MXPA01003011A - Process for making a laminate of unaged film and an unaged nonwoven web and products produced therefrom - Google Patents

Abstract

The present invention is directed to an in-line, continuous process for making a laminate of film and nonwoven web wherein the film and nonwoven web are made simultaneously, and are therefore nascent or unaged when directly formed into a laminate. In the process of the present invention, the film is formed in-line while the nonwoven web is formed, the newly formed film and nonwoven web being immediately laminated upon forming. Hence, the laminate is formed from"unaged"film and"unaged"nonwoven web. As used herein, the term"unaged", which is synonymous with"green", means that the film and nonwoven web are immediately laminated upon forming, for example, neither the film nor the nonwoven web is pre-wound into a roll prior to forming into a laminate.

Description

PROCESS TO MAKE A LAMINATE OF A NON-ANNEATED PEL CULA AND A NON-ANNEATED FABRIC AND PRODUCTS PRODUCED BY ME FIELD OF THE INVENTION The present invention is directed to a process for making a laminate of a non-aged film and a non-aged woven fabric and products produced by it. In particular, the present invention is directed to a continuous online process for making the laminate wherein the nonwoven film is made simultaneously, a laminate being formed directly.

BACKGROUND OF THE INVENTION The industry has long recognized the benefits of combining the barrier properties of films and the cloth-like attributes of non-woven fabrics for various medical, personal care and commercial applications. Laminates have traditionally been produced using both the aged film and the non-woven fabric aged as by using an aged film and a non-aged non-woven fabric, or vice versa, a non-aged film and an aged woven fabric. As an example, a typical prior art process involves first winding a pre-made film onto a roll and then subsequently unwinding the roll film while it is laminated to a nonwoven fabric by making the non-woven fabric, thereby forming the laminate . There are many techniques to make either a film or a non-woven fabric on a continuous basis. In addition, combining such complex processes such as film making and manufacturing nonwoven fabric will place success at the mercy of a simultaneous solution of the technical issues of both systems. The inherent difficulties in each process, as indicated by the theory of reliability, would in fact lead an art expert to move away from such a combination without expecting benefit from a particular product attribute, as discussed more fully below.

In addition, the above processes for unwinding either a preformed film or a non-woven fabric have had technical issues to overcome. A problem with the unwinding procedures previously used refers to the additional steps required when a roll of aged film s runs out and a new roll of aged film must be replaced. The splice is required to hold the end of the first film roll at the beginning of the film. second roll of film. Since in a continuous process it is necessary to carry out the splicing if the machine is stopped, the splicing is difficult since the rolls are usually rotating at high speeds. There are at least two known ways of carrying out the splicing. In one method, a tape is employed to take the loosening of the film l which allows a zero velocity splice. The sheet of film wrapped through the bars of the ribbon which is expanded, for example, in a vertical form. When the splice begins, the tape is lowered, which allows the roll speed to approach zero. This method facilitates splicing the sense that the movement of the rollers of the aged film is eliminated. The disadvantage of such a process is that additional expensive equipment must be purchased, which must be maintained and operated.

Another method for splicing is generally known as the "splice on flight" which requires the splice while the rollers are spinning. This method is carried out by decelerating the rotational speed of the first roller, while accelerating the second roller, thereby equalizing the surface velocities of the two rollers to perform the splicing. The "flying splice" method may be the most cost-effective method in the sense that the purchase is not required as maintenance and operation of expensive equipment. As one with an ordinary skill in the art of knowledge, however, it is much more difficult to perform "splicing on flight" especially when long rollers are employed and when speeds of between 40 and 1500 feet per minute are employed (fpm). ) (or from 122 to 457 meters per minute (m / min)).

The splice can be achieved by many media as it is known by those with an ordinary skill in art. One such method is to tape the sheets of film together. A disadvantage of taping is that the location of the corked part must be monitored and removed as the tape interferes with the film properties such as the ability to breathe.

A further disadvantage of unrolling a pre-made or aged film is that the adjacent rolls of the film tend to stick to each other (otherwise known as film blocking) resulting in the tearing of the roll as it is unrolled. of the roll. In fact, each film layer has an affinity for the next film layer and the layers prefer to adhere together rather than unwind. Both the nature of the material used to form the film and the compressive forces resulting from unwinding the film on the roll tend to cause the layers to adhere together resulting in tearing of the film when unrolling. Such tearing results in a lack of product uniformity, thereby decreasing the barrier properties. Additionally, the film may be torn completely so that the process must be stopped requiring the re-film of the film.

Also, it is not uncommon to use film rolls as long as 120 inches (3.05 meters) wide that weigh as much as 3000 pounds (1360 kilograms). As one knows with an ordinary skill in art, handling such rolls is difficult and cumbersome to say less.

The present invention avoids these and other difficulties by an in-line fabrication of both the non-aged non-woven tea and the non-aged film. Apart from super the difficulties discussed above, there are advantages to using the online continuous process of the present invention. One such advantage is that the non-aged film does not have the opportunity to fully crystallize before laminating film to the non-woven fabric. When a film is rolled onto a roller and allowed to age in storage for likewise 48 hours and as long as 2 weeks, the temperature of the film will cool and the film will crystallize. The non-aged film of the present invention will remain more amorphous, meaning that this will be softer and easier to guide. Additionally, this for-feature may result in the ability to use a basis weight plus film ba in either a pre-stretched film and / or resulting sheet. In this manner, the barrier and breathability properties of the film are maintained, or possibly improved, while reducing the overall costs associated with the manufacture of the resulting film and laminate.

All these disadvantages of previous known processes have been eliminated by the processes of the present invention wherein the non-aged film is simultaneously produced with a non-aged non-woven fabric immediately formed into a continuous web process. Such laminates exhibit unexpected improvements in the pre-stretching and in the hydro head making them particularly useful in applications where the laminator will be converted into absorbent articles. The conversion process has typically been replete with problems associated with delamination. These problems have been improved when the laminates made by the process of the present invention are used.

The notion of using a continuous online process to produce laminates is suggested previously as a possibility. See, for example, the publication of the Patent Cooperation Treaty WO 96/19346 granted to the common cessionary. Like airplane models drawn before the Wright brothers' successful flight, however, the current leap to the notion of creating a continuous online process of the present invention has only gone through a long step, concentrated efforts and individuals In addition, the laminate produced by the present invention exhibits unexpected properties as will be discussed in more detail.

SYNTHESIS OF THE INVENTION The present invention is directed to an on-line continuous process for preparing a film laminate and non-woven fabric wherein the process includes the steps of forming a non-aged film, simultaneously forming a non-aged woven fabric, and laminating said film not aged oriented and said non-woven non-aged fabric to form laminate in 1-60 seconds of formation of the oriented non-aged film and said non-aged non-woven fabric.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a process for the continuous online formation of a laminate according to the present invention. From a non-aged film and a non-woven and aged fabric.

Figures 2a, b and c depict a later schematic view of a 3-step process of the prior art to form a laminate of an aged film and an aged non-woven fabric.

Figure 3 is a schematic side view of the 2-step process of the prior art to form a laminate of aged film and non-aged non-woven fabric.

Figure 4 is a plan view partly in section of an absorbent article for personal care example, in this case a diaper, which may use the nonwoven laminate / film according to the present invention.

Figure 5 is a perspective view of the threading means of the present invention.

Figure 6 is a schematic side view of orientator in the direction of the prior art machine.

Figure 6b is a schematic side view d orientator in the machine direction of the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to an on-line continuous process for making a film laminate and a non-woven fabric where the film and the non-woven fabric are made simultaneously, and are therefore nascent or non-aged when formed directly in a laminate . The formation of laminate t through a continuous online process is unknown until now. In the process of the present invention the film is formed in line while the nonwoven te is formed, the film and the newly formed nonwoven fabric are immediately laminated in the formation. Therefore, laminate is formed of a "non-aged" film and of a "non-aged" woven fabric. As used herein, the term "do not age which is synonymous with" greens ", means that the film and non-woven fabric are immediately laminated when formed, for example, neither the film nor the non-woven fabric always rolls a roll before the formation in a laminate.

As used herein, the term "woven or woven fabric" means a fabric having a fiber structure of individual strands which are interlocked but not in an identifiable manner as in a woven fabric. Fabrics non-woven fabrics have been formed from many processes such as meltblowing processes and spinning processes. The basis weight of the non-woven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and useful fibr diameters are usually expressed in microns. (Note that to convert from ounces per square yard to grams per square meter you must multiply ounces per square yard by 33.91.

Referring to Figure 1, the n-aged film 10 of the present invention can be made of polymer which are capable of being formed into films and then attached to a non-aged non-woven fabric 30. As used herein, the term "polymers" "generally includes but is not limited to homopolymers, copolymers, such as for example block, graft, random and alternating copolymers, terpolymers, etc. mixtures and modifications thereof. In addition, unless specifically limited otherwise, the term "polymer will include all possible geometric configurations of the molecule." These configurations include but are not limited to syndiotactic symmetries., isotactic and random. Such polymer include but are not limited to extrudable thermoplastic polymers such as polyolefin or a mixture of polyolefins. More particularly, useful poleolefins include polypropylene, polyethylene. Other useful polymers include those written in the patent of the United States of America no. 4,777.07 issued to Sheth and assigned to Exxon Chemical Patents, Inc. as a polypropylene copolymer and low density polyethylene or linear low density polyethylene. Additional polymers useful in the present invention include flexible polyolefins. As used herein the term "flexible poleolefin" refers to polyolefin materials containing a propylene-based polymer with controlled regions of polypropylene unit to tactics to achieve a desired crystallinity as described in US Pat. America No. 5,910,136 granted to Hetzler and Jacobs jointly assigned; the complete contents of which are incorporated by reference in their entirety. The additional description such flexible polyolefins can be found in U.S. Patent No. 5,723,546 issued to Sustick assigned to Rexene Corporation.

Other useful polymers for the non-aged film of the present invention include the elastomeric thermoplastic polymers. Such polymers include those made from block copolymers such as polyurethanes, polyamide copolyethers, polyether block copolymers, vinyl ethylene acetates (EVA), block copolymers having the general formula ABA 'or AB as copoly (styrene / ethylene-butylene) styrene-poly (ethylene-propylene) -styrene, styrene-po (ethylene-butylene) -styrene, polystyrene poly (ethylene-butylene polystyrene, poly (styrene / ethylene-butylene / styrene), etc. Specifically, thermoplastic elastomeric polymers include: polyester elastomeric materials such as, for example, those available under the trade designation HYTREL® of E.l. du Dupont de Nemours and Company; amide copolymers of a polyester block, such as, for example, several classes available under the trade designation PEBAX® from E Atochem Inc. of Glen Rock, New Jersey; and polyurethane elastomeric materials such as, for example, those available under the trademark ESTAÑE® of B.F. Goodrich & MORTHANE® Co. of Morton Thiokol Corporation.

Elastomeric polymers have been used in the past for many applications but are somewhat limited by their intrinsic properties. These materials have recently joined a new class of polymers which has an excellent barrier, breathability and elasticity. new class of polymers is mentioned as single site catalyzed polymers such as "metallocene" polymers produced according to a metallocene process.

Such metallocene polymers are available from Exxon Chemical Company, of Baytown, Texas under the trade name EXXPOL® for polymers based on polypropylene and EXAC for polymers based on polyethylene. Dow Chemical Company Midland Michigan has polymers commercially available under the ENGAGE® brand. Preferably, the metallocene polymers are selected from the copolymers of ethylene and of 1-bute copolymers of ethylene and 1-hexene, copolymers of ethylene and octene and combinations thereof. For a detailed description of the metallocene polymers and the process for producing them which are useful in the present invention see the application of the jointly assigned patent cooperation treaty WO 98/29246 granted to Gwaltney others which is incorporated herein by reference In its whole The non-aged film 10 may be a multi-layer film which may include a core layer, a "B" layer and one or more skin layers, or "A" layers on either side of the core layer. Any of the polymers discussed above are suitable for use as the core layer of a multiple layer layer. Any fillers described herein are suitable for use with any film layer.

The skin layer will typically include extrudable thermoplastic polymers / or additives which provide specialized properties to the film 10. Thus, the skin can be made of polymers which provide such properties as antimicrobial activity, water vapor transmission, properties of adhesion and / or against blocking. Polymers are thus chosen for the desired particulare attributes. Examples of possible polymers that can be used alone or in combination include homopolymers, copolymers and polyolefin tables as well as ethylene vine acetate (EVA) ethylene ethyl acrylate (EEA), ethylene acrylic acid (EAA), ethylene methyl acrylate (EMA), ethylene buty acrylate (EBA), polyester (PET), nylon (PA), ethylene vinyl alcohol (EVOH), polystyrene (PS), polyurethane (PU) and olefinic thermoplastic elastomers which multi-step reactor products wherein a random amorphous ethylene propylene copolymer is dispersed molecularly in a continuous matrix of ethylene monomer low-predominantly semi-crystalline polypropylene monomer.

Suitable copolymers for layer "A" are commercially available under the designation of "Catalloy" from Himont Chemical Company of Wilmington, Delawa. Specific commercial examples are Catalloy, KS 357P, 084P and KS-057P. Other suitable polymers include polymers which are semi-crystalline / amorphous or heterophasic character. Such polymers are described in the European patent application EP 0444671 A3 (based on the application 91103014.6), on the European patent application No. EP 04729 A2 (based on the application No. 91112955.9), European patent application EP 0400333 A2 based on the application N 90108051.5), U.S. Patent No. 5,302,454 and U.S. Patent No. 5,368,927.

For a more detailed description of the films having skin and core cape see patent application of the Patent Cooperation Treaty 96/19346 granted to McCormak and others assigned to the assignee as herein incorporated by reference in its entirety.

The films can be made of breathable material or without capacity to breathe. In addition, the films can be perforated. In film formation, films can be co-extruded to increase bonding and alleviate matrix lip buildup. These films can be filled with such fillers as the fillers that develop micropore, for example calcium carbonate; opacifying agents, for example, titanium dioxide; and additives against block, for example, diatomaceous earth.

The fillers can be incorporated to develop micropores during the orientation of the film resulting in films with a capacity to rest. Some films are made breathable during the addition of filler particles to the film during the process of forming a film. Once the film filled with particles has been formed, it is then stretched or squeezed to create paths through the film. Generally to qualify as "capable of breathing" for the purposes of the present invention, the resulting laminate should have a water vapor transmission rate (WVTR) of at least about 250 grams per square meter per 24 hours as can be measured by a test method, as described below.

As used herein, "filler that develops micropores" is intended to include particles and other material forms which can be added to the polymer and which do not chemically interfere with or adversely affect extruded film but which are capable of being dispersed uniformly throughout the film. movie. Generally the fillers that develop the micropore will be in particle form and will usually have something of a spherical shape with average particle sizes in the range of about 0.5 about 8 microns. As used here, a "miera" means a micrometer. The film will usually contain at least about 30 percent of the microporous developer filler based on the total weight of the film layer. A unique advantage for the present invention is that less micropore developer filler may be required than has previously been the case. previously used. Both organic and inorganic micropore developer fillers are contemplated as being within the scope of the present invention providing that this does not interfere with the film formation process, with the resulting film's ability to breathe or its ability to bind to another layer t as a fibrous poleolefin nonwoven fabric.

Examples of micropore developer fillers include calcium carbonate (CaCo3), vari kinds of clay, silica (Si02), alumina, barium carbonate sulfate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate , powders of cellulose type, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder wood powder, cellulose derivative, chitin polymer particles and chitin derivatives. The microporous developer filler particles can optionally be coated with fatty acid, such as stearic acid, or a chain fatty acid longer than starch such as behenic acid, which can facilitate the free flow of particles (by volume) its ease of dispersion inside the polymer matrix. Fillers containing silica may also be present in an effective amount to provide anti-blocking property.

The non-aged film 10 can be made by any blown or set film equipment, it can be co-extruded and it can be recorded if desired. Preferably the film will be made by setting extrusion. There are two known types of setting extrusion equipment: cold setting and setting engraving. The typical etched engraved extrusion is shown in Figure 2a where the film is extruded into a pair of forging roll reels 42. The cold curing extrusion is the preferred film extrusion technique of the present invention for reasons that will be discussed. down. Turning now to FIG. 1, in the cold curing extrusion, the polymer enters the coextrusion film apparatus 40 and is extruded through the core film extruder 47 and the skin film extruder 45. The co-extruded polymer in the head of matrix 43 and then only one roller a cold curing roller 49 is used to decide the extruded film 10, not two rollers as is done in the engraved and cured extrusion. The advantage of cold curing over engraving and curing extrusion is that cold curing extrusion is more efficient when wide film sheets are extruded and manufacturing speeds can be increased. Also, engraved curing extrusion and partly texture the film against the smooth surface of the film extruded and cured cold. In other words, the films made from the cold-curing extrusion can be cured from a 406-centimeter matrix, resulting in an anc film of approximately 391 centimeters, produced at such speeds of 122 meters per minute and even 150 meters per minute. minut Films made by engraved and cured extrusion, on the other hand, frequently turn out to be only one film of width 356/368 centimeters at speeds of only 91.5 meters per minute since the distance traveled by the extruded material from the extruder to the rollers is typically greater that the extruded and cold-cured material. Films made by cold-setting extrusion therefore exhibit narrowing (width reduction) and have a uniform m-gauge.

Additionally, the film 10 can be stretched or oriented by the passage of the film through a film stretching unit 20 as shown in the figure. Stretching reduces the caliper or thickness of the initial gauge film of 1.5-2.0 thousandths of an inch to an effective final calibration of 0.5 mils (12.7 microns) or less. Generally, this stretching may take place in the direction transverse to the machine or in the direction of the machine. Co is used here, the "term machine direction" or MD means the length of a fabric in the direction in which it is produced. The term "cross machine direction" or means the width of the fabric, for example a direction generally perpendicular to the machine direction.

The non-woven and non-aged fabric 30 as illustrated in Figure 1, in a laminate 32 containing the aged film 10 of the present invention, can be formed of a number of processes including, but not limited to, the yarn-joining process. and of blowing with fusion. The woven fabrics may be a bonded polypropylene yarn bonded material, a meltblown or meltblown polypropylene spunbonded material produced from the elastomeric resins. As used herein, the term "constricted" refers to constraining at least one dimension by such processes as, for example, pulling or puckering.

Suitable fibers for forming non-aged non-woven fabric 30 include natural and synthetic fibers as well as bicomponent and polymer / multiple component fibers. A plurality of layers of non-woven fabric in the laminate 32 can also be used according to the present invention. Examples of such materials may include, for example, the meltblown / meltblown composite and the meltblown / spinbond / meltblown uni compounds such as those taught in the Brock patent and others of United States of America No. 4,041,203 which is incorporated herein by reference in its entirety.

As used herein, the term "fibers co-bound" refers to small diameter fibers which are formed by extrusion through one or more extruders, which are attached to one or more banks made of at least plates of yarn and transfer pipe, to produce molten thermoplastic material as filaments from a plurality of thin capillary vessels as usually circular in a spinner organ with the diameter of the extruded filaments then being rapidly reduced such as, for example, is indicated in FIG. U.S. Patent No. 4,340,563 to Appel et al .; Matsuki and other US Pat. No. 3,802,817; U.S. Patent No. 3,692,618 issued to Dorschner and other US Patents Nos. 3,338.99 3,341,394 issued to Kinney; U.S. Patent No. 3,502,763 issued to Hartman; and US Pat. No. 3,542,615 issued to Dobo and other Spunbonded fibers are generally non-sticky when deposited on a collecting surface. Yarn bonded fibers are generally continuous and have average diameters greater than 7 microns, more frequently, between about 10 and 20 microns.

As used herein the terms "blown fibers" means fibers formed by extruding molten thermoplastic material through a plurality of thin matrix capillaries as usually circular as filaments or fused filaments into gas streams (eg, air). ), usually hot and high speed and convergent which attenuate the filaments of molten thermoplastic material to reduce its diameter, which can be to a microfiber diamet. Then, the melt blown fibers are carried by the high velocity gas stream and an annealing surface is deposited to form a meltblown fabric and randomly dispersed. Such a process is described, for example, in the United States of America patent No. 3,849,241 issued to Butin et al. Fibers blown with melt are microfibers which can be continuous or discontinuous, are generally smaller than 10 microns average diameter, and are generally sticky when deposited on a collecting surface and may not require a separate bonding step.

As used herein the term "microfiber" means small diameter fibers having an average diameter of no more than about 75 microns, for example, having an average diameter of from about 0.5 micron to about 50 microns, particularly microfibr can often have an average diameter of about 2 microns to about 40 microns Another frequently used fiber diameter expression is denier, which is defined as grams per 9000 meters of a fiber and can be calculated as a fiber diameter in square microns multiplied by the density in grams per cubic centimeter multiplied by 0.00707. A lower denier indicates a finer fib and a higher denier indicates a thicker or heavier fiber, for example, the diameter of polypropylene fiber gives as of 15 microns may be converted to denier by the square, multiplying the result by 0.89 grams cubic centimeter and multiplying by 0.00707. Therefore, 15 micron polypropylene fiber has a denier of around 1.42 (152x 0.89 x 0.00707 = 1.415). Outside the United States of America, the unit of measurements is more commonly "tex" which is defined as grams per kilometer of fiber. tex can be calculated as denier / 9.

Many polyolefins are available for fiber production according to the present invention, for example, fiber-forming polypropylenes including polypropylene Escorene® PD 3445 from Exxon Chemical Company and PF-304 from Himont Chemical Company. Polyethylenes such as ASPUN® 6811A linear low density polyethylene from D Chemical, high density polyethylenes 25355 and 12350 and linear low density polyethylene 2553 are also suitable polymers. Polyethylenes have melt flow rates, respectively, of around 26, 40, 25 and 12. Many other polyolefins are commercially available.

The processes for forming the films and l-processes for forming fibrous non-woven fabrics are generally known. Similarly, the formation of nonwoven film / fabric laminate through 2-step 3 process is also known. As illustrated in Fig. 2, the three-step process of the prior art generally forms aged film 10 'with continuous shape which includes the winding of the resulting film in the roll 14. The film 10' can then be placed in storage as usual for as many as two days to four weeks. The aged nonwoven fabric 30 'formed in another step which similarly is rolled on a roll 16. Each of the rolls 14 and 16 of the aged film 10' and the aged nonwoven fabric 30 'respectively are unwound, the film 10 'can be stretched or oriented in the film stretching unit 44, and laminated in a third step to form the laminate 32'.

A prior art process of two pas usually includes preforming either the film or the woven fabric which is wound on a roll, then the preformed material is unrolled in a process line which is simultaneously forming the opposite material. For example, and as shown in Figure 3, the aged film 10 'is preformed wound on a roll 14. The non-aged non-woven fabric 30 formed while unwinding the rolled-up pr film 10' to form the laminate 32 '.

The formation of a film / non-woven laminate through a continuous online process in practice has here been unknown. As mentioned above, the reliability theory would dictate that very low yields of the process would be expected from the present invention, which would tend to lead a person with ordinary skill in the art to shy away from pursuing the present invention. In practice, the efficiency of the overall process for a typical film manufacturing process is usually in the order of 74 percent (90 percent yield of raw material and 82 percent of machine utilization), while the overall process efficiency for process Typical yarn bonding (non-woven fabric) is usually in the order of 89 percent (97 percent raw material yield and 92 percent machine utilization) By combining these two processes in the continuous process line of the present invention, one would expect An overall process efficiency of approximately 66 percent without particular anticipated product advantages The efficiency of the process of the present invention has in fact been found to be on the order of 70 percent and even at least 75 percent addition to the improvements of property exhibited by the products made according to the present invention At high production rates, such increase in efficiency ia is m significant, and is a function of the process conditions and parameters described here.

In the process of the present invention, non-aged film 10 is formed in line while nonwoven and non-aged tea 30 is formed, which is immediately laminated in the formation. Thus, the laminate 32 is a "non-aged" film and a "non-aged" fabric. P "immediately" what is meant is that the aged film 10 and non-aged non-woven fabric 30 are joined together a laminate 32 without first winding any layer Preferably, the layers will be laminated within 1 to seconds, more preferably within 1 to 30 seconds frequently even in the range of 1 to 10 seconds, from the time each layer is made. It is through this immediate lamination, brought by the ability to simultaneously process non-aged film 10 and non-aged non-woven fabric 30, that unexpected and surprising improvements in peel and hydro head resistance are found as will be highlighted in detail below.

More specifically, Figure 1 illustrates a general approach to the formation and orientation of a non-aged film 10 such as one according to the present invention. Referring to Figure 1, the non-aged film is formed by means of a coextrusion film apparatus such as a blowing or curing unit as previously described above. Typically the apparatus 40 will include one or more polymer extruders such as the No. 47 film extruder and the skin film extruder 45. The non-aged film 10 is extruded onto the cooling curing roll 49.

From the coextrusion film apparatus 40, non-aged film 10 is directed through the median threaders 18 (as shown in FIG. 5 and discussed below) through a film stretching unit such as an orienter in FIG. the machine direction (MDO) 20 (co is shown more particularly in figure 6b). Such an apparatus 2 has a plurality of stretching rollers 46 which stretch progressively and thin the film 10 in the machine direction of the film which is in the direction of displacement of the non-aged film 10 through process. After leaving the orienter in the machine direction 20.1a the non-aged film 10 should have a maximum thickness of approximately 12 microns (0.47 mils).

The stretch in the direction of the prior art machine, generally shown at point 44 in the figure generally includes the use of six stretching rollers 46 'which generally use 3-4 heating zones and one more cooling zones. In other words, some rodil extruders can be heated and some can be cooled. The prior art process also includes the pressure pu rolls 21 placed to maintain contact of the film c the stretching rolls 46 while stretching the conductive heating conditions. by the roller. It is believed that stretching while warming against the rollers of the prior art results in an uneven heating of a narrowing envelope and a property profile in the transverse direction to the poor machine. Figure 6b on the other hand illustrates the winding of film through the orienter in the direction of the machine 20 according to one aspect of the present invention. The amount and type of stretching is a function of the placement of the pressure point rollers 21 in cont of the stretching rollers 46 which may be a plated chromium roller. The pressure point rollers 21 are crowned rollers which provide a uniform pressure point effect against the stretching rollers 46. The pressure point rollers 21 of the present invention are placed so that the wrapping of the non-aged film 10 maximized against the stretching rollers 46, eg, 270 ° around the diameter of the roller. According to an embodiment of the invention, the guide in the direction of the machine 20 stretches the film after it leaves the pressure point rollers 21 which means that the stretching occurs in the space between the rollers, thus avoiding the problems of prior art. The orienter in the direction of the machine is configured with at least stretching rollers. Each drawing roller can be heated from room temperature to 250 ° F (121 ° C) or it can be cooled from room temperature to 55 ° F (13 ° C) and boosted separately. The rate at which each stretched roller rotates is in the range of 116-473 meters per minute. Therefore, the final pull rate may be in the range of 1.00 4.08. This machine direction as described is designed to maximize flexibility and is more versatile than the prior art film stretching apparatus in the sense that processing and stretching of many different types of films are allowed under many conditions. different process condition. It has been found in the non-aged film of the present invention that the film tension bleaches at a lower stretch ratio, meaning that not much stretch is required. There are several advantages to this phenomenon. One such advantage is that the stretching of the film means that the film is not stressed since the higher stretch ratios used in the prior art result in less film breakages and decreased film defects. The ne effect is that the process can run at higher rates, in addition to producing higher yields. Another advantage, as alluded to here, is that less filler micropore development will be required, meaning that more polymer is used in the composition. Such compositions will result in firmer films meaning that thinner films can be used in the resulting articles and in final laminate.

The threading means 18 provided for supplying or threading the undyed film formed through the entire continuous process, releasing the film once the film is laminated to the non-woven fabric. Some typical threaders are illustrated in Figure 5 where three strings are used in concert to grasp one end of the film sheet and feed it through the process. The strings work essentially like three fingers in the sense that one string is in close contact with one side of the ho while the other two strings are in close contact with the opposite side of the sheet and the three strings are compressed together for Hold the leaf end and feed it through the process.

As the film is not aged at one point in the machine, a non-woven fabric is being formed simultaneously. Referring again to Figure 1, conventional non-woven fabric forming apparatus 48, such as a spinning machine, is used to form the non-aged woven fabric 30. The essentially long continuous fibers 50 are deposited on a forming wire 52 As a non-woven fabric 54 and the non-woven fabric 54 is then sent through a pair of jointing rollers 56 to join the fibers together. One or both of the rollers are frequently heated to aid in the joint. The temperature at which the bonding rollers 56 is heated is in the range of 121,777 ° C. Typically, one of the rollers 56 also has a pattern such as to impart a discrete bonding pattern with a prescribed bonding area area to the non-aged non-woven fabric 30. This is referred to as thermal bonding as more fully described more ahead. The other roller is usually a smooth anvil roller but this roller can also have a pattern if desired. Once the non-aged film has stretched 10 s sufficiently the non-aged non-woven fabric 30 is formed, the two layers are put together as described above and laminated to each other in this continuous process using pair of laminating or other rolls. means 58.

In a preferred embodiment, the smooth anvil roller is placed on the side of the aged nonwoven fabric 30 to which the unleavened film 10 will be fastened. Another words, smooth side of the non-aged nonwoven fabric 30 will hold the non-aged film 10, which results in a better union of the two layers together.

When the non-aged film 10 and the non-aged woven fabric 30 are joined again from the use of heat and / or pressure, the rolling means 58 such as the rolling mills can be used. As with the nip rollers 56, the laminating rollers 58 can be heated and the thermal stitch joint can be used. The temperature at which the laminating rolls are heated is in the range of 93-135 ° At least one of the rolls may have a pattern for creating a discrete bonding pattern with an uni surface area prescribed for the resulting laminate. Generally, the maximum junction surface area for a given area of surface on one side of laminate 32 will not exceed about 50 percent of the total surface area. There are a number of discrete union patterns which can be used. See, for example, United States of America Patent No. 4,041,203 issued to Brock et al.

The "thermal point joint" involves passing fabric or a non-woven fabric of fibers to be joined in a heated calender roll and an anvil roll. The calendering roller has a pattern in some way so that the entire nonwoven fabric is not bonded across the entire surface. Many patterns for the cramped rollers have been developed for functional reasons as well as aesthetics. As it will be understood by those experts in the art, the percentages of joint area are, of necessity, described ranges or approximations since the union bolts are normally used and wear out over time. Co will recognize those skilled in the art, the references "square inch bolts" and "joints per square inch are somewhat interchangeable since the anvil bolts create joints in the substrate in essentially the same sizes and the same surface ratio as the bolts above the yunqu An example of a pattern has dots and is the pattern of Hans PENNINGS O "H &P "with about 200 unions / per square flea as taught in U.S. Patent No. 3,855,046 issued to Hansen and Pennings.Parent Hansen and Pennings have bolt or square punctures in where each bolt can have a lateral dimension of 0.965 millimeters, for example, resulting in a pattern that has a joint area of about 30 percent Another typical knit uni pattern is the Hansen and Pennings union pattern expanded "H &P" which produces a joint area of about 15 percent to about 18 percent which can have a square bolt that has a side dimension of 0.94 millimeters, for example, and a bolt density of about 100 bolts per square inch. typical union point designates "714" has square point joining areas where each per can have a lateral dimension of 0.023 inches, for example for a united area of 15 percent to 20 percent and around 27 0 bolts / square inch. Other common patterns include "Ramish" diamond pattern with repetitive diamonds that have an area of union of 8 percent to 14 percent and 52 bolts per square inch, an HHD pattern which includes point joints that have about 400 bolts per square inch. a joint area of about 15 percent around 23 percent, as well as a pattern of wire weave that is as its name suggests, like a window grate and has a joined area of 15 percent to 20 percent and 302 units per inch square Another bonding pattern for a spunbond ac fabric is an "S" weave pattern as described in the United States patent application of America granted series No. 929,808 filed on September 15, 1997 on behalf of McCormack, Fuqua, and Smith, and entitled "Non-woven union pattern that produces fabrics with improved abrasion resistance and strength" which is incorporated herein by reference in its entirety. Typically, the percent bond area varies from about 10 percent about 3 percent of the area of the non-woven fabric. Once the laminate 32 leaves the rolling rollers 58, it can be wound into a roll 60 for further processing. Alternatively, the laminate 32 can continue in line for further processing or conversion.

As will be explained in more detail below, surprising and unexpected improvement of the present invention lies in its increase in peel strength and hydro head which results in an advantage in converting the laminate into an article such as an absorbent article for personal care. A major disadvantage of current known laminates is the tendency to laminate before or during conversion. Such delamination results in several problems with commercial production as well as with the increase of waste products. As one with an ordinary skill in the art, an increase in either the peel strength or the hydrocabe usually results in a decrease in another property. An advantage of the present invention lies in that the peel strength and the hydro head are increased at the same time. In addition, the process shown in FIG. 1 can be used to create a laminate in addition to two layers. The previously described process can be modified to provide supply 16 of a second aged non-woven fabric 30 'in front of the laminating rollers 58 on one side of the film 10 which is opposite that of the other non-aged non-woven fabric 30. It is also It contemplates by the present invention the formation of a second non-woven fabric n ned directly in the continuous process line as written above for the aged non-woven fabric 30. Such three laminated layers are particularly useful in industrial medical protective garment applications. Similarly, other aged or aged film layers can be combined.

As previously stated, the laminate can be used in a wide variety of applications, the menu of which includes as a component of absorbent articles for personal use such as diapers, underpants learning, incontinence devices and products for women's hygiene such as sanitary napkins. An example article 80 in this case a diaper is shown in the figure. Referring to Figure 4, most absorbent articles for personal care 80 include a liner or upper liquid permeable 82, a lower sheet or outer cover 84. and an absorbent core 86 positioned between and contained by the upper sheet 82 and the lower sheet 84. The articles 8 such as the diapers, may also include some type of fastening means 88 such as the adhesive fastening tapes or fasteners of the fastener type. Mechanical loop hook to keep l garment in place on the user.

The laminate 32 can be used to form various parts of the article including but not limited to the upper blade 82 and the lower blade 84. If the laminate is to be used as the upper blade 82, it is more likely to be perforated or otherwise will make it permeable to liquid When the laminate is used as a bottom sheet 84, it is usually advantageous to place the non-woven fabric facing away from the wearer. Furthermore, in such embodiments it may be possible to use the non-woven part of the laminate as the terry cloth of the hook-and-loop combination of the securing means 88.

Other uses for the woven fabric / film laminates according to the present invention include, but are not limited to surgical covers and gowns, cleaning cloths, barrier materials and articles of clothing or parts thereof including such articles as work clothes and lab coats.

The advantages and other features of the present invention are best illustrated by the following examples EXAMPLES The samples of the present invention were prepared as described below. The samples were then subjected to the following tests: Peeling test: in the peeling or delamination test a laminate was tested with respect to the amount of tension force required to pull and separate the film layer from the non-woven fabric layer. The values for peel strength were obtained using a cloth sample width of approximately 4 inches (cross machine direction) by 6 inches (machine direction) (102 x 1 millimeters) held between parallel clamps of 2 millimeters long (or jaws) and extending at a constant extension rate of 300j00 millimeters p minute. The masking tape or some other suitable material was applied to the side of the sample film to prevent the film from tearing and separating during the test. The masking cin was only on one side of laminate and contributes to the peel resistance of the sample. The sample was delaminated by hand by an amount sufficient to allow it to be held in a position usually at approximately 5 millimeters. The sample was seized, for example, in an Instron Model TM apparatus, available from Instron Corporation, 250 Washington Street, Canton, MA. 02021, or a Sintech tension tester available from Sintech, Inc. of P.O. Box 14226 of Researc Triangle Parí. North Carolina 27709-4226. The sample was then pulled and separated by a distance of 51 millimeters 180 ° apart and the average peel strength was recorded in grams.

Stress Test: The stress test measured resistance to breakage and elongation or tension of a fabric when subjected to a unidirectional tension. The results were expressed in grams at break and percentage of stretch before breaking. The upper numbers indicate a more stretchable and stronger fabric. term "peak load" means the maximum load or force expressed in units of weight, required to break or tear a sample in a stress test. The term "energy" means the total energy under a peak load against the elongation curve as expressed in units of length and weight. term "tension" or percentage of stretch "means increase in length of a sample during a stress test expressed as a percentage.The values for the peak load, energy and tension were obtained using a tea sample of 76 percent 52 millimeters, a handle width of millimeters, a measuring length of 3 inches (millimeters) and a constant extension rate of 12 inches p minute (300 millimeters per minute), where the full sample width was grasped in the clamps. was grasped, as for example, in an Instron 113 apparatus available from Instron Corporation, or an INTELLECT II Thwing-Albert apparatus available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, Pennsylvania 19154.

Ball burst; This test measures the resistance to bursting of textile fabrics that exhibit a high degree of final elongation and was carried out in accordance with AS D 3787-89. Burst strength is defined as the force or pressure required to break a textile fabric by stretching it with a force, applied at right angles to the fabric's plating under specific conditions. The pressure was generated by forcing a polished steel ball against the sample until the sample burst using a modified Instron voltage tester for the bolt burst test. The pressure was then recorded for the burst resistance in lbf (N) the sample was conditioned to unit balance for textile testing in a standard atmosphere as described in the ASTM Practice D 1776 test.

Breathing capacity: One measure of breathability of a fabric is the water vapor transmission rate (WVTR), which for sample materials calculated in accordance with the standard ASTM - E96-80. L circular samples that measured three inches (7.6 centimeters in diameter) are cut from each of the test materials. A sheet of CELGARED® 2500 from Celanese Separation Products Charlotte, North Carolina is used as a control sheet CELGAR 2500 and is a sheet of microporous polypropylene S prepared three samples of each material The test tray and a tray Vapometer number 60-1 distributed by the Thwing-Alber Instrument Company of Philadelphia Pennsylvania One hundred millimeters of water were poured into each Vapometer tray and the individual samples of the Test materials and control material were placed through the open top parts of the individual trays, the bolted flanges are tightened to form a seal along the edges of the trays leaving the associated test material or control material exposed. to the ambient atmosphere on a circle 6.5 centimeters in diameter that has an exposed area approximately e 33.17 square centimeters. The trays are placed in a forced air oven at 32 ° C for one hour equilibrium. The furnace is at a constant external temperature circulating through it to prevent the accumulation of water vapor inside. The suitable forced air furnace is for example, a Blue M Power-O-Matic furnace distributed by Bl M Electric Company of Blue Island, Illinois. After the balance is completed, the trays are removed from the horn and weighed and immediately returned to the oven. After hours, the trays are removed from the kiln and weighed again. The preliminary water vapor transmission rate values are calculated as follows: Water vapor transmission rate test (weight loss grams over 24 hours) x 315.5 grams / square meter / 24 hours.

The relative humidity inside the oven is not specifically controlled.

Under predetermined set conditions of 100 ° F (32 ° C) and ambient relative humidity, the water vapor transmission rate for the CELGARD® 2500 control is defined as being 5000 grams per square meter per hour. Accordingly, the control sample is run with each test and the preliminary test values are corrected for established conditions using the following equation: Water vapor transmission rate = (test water vapor transmission rate / control water vap transmission rate) x (5000 grams per square meter per hour).

Hydrohead: A measurement of the barrier properties of. Liquid from a cloth is the hydro head test. Hydrohead test determines the height of water (centimeters) that the fabric will support before a predetermined amount of liquid passes through it. A cloth with a higher hydro head reading indicates that it had a greater barrier to penetration of the liquid than a cloth with a lower hydro head. The hydro head test was carried out according to federal test standard 191, Method 551 using a Tex FX-3000 hydrostatic head tester test available from Mario Industries, Inc. P.O. Box. 1071 Conco North Carolina.

Standard deviation: The standard deviation c used in these examples represents a measure of the dispersion and measures the average distance between a single and a half observation. This is useful to understand how a variable game data can be. For example, the standard deviation can be used to allow one to predict failure rates and / or determine how much variability is acceptable in a finished product. For the examples as described below, forty and thirty samples of material were tested for each of the properties, twenty-two of the samples were tested from the edge of the laminated sheet to leave this one from the production line and twenty-two were taken from the center of the laminate. This number of samples represents a statistically significant sample size.

The formula used for the standard deviation was In the formula "n" is the observation number The use of n-l in the denominator instead of n more natural was used because if n (instead of n-l) were used, it would be estimated deviated from the population standard deviation. The u of n-l made the correction for that deviation with small sample sizes. The distance of each observation (xj calculated average (x-bar) provides the basis for measuring variability.The nearest of these observations are for average, the smallest of the standard deviation.If all observations are the same, the standard deviation The deviations are square to the average being the fulcr of the data (a point of balance between those observations greater than the average and those less than the average, these deviations were not square, the sum would be 0 the square root of the sum is then taken to obtain the return value in units of the original data.

The statistics are used here to compare the examples as noted below. The following is an explanation of the statistical analysis that was carried out for these examples. A formal method for making statistical interferences of samples to the population is through a hypothesis test. Statistical sample distributions provide a method to substantiate or disprove or hypothesize about group means. The t test is the most commonly used method for evaluating differences in media in two normally distributed groups. There are two tests available. The standard lowercase t test for independent samples is based on the assumption that the variations in the two groups are the same (homogeneous), and a stagnant standard deviation is used. If the variations of the two groups are widely different then the test with separate variation estimates is used. The equality of assumption of variations can be verified with the F test. F test is used to compare the variations of normal d populations by looking at the proportion of the sample variations. The null hypothesis is proof that variation 1 = variation 2 (or variation 1 / variation 2 = 1).

In the fundamental two-sample test, statistical hypothesis is that two means are (varl = var2). The alternative hypothesis is that there is a difference (varl-var2 < > 0). If the probability level is lower than at the chosen alpha level (0.05) you will reject the null hypothesis equal means and conclude that the means are different. level -p reported with the test t represents the probability error involved in the acceptance of our research hypothesis about the existence of a difference.

EXAMPLE 1 A laminate of a non-aged film and a non-aged non-woven fabric according to the present invention was prepared. The non-aged film was co-extruded as a three-layer structure, otherwise known as a film.

A / B / A /.

Layer "B" or the core layer was made up to 44.5 percent by weight of low density polyethylene line (LLDPE) available under the trade designation 3310 as manufactured by The Dow Chemical Company ("Dow"); 5.3 percent by weight of low density polyethylene (LDPE) available under the trade designation 4012 as manufactured by Dow; 5 percent by weight of calcium carbonate coated with behenyl acid available under the trade designation FilmLink®202 as manufactured by ECC International, Inc. of Sylacauga Alabama; and 2000 parts per million antioxidant available under the trade designation B900 as manufactured from the Cib Specialties Company of Tarrytown, New York.

The layer "A" otherwise known as outer skins, on opposite sides of the core layer made up to 50.4 percent by weight of ethylene vini acetate under the trade designation 768.36 as manufactured by Exxon Chemical Company of Houston Texas; 49.1 percent catalloy under the trade designation KS 357P as manufactured by Montell USA Incorporated of Wilmington, Delawar and 5000 parts per million of antioxidant available under the trade designation B900 as manufactured by Ciba Specialti Company.

The three-layer film was cold-set extruded as described above and to conditions as described below. The melt-out temperature for the skin layers measured, as being approximately 185 ° C and for the core f of approximately 215 ° C. C. The skin layers comprise approximately: 5 percent by weight of the total film composition.

CONDITIONS OF FILM PROCESSING BW means base weight The film was passed through a directional machine direction (MDO) that has seven rollers under the conditions tabulated below. The final film pull f defined, the ratio of the speed of the last roller first roller. The film was stretched 3.5 X and the resulting stretched film had a basis weight after stretching 0.54 ounces per square yard. By saying that the film was stretched XXX that means that as, for example, u length of a meter of films would be stretched to a length of one meter of film would be stretched to a resultant length of 3 meters.

CONDITIONS OF ORIENTER PROCESS AT THE ADDRESS OF THE MACHINE The non-aged non-woven fabric was prepared from a spin-bonding process as described above using a two woven fabric forming apparatus as shown in Figure 1. The non-woven fabric was formed from a polypropylene having a flow cup. of melt (MFR) of 38 available under the trade designation E5D47 as manufactured by Union Carbid Corporation of Danbury, Connecticut and 2 percent by weight titanium dioxide concentrate available from Standridge Col Corporation of Social Circle, Georgia. The fibers are extruded through two extruders and the two banks are pulled down to an average diameter of 15-20 microns and deposited under the forming wire. The speed of the forming wire f adjusted to result in a non-woven fabric having a basis weight of 17 grams per square meter which was then knitted thermally through pattern wire-bonding rolls and heated to 157 °. C.

The non-aged non-woven fabric was then carried under the orienter in the machine direction to laminate the non-aged and stretched film using rolling mills with star pattern in C and one of anvil in heat and pressure conditions, with the lamination conditions (61,800N / M) the top anvil rolling rolls au temperature of 104.4 ° C and the laminating rollers with lower patr at a temperature of 137.8 ° C.

The non-aged and stretched film was immediately laminated to the unwoven non-woven fabric within less than 50 seconds of being made. The laminate was passed through the rolling rolls in such a manner that the spun bonded layer was adjacent to the patterned roll and the film layer subjacent to the smooth anvil roll. A statistically significant sample group was tested and the properties shown in tables IA and IB. Unless otherwise noted, the basis weight of the following numbered tables represent the basis weight of the laminate.

EXAMPLE 2 A laminate of a non-aged film and a non-aged nonwoven fabric was prepared as described above for example 1 with the following different process conditions.

CONDITIONS OF ORIENTER PROCESS IN THE DIRECTION FROM THE MACHINE Final film pull ratio was 3.23 AMINATION CONDITIONS A sample group statistically significant f tested and the properties are shown in tables 2a and 2b.

COMPARATIVE EXAMPLE A laminate of an aged film and a non-aged non-woven fabric was prepared. The film was constructed as an A / B / A film as described below and was manufactured by Huntsma Packaging Company of Salt Lake City, Utah.

Layer "B" was made from the same composition as d Example 1. Layers "A" were made essentially the same as in Example 1 except that 45.1 percent by weight d was used together with 4 percent by weight of diatomaceous earth. Superfloss® registered trademark is available from Celite Corporation of Lompoc, California. The foot layer comprises approximately 3.3 percent by weight of the total film composition.

The aged film was left to age for four days storage.

The aged film was then oriented in the direction of the conventional machine manufactured by Marshall and Williams Company, under the following conditions: CONDITIONS OF ORIENTING PROCESSING IN THE DIRECTORATE OF L MACHINE The final film pulling rate was 44 x.

A non-aged non-woven fabric bonded with spinning the cu was made from the same composition as in Example 1 was then laminated to the aged film under the following conditions CONDITIONS OF LAMINATION A group of statistically significant samples and probo properties are shown in tables 3a and 3b.

Conclusions The tables were created summarizing the statistical analysis of these aforementioned property tables as can be seen in tables 4a and 4b.

The data show an unexpectedly improved sweep performance and a rolling resistance in both examples of the invention for both peel and hydro head resistance, respectively, compared to the d-step process (comparative example). Contrary to popular belief, which prescribes that there is a commitment to one of these properties (hydro head and peeling) if an increase in ownership is found, the process of the present invention produces material having improvements in both properties simultaneously. This is extremely desirable in articles produced in the products of this invention.

Additionally, the process also produces materials which are strong enough to be used in the product as described herein which have been demonstrated by a sufficient tensile strength and bursting properties of the ball. Seeing therefore described the invention in detail it should be evident that various modifications can be made in the present invention without departing from the spirit and scope of the following claims.

Claims (30)

1. A continuous online process to prepare laminate that includes the steps of: a) form a movie, while; b) forming a non-woven fabric afterwards; c) immediately joining said film and said woven fabric to form a laminate.

2. The process, as claimed in clause 1, characterized in that said forming of the film comprises the extrusion of the set film or the extrusion of the blown film.

3. The process, as claimed in clause 1, characterized in that said formation of the film comprises the cold setting extrusion.

4. The process, as claimed in the clause 1, characterized in that said formation of the film results in a maximum film thickness of less than about 12 microns

5. The process, as claimed in clause 1, characterized in that said formation of the non-woven fabric comprises the formation of one or more types of fiber selected from the group comprising fibers joined with spinning and blow molding.

6. The process, as claimed in clause 1, characterized in that said formation of the non-woven fabric comprises the joining of the fibers of said non-woven fabric.

7. The process, as claimed in clause 1, characterized in that said joining of said film and said non-woven fabric occurs within 1-60 seconds of said formation of said film and said forming of said non-woven fabric.

8. The process, as claimed in clause 1, characterized in that the joining of said film and said non-woven fabric comprises the thermal bonding.

9. The process, as claimed in clause 1, characterized in that the overall process efficiency is at least about 70 percent.

10. The process, as claimed in clause 1, characterized in that said laminate has a greater peel strength and higher hydroheap values and similar laminates constructed of aged materials.

11. A continuous online process for preparing laminate comprising the steps of: a) form a film, then; b) immediately stretch said film to make it able to breathe, while; c) a non-woven fabric is formed after; d) immediately joining said film with breathable capacity and said non-woven fabric to form a laminate.

12. The process, as claimed in clause 11, characterized in that said film formation with capacity to breathe comprises the extrusion of the cured film or the extrusion of the blown film.

13. The process, as claimed in clause 11, characterized in that said formation of the film with capacity to breathe comprises the extrusion of cold forge.

14. The process, as claimed in clause 11, characterized in that said stretch of said film comprises pulling said film by more than 1.00 to about 4.08 times its original length.

15. The process, as claimed in clause 14, characterized in that the magnitude of said stretch of said film required to make the film capable of breathing is reduced compared to the amount of stretching required to make a similar film with a capacity to breathe. .

16. The process, as claimed in clause 15, characterized in that said reduced magnitude said stretching of said film required to make said film results in higher rates and performances during said stretch of said film than during stretching required to make a similar aged film. with ability to breathe.

17. The process, as claimed in clause 11, characterized in that said stretching of said film results in a maximum film thickness of less than about 12 microns.

18. The process, as claimed in clause 11, characterized in that said formation of the woven fabric comprises the formation of one or more types of fibr selected from a group comprising coiled and meltblown fibers.

19. The process, as claimed in clause, characterized in that said formation of the woven fabric comprises the joining of the fibers of said non-woven fabric

20. The process, as claimed in clause 11, characterized in that said union of said breathable film and of the non-woven fabric takes place within 1-60 seconds of said formation of the film with a capacity to breathe and of said formation simultaneously of said woven fabric.

21. The process, as claimed in clause 11, characterized in that said attachment of said breathable film of said non-woven fabric comprises thermal bonding.

22. The process, as claimed in clause 11, characterized in that the overall process efficiency is at least about 70 percent.

23. The process, as claimed in clause 11, characterized in that said laminate has a greater peel strength and higher hydrohead values than similar laminates constructed from aged materials.

24. A laminate prepared through a continuous online process, whose steps include: a) forming a film, while, b) forming a non-woven fabric, then; c) immediately joining said film and said woven fabric to form a laminate.

25. The laminate, as claimed in clause 23, characterized in that said film has a capacity to breathe.

26. The laminate, as claimed in clause 23, characterized in that said non-woven fabric comprises one or more types of fibers selected from the group comprising fibers joined with spinning and blown with fusion.

27. The laminate, as claimed in clause 23, characterized in that said film and said woven fabric comprises poleolefins.

28. The laminate, as claimed in clause 23, characterized in that said woven film and said woven fabric are thermally bonded together.

29. The laminate, as claimed in clause 23, characterized in that said laminate has a greater peel strength and higher hydrohead values than similar laminates constructed of aged materials.

30. An absorbent article comprising a liquid permeable for, a liquid impermeable outer cover, and an absorbent core placed therebetween, wherein at least one outer shell impervious to the liquid and the liquid permeable liner comprises in a laminate agreement in the clause 2. 3.