibrous nonwoven elastic web is unrolled and stretched in the machine direction (MD) by applying a tensioning force, that is, a pie scar, to maintain the fibrous nonwoven elastic web at its stretched length. The upper surface of the woven elastic web is coated with polypropylene (product name PF301 manufactured by Himont Compa).
The fibers are made by melt-blown molding (commercially available products) into ultrafine fibers! A fibrous nonwoven gatherable web of a was formed.

Melt blown molding of the fibrous nonwoven gatherable web was accomplished by extruding polypropylene through a melt blown mold having 30 extrusion capillaries per linear inch of mold tip. The diameter of each capillary is approximately 0.0145
inch, and the length was approximately 0.113 inch. Polypropylene was extruded through the capillary tubes at a rate of about 0.75 grams per capillary per minute at a temperature of about 590F. The extrusion pressure applied to the polypropylene was 186 bonds/square inch gauge at the capillary. The mold tip configuration was adjusted so that it protruded approximately 0.010 inch from the plane containing the outer surface of the air plate forming the molding air gap on each side of the capillary. Adjust the air plates so that the two forming air gaps, one for each extrusion capillary, are approximately 0.

An air gap of 0.018 inches was created. The molding air required for melt blow molding polypropylene is approximately '60.
The air gap was supplied at a temperature of 0'F and a pressure of approximately 2 pounds per square inch gage. The distance between the mold tip and the surface of the fibrous nonwoven elastic VEFF that formed the gatherable polypropylene web was approximately 10 inches. Due to these processing conditions, the viscosity of the polypropylene was approximately 124 poise, forming larger diameter polypropylene microspheres on the surface of the nonwoven elastic web.

The fibrous nonwoven elastic web is then reduced by reducing the stretch tension and shrinking the melt blown polypropylene 2
Gears are attached to the web in the machine direction. Since the composite non-fibrous elastic web thus formed is not bonded by adhesive or thermal bonding between the two webs, it is clear that the interlayer bonding is caused by the intertwining of the individual r-fibers of these webs. I had.

Samples of the nonwoven elastic web itself and samples of the composite nonwoven elastic web were stretched in an In5tron tensile tester model 1122 to obtain an elongation of 100 percent for each sample, i.e., twice the unstretched length; was returned to its non-stretched state. This 1,000 Iff was repeated three times, after which each sample was stretched to the breaking point. Each sample was 2 inches wide and 5 inches long, and the initial jaw separation on the tester was set at 1 inch. The sample was placed lengthwise in the testing machine and stretched at a speed of 5 inches per minute. Machine direction data was obtained from samples having a machine direction length of 5 inches and a cross direction width of 2 inches. Transverse measurements were taken from samples having a length of 5 inches in the lateral force direction and a width of 2 inches in the machine direction. The data obtained for the composite non-woven elastic web formed in Example 2 is shown in Table 7 below.

Table 7 shows that when a composite nonwoven elastic web is stretched in the machine direction until it breaks, the energy or load in the machine direction required for 100% elongation is small, the total absorbed energy increases approximately 7 times, and the peak This shows that the load has increased approximately three times. In the transverse direction, where the meltblown compact is not geared, the initial 100 percent elongation absorbs about 3.5 times the total energy to failure, and any subsequent 100 percent elongation absorbs about 40 It absorbed five times the energy from Additionally, the peak load for the first stretch in the lateral direction was approximately 40 percent higher than the peak load for any subsequent stretch in the same lateral direction.

Table V - Composite Nonwoven Elastic Web Load Peak TEA Peak Load Peak Elongation Retraction Number (inch-pounds) (pounds) (inches) 1
0(H11Avg", 95.7
708. 9978Std Dev””
, 28. 1742. 00161
00z 2 Avg, 75
．． 7:188. 9870Std D
ev, 23. 1675
．． 0015100$ t:l Avg
, 71. 7204. 98
64Std Dev, 22-
1636. 0010100$! 14
Avg, 68. 7083
．． 9860Std Dev,
22. 16:II, 0011 break 15 Avg 5.75 L, 974
2.023Std Dev 1.36
．． 2437. 2037 Lateral Measurement Extension Peak TEA” Peak Load
Peak Growth Number (inch-pound) (, pound) (inch) 100
$ 11 Avg” 3.08
2.042. 7529Std Dev”
” , 77 .2333 .09
13100% 12 Avg,
8:l 1.422. 9876S
td Dcv, 08. 3076. 0
010100$ 63 8vg
, 72 1.3403. 9870St
d Dcv, 118. 2950
．． 0009100% #4 Avg
, 65 1,281. 9878Std
Dev, 07. 2740
．． 0012 breakage #5 8vg, 8
5 1122 1.052Std D
ev, 07. 2500. 0
445 Chapter 1 II, ■, Notes on Table 7 * = Total absorbed energy ** = Average *** = Standard deviation *** = Average of two measurements. The third measurement yielded values of 2,376 for peak TEA, 1.232 for peak load, and 5,609 for peak elongation. These values are considered incorrect as they are too far from the values obtained in the other two measurements.

It is understood that, unless otherwise specified, the data listed in Tables ■, ■, and Table 7 are average values obtained from five measurements for each machine direction specification and three specific values for each transverse direction measurement. I want to be

The basis weight of the null 1-blown fibrous nonwoven elastic web used in the example construction was 67.3 grams/square, and the J
The basis weight of the melt-flow-formed gatherable polypropylene web was 12.2 grams per 1-mile. The degree of relaxation or shrinkage of the composite nonfibrous elastic web of Example 2 was about 54 percent. The degree of relaxation of the composite non-woven elastic web is determined by taking a sample of the composite non-woven elastic web having a relaxed length of approximately 4.0 inches in the machine direction, and machine-machine the sample until it resists stretching by the geared polypropylene web. Determined by stretching in the direction. That is, until the polypropylene web is free of gears. At this point, 4.
The 0 inch sample stretched approximately 8.75 inches in the machine direction.

The basis weight of the fibrous nonwoven elastic web used in Example 2 is approximately 66.2 crumbs/m2, and the M&fiber fibrous nonwoven gatherable web melt-blown onto the surface of the elastic web in Example 2 Basis weight was approximately 21.4 grams/square meter. The degree of relaxation or contraction of the composite non-fibrous elastic web of Example H was about 42 barnes 1 to
Met. The degree of relaxation is determined by taking a sample of a composite nonwoven elastic web having a relaxed length of approximately 12 inches in the machine direction and stretching the sample in the machine direction until it resists stretching by the geared polypropylene web. /Ta. That is, the polypropylene web is stretched until it is free of gears. At this point, the 12-inch sample is approximately 20. It grew to Finch.

When the composite non-fibrous elastic web was relaxed and contracted, it was observed that the following was true. That is, the meltblown polypropylene web exhibits a creped, geared appearance, and lines of crepe or gears are formed on the surface of the fibrous nonwoven elastic web during the formation of the meltblown polypropylene web. Interestingly, the fibrous nonwoven elastic web or polypropylene web of the shrunken composite nonwoven web was oriented approximately transversely to the direction in which the web was stretched (i.e., transversely to the machine direction). The crepe or gear wires are approximately parallel to the direction of elongation of the fibrous nonwoven elastic web during melt-blowing (= 1., i.e., the crepe or gear wire of the fibrous nonwoven elastic web is The lines are generally parallel to the machine direction).Thus, a composite non-woven elastic web consisting of two webs includes webs having alternating lines of gears or crepes that cross each other at approximately right angles. The occurrence of gears or crepe lines in a fibrous nonwoven gatherable polypropylene web of ti1 fibers can be predicted from the gathers of the web in the machine direction.

However, the formation of fi&m non-woven elastic webs and gears or crepe lines, in particular the formation of gears or crepe lines on a non-woven elastic web at approximately right angles to the gears or crepe lines of a fibrous non-woven gatherable web of polypropylene fibers. The occurrence was not predicted.

approximately 5-7 layers and 8 inches approximately machine direction (MD) length;
Cut a portion of a composite non-woven elastic web having a general transverse dimension (TD) of approximately 4-172 inches and prepare a geared FI! 1 Oga non-woven melt-blown polypropylene
The web was separated from the fibrous nonwoven elastic web. After this separation, the geared fibrous nonwoven meltblown polypropylene web had a relaxed machine direction dimension of about 7 inches and maintained a lateral dimension of about 4-1 layers of 2 inches.

Importantly, the geared fibrous nonwoven meltblown polypropylene web maintained substantially its creped or geared configuration in the machine direction. In addition, the separated geared Fa Mega nonwoven meltblown polypropylene web can be stretched in the machine direction by applying tension in the machine direction and adding a pie scar, and when the tensioned pie scar is removed, the relaxation of the flaps occurs. Unbiased, untensioned, returned to gathered dimensions (finches x 4-1/2 inches), ie, shrunk. For example, R with gears in the machine direction (MD) until the gears are almost gone.
When a Finch X 4-1/2 inch sample of m-quality nonwoven meltblown polypropylene web was stretched,
This sample was measured and found to have a machine direction (MD) length of about 9-172 inches and a transverse direction (TD) dimension of about 4-1 layers 2 inches. When Piusca was removed from the sample, the sample returned to a machine direction (MD) dimension of just over the finch and a transverse direction (TD) dimension of approximately 4-172 inches within one minute. After repeating the stretching procedure, the sample had a machine direction (MD) dimension of about 9-1 layers and 2 inches and a transverse direction (TD) dimension of about 4-1 layers and 2 inches. Excluding the second stretching force, the polypropylene web has a machine direction (MD) dimension of about 7-172 inches, about 4
A transverse direction (TD) dimension of -172 inches was taken within one minute. This result was unexpected since PF301 polypropylene was thought to be non-elastic.

The method of the present invention and the products formed by the method are capable of variations. For example, two or more fibrous nonwoven geared webs 50 could be stacked and bonded one on top of the other to increase the thickness of the fibrous nonwoven geared web 50. Furthermore, one fibrous nonwoven geared web 50 may be separably bonded to both sides of the fibrous nonwoven elastic web 22 in the manner described above to produce the following three-web sequence: the fibrous nonwoven geared web 50. /Fibrous Nonwoven Elastic Web/I, *A composite nonwoven elastic web having a textured nonwoven geared web could be formed.

Two sheets of fibrous nonwoven elastic web Ha! A three-web sequence with a nonwoven geared web is particularly desirable when the fibrous nonwoven elastic web 22 is made of a cohesive elastomer material, as described above. This is because sandwiching the adhesive elastic web 22 between two webs prevents the adhesive web 22 from adhering to other parts of the web 52 when the web 52 is rolled up for storage. The 3-web material could be formed by the method shown schematically in FIG. The method is identical to the method shown schematically in FIG. 1 until the bilayered composite nonwoven elastic web 52 exits the rollers 40,42. Thereafter, rather than proceeding to nip 54 between rollers 56,58, composite web 52 passes through nip 78 between rotating roller 80 and rotating nip roller 82.

Composite web 52 then passes through third porous collection screen 8
4 into a nip 86 between rotating nip rollers 88 and rotating rollers 74. Porous collection screen 68 is driven to move around rollers 80, 84 in the direction shown by arrow 92 in FIG.

By adjusting the rotation of the roller 80.82.88.90, the circumferential speed of the roller 80.82.88.90 is adjusted to the roller 40.4.
It is assumed that the circumferential speed of 4 is the same. Thus, the fibrous nonwoven elastic web 22 is maintained at a stretched bias length as it is conveyed through the porous collection screen 84.

A conventional melt blown mold 9
4 (if desired, Satoshi's binder-free bonding or carding equipment can be used) or by melt-blowing the microfibers 98 directly onto the stretched top surface of the nonwoven elastic web 22. On the opposite side of the ia fibrous nonwoven elastic web 22, a second R-shaped nonwoven geared web 9 is attached.
form 6. Materials that can be used to form the second gatherable web 96 can include any of the materials described above as available for forming the first fibrous nonwoven gatherable web 50. Particulate material may be included within web 96 as described above in connection with web 22.50. Then the second! a The male nonwoven geared web 96 is rolled into the fibrous nonwoven elastic web 22 by the action of rollers 88.90 essentially equivalent to rollers 40.44.
It may also be thermally bonded to. The thermal bonding of the second u & fibrous nonwoven geared web 96 to the fibrous nonwoven elastic web 22 is related to the thermal bonding of the first fibrous nonwoven geared web 50 to the fibrous nonwoven elastic web 22. It can be carried out within the same temperature range and pressure range as previously described.

If desired, conventional sonic bonding techniques (not shown) may be used in place of the thermal bonding step. Alternatively, if the fibrous nonwoven elastic web 22 is tacky, thermal bonding of the ffl fibrous nonwoven geared web 96 to the fibrous nonwoven elastic web is not necessary, as previously discussed. This is because the second fibrous nonwoven geared web 96 is simultaneously formed on and bonded to the surface of the male nonwoven elastic web 22.

In another embodiment, if the fibrous nonwoven geared web 96 is to be separated from the elastic web 22 at a later stage, the second fibrous nonwoven geared web 96 may be
The ma: of the web 96 is separably bonded to the surface of the fibrous nonwoven elastic web 22 by intertwining it with the fibers of the web 22 while it is being formed on the surface of the fibrous nonwoven elastic web 22. I can do it. In this example,
The fibrous nonwoven geared web 96 is formed and bonded to the fibrous nonwoven elastic web 22.

In any of these embodiments, the web 50,96 is formed by applying adhesive to the surface of the elastic web 22 prior to forming the web 50,96 on the stretched surface of the web 22.
to the web 22. Application of adhesive to the surface of the web 22 can be facilitated in the usual manner by means of nip rollers 32.82. For example, the adhesive is normally applied to the surface of the roller 32.82 and the adhesive is applied to the surface of the roller 32.82 as the web 22 passes through the nip 28.78.
．． The adhesive can be transferred to the surface of web 22 at 82 . Alternatively, the adhesive may be applied in spots to the surface of the web 22.

After bonding the fibrous nonwoven geared web 96 to the elastic web 22, two rotating nip rollers 104.10 are used to loosen the tension applied to the web 22.
3-way type composite non-woven elastic web 1 in the nip 102 between 6
Pass 00.

By adjusting the rotation of rollers 104 and 106,
．． The composite web 100 is relaxed at a circumferential velocity of 106.

Due to its elasticity, the composite web 100 contracts to its relaxed, unbiased length.

Upon relaxation and contraction of web 100 to a relaxed unbiased length, both U
& Gathering occurs due to relaxation and contraction of the fibrous non-elastic web 22. Finally, the composite web 10 as shown at 108
0 can be rolled up and stored. Because the adhesive elastic web 22 is sandwiched between the webs 50.96, the adhesive elastic web 22 does not adhere to other portions of the composite web 100 during storage. This material can be used to form a variety of products, such as diaper products.

It should be appreciated that the two-wafer composite web 100 described above in connection with the adhesive elastic web 22 can also be formed without the adhesive material forming the web 22. In this case, the web 96 must be bonded to the web 22 by a bonding method other than fiber entanglement, thermal bonding, sonic bonding, or the like.

In another aspect of the invention, the machine direction (MD
) rather than one or more gatherable webs 50.96 in the transverse direction (TD).

What if I want to gear the web 5o or 96 or both in the lateral direction? Additional devices are utilized to laterally stretch and contract the xI web 22.

For example, FIG. 4 illustrates another embodiment of the present invention that avoids the requirement of forming the geared nonwoven elastic web 50 of the FIG. 1 embodiment on the stretched surface of the nonwoven elastic web 22. In the embodiment of FIG. 4, the geared nonwoven elastic web 50 is formed directly onto the surface of a porous forming screen 110, which itself is stretchable in the machine direction as indicated by arrows 112. For example, the retractable porous collection screen 110 can be made from a continuous web of nonwoven elastic web 22. Alternatively, the retractable porous collection screen 110 may be constructed from a wire mesh screen 114 shown generally in FIG. This wire mesh screen 1
14 is formed by a plurality of substantially parallel springs 116 coiled and deployed in the machine direction, which springs 116 are connected to a plurality of thin, substantially parallel wires 11 extending in the transverse direction (TD).
8. They are laterally connected to each other by 8. The lateral wires 118 are placed very close to each other;
When the wire mesh screen 114 is in the unbiased, retracted configuration, these lateral wires 118 contact each other. Upon application of a tensioning force or tension force in the machine direction, the coil spring 116 deploys or stretches in the machine direction and the thin transverse wires 118 separate from each other and form the porous collection surface 1.
form 10. FIG. 6 shows the expanded form with the addition of this pie scar.

Alternatively, the wire mesh screen 114 can be formed by a plurality of laterally coiled and deployed generally parallel springs connected to each other in the machine direction (MD) by a plurality of thin generally parallel wires extending in the machine direction (MD). has been done.

This configuration is shown in FIG. 5 and allows the web to be 9
Gears can be added to 6. If it is desired to gear web 96 in the lateral force direction, additional conventional devices (not shown) for laterally stretching screen 114 may be used in place of the illustrated device for stretching screen 114 in the machine direction.

As can be seen with reference to FIG. 4, the movement of the retractable porous collection screen 110 in the machine direction 112
This is achieved by being driven by 0.122. These rollers are driven by a conventional drive mechanism (not shown). Not shown for the sake of simplicity, is a conventional vacuum polygon between the rollers 120, 122 and below the underside of the upper portion of the screen 110. The vacuum polyx helps hold web 22 on top of screen 110. Retractable porous collection screen 110
passes through a nip 124 between a pair of rotating nip rollers 126,128.

The nip 124 is adjusted so that the rollers 126, 128 firmly engage the retractable porous collection screen 110 without adversely affecting it. roller 1
26.128 by adjusting the rotation of roller 126.128.
The circumferential speed of rollers 120 and 122 is approximately the same as that of rollers 120 and 122. A retractable porous collection screen 110 is installed in the nip 1 between another pair of rotating nip rollers 132 and 134.
30 and by adjusting this nip 130, the rollers 132, 134 pass through the porous collection screen 110.
and engage firmly without adversely affecting it.

By adjusting the rotation of the rollers 132 and 134, the rotation of the rollers 132 and 134 is adjusted.
．． The circumferential speed of roller 134 is made greater than the circumferential speed of rollers 120 and 122. As a result of making the peripheral speed of rollers 132, 134 higher than the peripheral speed of rollers 120, 122,
A longitudinal or machine direction bias tension force is applied to the extensible porous collection screen 110 such that the screen 110 extends in the longitudinal direction to a tension bias length in region 136. Between rollers 126 and 128, roller 13
2.134 The degree of stretching of the porous collection screen 110 that occurs in the region 136 between the rollers 126 and
, 128 by varying the circumferential speed of the rollers 132, 134. For example, the surface speed of rollers 132, 134 or roller 12
For approximately twice the surface velocity of 6.128, the retractable porous collection screen 110 will extend to approximately twice its retracted valve bias length, or approximately 200 percent of its extended bias length. Preferably, the retractable porous collection screen 110 extends in region 136 to a length of at least about 125 percent of its retracted unbiased unstretched length. In particular, it is preferred that the screen 110 be stretched in region 136 to an extended length of at least about 150 percent of its contracted unbiased unstretched length. More preferably, the porous collection screen 11
0 may extend from at least about 150 percent of the unstretched unbiased length to about 700 percent or more.

Melt blown microfibers 1 formed by a conventional melt blown mold 140 while the retractable porous collection screen 110 is in an elongated configuration in region 136
40 is melt blown onto the stretched surface of the porous collection screen 10. Meltblown ultrafine fiber 1
When 38 is deposited on the stretched porous collection screen 11041, it becomes entangled and aggregates, agglomerating! a) Form a fibrous nonwoven geared web 96. The intertwined and aggregated fibrous nonwoven geared web 96 is conveyed by a porous collection screen 110 through a nip 130 to a nip 142 formed between rotating rollers 120 and rotating nip rollers 144 around the circumferential surface of zero rotation nip rollers 144. The speed is adjusted so that it is approximately the same as the circumferential speed of the rotating rollers 120, 122, 126, 128.

The circumferential speed of the roller 144.120 is the roller 122.12.
6.128, the tension force is removed from the expanded porous collection screen 110, causing the screen 110 to retract and its retractability to the retracted valve bias length. Relaxation and contraction of the porous collection screen 110 to the contraction valve bias length causes the fibrous nonwoven geared web 96 to contract together and become geared on its upper surface. Once this occurs, this gearing action occurs in the area 146 between the pair of rollers 132, 134, 120, 144.

After relaxation and deflation of porous collection screen 110, fibrous nonwoven geared web 96 may be wound onto feed rollers 148 for storage and transportation. For the reasons discussed above, the rotational speed of the feed roller 148 must be controlled to store the geared ta fibrous nonwoven elastic web 96 under substantially no tension. this is,
This is accomplished by adjusting the rotational speed of roller 148 so that the circumferential speed of roller 148 is approximately equal to, or slightly greater than, the circumferential speed of rollers 120,144.

When a three-layer composite web is formed as shown in Figure 3,
It may be desirable to separate the two outer geared nonwoven webs from the elastic nonwoven web. in this case,
Nip 150 between two nip rollers 152, 154 rotating the fibrous nonwoven geared web 50 and two nip rollers 158°1 rotating the web 96
The fibrous nonwoven geared web 96 is separated from the fibrous nonwoven elastic web 22 by passing it through a nip 156 between the fibrous nonwoven elastic webs 22 and 60 . The web 50.96 is then wound onto respective storage rolls 162.164 for later use. For the reasons stated above, the fibrous nonwoven geared web 5o.

Care must be taken when winding up the web 5o, 96 so that the web 5o, 96 is stored on the roll 162, 164 with no or very little tension. This rotates the rolls 162, 164 such that the circumferential velocity of the rollers 162 is equal to or only slightly greater than the circumferential velocity of the rolls 152, 154, and the circumferential velocity of the rollers 164 is reduced to the circumferential velocity of the rollers 158. 160, or only slightly greater than that of the web 50.
After separation at 96 , the edge male nonwoven elastic web 22 passes through a nip 166 between two rotating nip rollers 168 , 170 and is wound onto a storage roller 172 .

In the particular embodiments discussed herein, fiber #I nonwoven geared webs are described as being formed utilizing conventional melt blown molds and melt blown methods, or alternatively, without the use of conventional binders. Bonding molds and binder-free bonding methods may be utilized and are within the scope of the present invention to form nonwoven gatherable webs in place of binder-free bonding molds and methods or melt-blown molds and methods 48.94. It is also intended to include materials formed by any other device or method that can be used. When utilizing a binder-free bonding type and method, the bonding of gatherable web 50 to fibrous nonwoven elastic web 22 is accomplished by bonding the gatherable web 50 to the fibrous nonwoven elastic web 22 by bonding the adhesive elastomer material to the web 22, as described above. (if used for forming), by thermal or sonic bonding, or by applying an adhesive to the surface of the web 22 prior to forming the web 50.96. These bonding methods must be utilized with binder-free bonded gatherable webs because the fibers of the binder-free bonded gatherable webs do not easily entangle with the fibers of web 22. It is from. The bonding of one or more webs 50.96 to web 22 is thermally bonded (web 50.
．． 96 is formed by binder-free bonding, melt blown molding, or other methods), relax the web 22 to a substantially tension-free, unbiased state as soon as possible after performing the thermal bonding step.
Care must be taken to deflate it. This is thought to be because if the nonwoven elastic web 22 is kept above its softening point for a long period of time, it will lose its elasticity. When the nonwoven elastic web 22 loses its elasticity, the cooled elastic web 22 will stretch. It will "solidify" in its state.

It should be understood that changes and modifications to the invention may be made without departing from the scope of the invention. Furthermore, the scope of the present invention is not limited to the specific embodiments disclosed herein;
It is also to be understood that the claims are to be limited only when read in light of the above description.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram illustrating one mode of carrying out the method of an embodiment of the present invention. FIG. 2 is a schematic diagram illustrating a mode of carrying out a method according to another embodiment of the present invention. FIG. 3 is a schematic diagram illustrating an embodiment of the method of separating a geared web from an elastic web according to an embodiment of the present invention. FIG. 4 is a schematic diagram illustrating another aspect for carrying out another embodiment method of the present invention for separating a geared web from an elastic web. FIG. 5 is a top view, shown in a non-biased retracted state, of a telescoping forming screen that can be utilized as a forming screen in the method shown in FIG. FIG. 6 is a top view of the telescoping molded screen of FIG. 5 in a biased, extended configuration; FIG. 7 is a schematic diagram illustrating another embodiment of the method of the present invention for separating two geared webs from an elastic web. In the drawings, 10...meltblown ultrafine fibers,
12... Melt blown mold, 14... Porous collection screen, 18. 20... Roller, 22... Fibrous nonwoven elastic web, 26-... Nip roller, 30...
Roller, 32... Nip roller, 36... Second porous collection screen, 40... Roller, 44... Nip roller, 46... Meltblown ultra-fine visceral fiber, 48
... Melt blown mold, 50 ... Fibrous nonwoven geared web, 52 ... Composite nonwoven i-characterized web,
56.58... Nip roller, 64.66... Nip roller, 70, 72... Nip roller, 74, 76... Storage roll FIG, 4 FIG, 5 FIG, 6

Claims (43)

[Claims] (1) A method of manufacturing a composite nonwoven elastic web comprising a nonwoven elastic web bonded to a fibrous nonwoven gathered web, the method comprising: providing a nonwoven elastic web; stretching, forming a fibrous nonwoven gatherable web directly on a surface of the stretched nonwoven elastic web, and bonding the stretched fibrous nonwoven gatherable web to the stretched nonwoven elastic web. forming a composite nonwoven elastic web; and loosening the composite nonwoven elastic web to gather a fibrous nonwoven gatherable web. (2) The method of claim 1, wherein the step of providing the nonwoven elastic web includes the step of forming a fibrous nonwoven elastic web of meltblown microfibers. Method. (3) The method of claim 1, wherein the step of providing a nonwoven elastic web includes the step of providing a porous elastic web. (4) The method of claim 2, wherein the fibrous nonwoven elastic web is at least about 125 percent of the relaxed length of the nonwoven elastic web and about 700 percent of the relaxed length of the nonwoven elastic web. A method characterized by stretching up to. (5) The method of claim 1, wherein forming the fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of meltblown microfibers. A method characterized by: (6) The method of claim 1, wherein the step of forming a fibrous nonwoven gatherable web comprises a binder-free bonded microfiber fibrous nonwoven gatherable web. A method comprising the step of forming. 7. The method of claim 1, wherein forming the fibrous nonwoven gatherable web includes forming a carded web. 8. The method of claim 1, wherein the step of bonding the fibrous nonwoven gatherable web to the nonwoven elastic web is performed by thermal bonding. (9) The method of claim 8, wherein the step of thermally bonding the fibrous nonwoven gatherable web to the nonwoven elastic web comprises melting of the material utilized to form either of the webs. A method characterized in that it is carried out by thermal bonding within a temperature range from about 50° C. below to about the melting temperature of the materials utilized to form either of the webs. (10) A composite nonwoven elastic web formed by the method according to claim 2 or 3. (11) In the composite nonwoven elastic web according to claim 10, the nonwoven elastic web essentially consists of A-B-A.
'block copolymers, where A and A' are each a thermoplastic polymer end block containing a styrene component and B is a poly(ethylene-butylene ), polyisoprene, and polybutadiene. (12) A composite nonwoven elastic web according to claim 10, wherein the nonwoven elastic web is essentially a blend of one or more polyolefins and an S-EB-S block copolymer. containing elastomeric fibers made from materials selected from the group consisting of "S"
is selected from the group consisting of polystyrene and polystyrene homologues, and "EB" is poly(ethylene-
butylene). (13) A composite nonwoven elastic web according to claim 10, wherein the nonwoven elastic web consists essentially of a blend of poly(alpha-methylstyrene) and S-I-S block copolymer. A composite nonwoven elastic web comprising elastomeric fibers made of a material, wherein "S" is selected from the group consisting of polystyrene, polystyrene homologues, and "I" is polyisoprene. (14) In the composite nonwoven elastic web according to claim 12, the polyolefin is at least one selected from the group consisting of ethylene, propylene, and butene.
1. A composite nonwoven elastic web, characterized in that it is selected from the group consisting of three polymers (including copolymers). (15) The composite nonwoven elastic web according to claim 14, wherein the polyolefin is polyethylene. (16) The composite nonwoven elastic web according to claim 10, wherein the fibrous nonwoven gatherable web includes inelastic meltblown microfibers. (17) A composite nonwoven elastic web according to claim 10, wherein the fibrous nonwoven gatherable web includes bonded ultrafine fibers without using a nonelastic binder. Woven elastic web. (18) In the composite nonwoven elastic web according to claim 16 or 17, the fibrous nonwoven gatherable web comprises polyester microfibers,
polyolefin microfibers, including inelastic microfibers selected from the group consisting of blends of one or more types of polyester microfibers and one or more types of polyolefin microfibers; A composite nonwoven elastic web characterized by: (19) The composite nonfibrous elastic web according to claim 18, wherein the polyester ultrafine fibers include polyethylene terephthalate ultrafine fibers. (20) In the composite nonfibrous elastic web according to claim 18, the polyolefin polyester ultrafine fibers constituting the fibrous nonfibrous gathered web are made of polyethylene.
A composite nonwoven elastic web characterized by containing terephthalate ultrafine fibers. (21) A method for producing a composite nonwoven elastic web comprising a nonwoven elastic web bonded to a fibrous nonwoven gathered web, comprising the steps of providing an adhesive nonwoven elastic web; Stretching the woven elastic web, forming a fibrous nonwoven gatherable web directly on the surface of the stretched nonwoven elastic web, and simultaneously forming the fibrous nonwoven gatherable web on the surface of the stretched nonwoven elastic web. While bonding the webs and forming a fibrous nonwoven gatherable web on the surface of the fibrous nonwoven elastic web that stretches the bonding of the adhesive nonwoven elastic web to the fibrous nonwoven gatherable web. forming a composite nonwoven elastic web by adhering these two types of webs together;
relaxing the adhesive composite nonwoven elastic web to gather the fibrous nonwoven gatherable web. (22) The method of claim 21, wherein the step of providing the adhesive nonwoven elastic web includes forming a fibrous nonwoven elastic web of meltblown microfibers. How to do it. (23) A composite nonwoven elastic web formed by the method according to claim 22, wherein the adhesive fibrous nonwoven elastic web consists essentially of (a) an A-B-A' block copolymer; Coalescing (where "A", "A'" are thermoplastic polymer end blocks selected from the group consisting of polystyrene, polystyrene homologs, and "B" is an elastomeric polymer midblock consisting of polyisoprene) and (b) poly(alpha-methylstyrene) and A-B-A' block copolymer (where "A" and "A'" are thermoplastic polymers selected from the group consisting of polystyrene and polystyrene homologs). and a blend of elastomeric polymer midblocks consisting of a composite end block and "B" is an elastomeric polymer midblock consisting of polyisoprene. Features a composite non-woven elastic web. (24) A composite nonwoven elastic web according to claim 23, wherein "A" and "A'" are selected from the group consisting of polystyrene. (25) The method of claim 23, wherein the step of forming the fibrous nonwoven gatherable web includes melt-blown microfibers formed on a surface of the fibrous nonwoven elastic web. A method comprising forming a gatherable web. (26) A composite nonwoven elastic web formed by the method according to claim 23, wherein the adhesive fibrous nonwoven elastic web consists essentially of (a) A-B-A' block copolymerized web; Coalescing (where "A", "A'" are thermoplastic polymer end blocks selected from the group consisting of polystyrene and polystyrene homologs, and "B" is an elastomeric polymer intermediate block consisting of polyisoprene) and (b) poly(alpha-methylstyrene) and A-B-A' block copolymer (where "A" and "A'" are thermoplastic polymers selected from the group consisting of polystyrene and polystyrene homologs). "B" is an elastomeric polymer consisting of polyisoprene. Features a composite non-woven elastic web. (27) A composite nonwoven elastic web according to claim 24, wherein "A" and "A'" are polystyrene. (28) The method of claim 22, wherein the step of forming the fibrous nonwoven gatherable web includes bonding agent-free bonded microfibers on the surface of the fibrous nonwoven elastic web. A method comprising forming a fibrous nonwoven gatherable web. (29) A method for producing a composite nonwoven elastic web comprising a nonwoven elastic web bonded to a fibrous nonwoven gathered web, comprising the steps of providing an adhesive nonwoven elastic web; Stretching the woven elastic web, forming a fibrous nonwoven gatherable web directly on the surface of the stretched nonwoven elastic web, and simultaneously forming the fibrous nonwoven gatherable web on the surface of the stretched nonwoven elastic web. When bonding the webs and forming a fibrous nonwoven gatherable web on the surface of the stretched nonwoven elastic web bonding the adhesive nonwoven elastic web to the fibrous nonwoven gatherable web. intertwining individual fibers of the gatherable web with a nonwoven elastic web to form a composite nonwoven elastic web; and relaxing the adhesive composite nonwoven elastic web to form a fibrous nonwoven gatherable web. and a step of gathering. (30) The method of claim 29, wherein the step of providing the nonwoven elastic web includes forming a fibrous nonwoven elastic web of meltblown microfibers. Method. (31) The method of claim 30, wherein the bonding is performed by intertwining the individual fibers of the fibrous nonwoven gatherable web with the individual fibers of the meltblown microfiber fibrous nonwoven elastic web. A method characterized by being carried out only by matching. (32) The method of claim 29, wherein the step of providing the nonwoven elastic web includes the step of providing a porous nonwoven elastic film. (33) The method of claim 32, characterized in that the bonding is effected solely by intertwining the individual fibers of the fibrous nonwoven gatherable web with the pores of the porous nonwoven elastic film. How to do it. (34) A method for producing an elastic gathered nonwoven web, comprising the steps of preparing a stretchable forming surface, forming a fibrous nonwoven gatherable web directly on the stretched forming surface, and stretching the web. releasably bonding a fibrous nonwoven gatherable web to the formed forming surface; contracting the forming surface to gather the fibrous nonwoven gatherable web; separating the fibrous nonwoven gatherable web. (35) The method of claim 34, comprising stretching the fibrous nonwoven elastic web from at least about 125 percent to about 700 percent. (36) The method of claim 34, wherein forming the fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of meltblown microfibers. A method characterized by: (37) The method of claim 34, wherein the step of forming a fibrous nonwoven gatherable web forms a fibrous nonwoven gatherable web of binder-free bonded microfibers. A method comprising the steps of: (38) A gathered fibrous nonwoven web formed by the method according to claim 34, characterized in that it has elasticity. (39) A gathered fibrous nonwoven web according to claim 38, characterized in that it contains inelastic ultrafine fibers. (40) The gathered fibrous nonwoven web according to claim 38, comprising non-elastic polyester microfibers, non-elastic polyolefin microfibers, one or more types of polyester microfibers, A gathered fibrous nonwoven characterized in that it includes non-elastic melt-blown microfibers selected from the group consisting of microfibers and a blend of one or more non-elastic polyolefin microfibers. web. (41) A gathered fibrous nonwoven web according to claim 39, characterized in that the gathered fibrous nonwoven web consists essentially of bonded ultrafine fibers without using an inelastic binder. . (42) A method for producing a gathered fibrous nonwoven web having elasticity, which includes the steps of: preparing a nonwoven elastic web forming surface having a non-bias contracted length when relaxed and a bias elongated length when stretched; stretching the elastic web-forming surface to the stretched length; forming a fibrous nonwoven gatherable web directly on the nonwoven elastic web-forming surface to maintain the nonwoven elastic web-forming surface at the stretched length; the fibrous nonwoven gatherable web is separably bonded to the surface thereof, and the fibrous nonwoven gatherable web is formed on the nonwoven elastic web forming surface to effect this separable bonding. the step of intertwining the individual fibers of the fibrous nonwoven gatherable web with the individual fibers of the fibrous nonwoven elastic web forming surface and shrinking the nonwoven elastic web forming surface to form the fibrous nonwoven gatherable web; A method comprising the steps of gathering a web and separating a gathered fibrous nonwoven gatherable web from a nonwoven elastic web forming surface. (43) The method of claim 43, wherein the step of providing the nonwoven elastic web forming surface includes forming a nonwoven elastic web of meltblown microfibers. Method.