MXPA05005010A

MXPA05005010A - Extensible laminate of nonwoven and elastomeric materials and process for making the same.

Info

Publication number: MXPA05005010A
Application number: MXPA05005010A
Authority: MX
Inventors: Warren Collier Leslie Iv
Original assignee: Kimberly Clark Co
Priority date: 2002-11-27
Filing date: 2003-07-24
Publication date: 2005-08-02
Also published as: US20040102125A1; KR20050086535A; BR0316276A; CN1694804A; WO2004050348A1; AU2003256685A1; EP1567329A1

Abstract

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

Description

WO 2004/050348 Al ??????????????????? European patent (AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HU, IE, IT, LU, MC, NL, PT, RO, SE, SI , SK, TR), OAPI patent (BF, BJ, CF, CG, CI, CM, no ofeach regular issue oftke PCI Gazette. GA, GN, GQ, GW, ML, MR, NE, SN, TD, TG). Published: - with intemational search repon 1 EXTENDABLE LAMINATE OF ELASTOMERIC AND NON-WOVEN MATERIALS AND PROCESS TO DO THE SAME Field of the Invention This invention is directed to the laminates of extensible nonwoven material and elastomeric material which are joined using the intermittent adhesive bonds and the thermal point bonds where the adhesive bonds cover a greater percentage of an interfacial plane between the tensile nonwoven material and the elastomeric material that the thermal bonds. The resulting extensible laminates exhibit increased elasticity in the transverse direction as compared to laminates in which the elastomeric material is completely bonded to the extensible nonwoven material. Additionally, the resulting laminates exhibit desirable surface aesthetics due to the pattern created by the thermal bonding points. A process to make the extensible laminates that provide more flexibility in the manufacturing process is also desired.

Background of the Invention Compounds of elastic and non-elastic material have been made by attaching the elastic material to the non-elastic material in a manner that allows the entire composite to stretch or elongate. Frequently these compounds are used in garment materials, pads, diapers, adult incontinence products and women's care products. A laminate or composite includes an expandable nonwoven material that has been bonded to an elastomeric sheet.

The ability of these laminates to stretch and recover is affected by the level of attachment or clamping between the elastomeric sheet and the expandable nonwoven material. Generally, the greater the level of clamping between the elastomeric sheet and the extensible nonwoven material, the greater the extension force and permanent settling, and the ratio of extension force / retraction force of the laminate will be lower. However, the level of bond between the non-woven material and the elastomeric sheet must be sufficient to provide internal cohesion to the laminate so that the layers do not peel off or separate from each other during use.

The layers of the laminate can be joined together using a variety of techniques including thermal bonding, adhesive bonding and point bonding which can also be thermal. Thermal bonding techniques include extruding a melted elastomeric material in the form of a film onto the expandable nonwoven fabric. The film and the nonwoven material are then smooth calendered to join the two layers together. Thermal bonding techniques also include passing a set elastomeric film or meltblown elastomeric fabric and a nonwoven fabric expandable through the smooth and heated calender rolls to affect bonding. However, in both cases, the elastomeric material is completely bonded in an essential way to the non-woven thus increasing the extension force and settling and decreasing the ratio of extension force / retraction force. Additionally, in the techniques of thermal bonding, great care must be taken not to overheat the laminates during the extrusion and / or calendering processes. Overheating can result in the degradation and / or melting of both the elastomeric material and the extendable nonwoven material causing defects in the laminate and the failure of the laminate during use.

Adhesive bonding techniques achieve similar results. Generally, an adhesive, typically a hot melt or melt type adhesive or a pressure sensitive adhesive, is applied to a surface of either an elastomeric sheet or an extensible nonwoven. The layers are then calendered to achieve bonding. The layers of the resulting laminate can be fully clamped or can be selectively bonded together.

Point joining techniques, which can be thermal, can also be used to join the layers of the laminate. Point joining techniques generally involve the mechanical forcing of parts of a layer in other areas of a second layer so that the parts of the first layer are trapped in the second layer thereby joining the layers together. Desirably, the production of the expandable nonwoven composites, the elastomeric material is in a melted or almost melted state in order to achieve effective bonding between the layers of the material. The elastomeric material can also be softened by heating the pattern and / or smooth calendering roller. An example of a process for bonding a non-woven material to an elastomeric sheet is described in U.S. Patent No. 6,001,460 issued to Morman et al., The disclosure of which is incorporated herein by reference.

Of the joining techniques typically used to join the layers of extensible laminates, the point bonding creates the most aesthetically desirable surface pattern, as well as the functional fastening between the layers. Frequently, the surface appearance, in addition to the performance characteristics, of a laminate is a key factor that drives consumer preference for one product over another. However, bonding techniques rely on heating to effect bonding and have limited flexibility in terms of production speeds and the types of materials that can be used in the individual layers.

The adhesive bond provides greater flexibility in the manufacturing process because a wide variety of of adhesives, such as, for example, elastic, elastomeric, pressure sensitive, meltblown or hot melt adhesives, can be used to bond a greater variety of materials. Additionally, adhesive bonding can be more cost effective and less process and material limiting than thermal bonding. In addition, adhesives can be applied in a wide variety of patterns capable of mimicking knit patterns without the use of costly calendering or engraving rolls. This feature also makes it possible to change the bonding pattern of adhesive rapidly during production so that different patterns and / or levels of adhesive bonding coverage can be achieved during a single production run.

With the foregoing in mind, there is a need or desire for an extensible laminate having improved elastic properties and having an aesthetically desirable surface pattern.

It is a feature and an advantage of the invention to provide an extensible laminate that can be produced at a higher speed and with greater flexibility. It is also a feature and advantage of the invention to provide an extensible laminate that can be produced without thermally degrading and / or melting the non-woven fabric. 6 Definitions The term "extensible" refers to a material that can be stretched without breaking by at least 50% (at least 150% of its initial unstretched length) in at least one direction, suitably at least 100% ( at least 200% of its initial unstretched length). For example, an extensible material having an initial unstretched length of 3 inches can be stretched without breaking it to a stretched length of at least 4.5 inches in at least one direction. The term includes elastic materials as well as materials that stretch but do not significantly retract such as, for example, narrowed nonwoven materials and inherently extensible nonwoven materials such as carded and bonded fabrics.

As used herein, the terms "elastic" and "elastomeric" mean a material which with the application of a pressing force is stretchable to a pressed and stretched length that is at least about 150 percent of its undrawn length and relaxed, and which will recover at least 55 percent of its extension with the release of the pressing and stretching force within about a minute.

As used herein, the term "recover" refers to a contraction of a stretched material with the termination of a pressing force after stretching of the material by application of the pressing force. For example, if a material that has an unpressed and relaxed width of one inch is extended 50 percent in its transverse direction by stretching it to a width of 1.5 inches, that material will be spread 50 percent (0.5 inches) and will have a Stretched width that is 150 percent of its relaxed width. If this exemplary stretched material is relaxed and has recovered to a width of 1.1 inches after the release of the pressing and stretching force, the material will have recovered 80 percent (0.4 inches) of its 0.5-inch extension. The recovery can be expressed as [(a maximum stretched dimension minus the final sample dimension) / (maximizing the stretch dimension minus the initial sample dimension)] X 100.

The term "biaxially extensible" refers to a material that can be stretched by at least about 50 percent in two directions perpendicular to one another (eg stretchable in one direction of the machine and in the transverse direction, or in one direction). longitudinal direction, front to back, and in a lateral direction, side by side The term includes biaxially extensible laminates such as those described in for example, United States of America patents 5,114,781 and 5,116,662 issued to Morman which are incorporated here for reference. 8 As used herein, the term "machine direction" or "D" means the length of a material in the direction in which it is produced. The term "transverse direction" or "CD" means the width of a material (for example an address generally perpendicular to the machine direction).

As used herein, the term "polymer" generally includes, but is not limited to homopolymers, copolymers, such as, for example, block, random graft and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. same. In addition, unless specifically limited otherwise, the term "polymer" will include all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

As used herein, the terms "elastomeric sheet" and "elastomeric fabric" refer to elastomeric films formed by extrusion, setting or other methods known in the art as well as elastomeric non-woven fabrics, such as, for example, elastomeric fabrics. blown with fusion as described in U.S. Patent No. 4,663,220 issued to isneski et al., which is incorporated by reference, and elastomeric foams.

As used herein, the term "metallocene" refers to polyolefins produced by the metallocene-catalyzed polymerization reactions. Such catalysts are reported in the book "Metallocene Catalysts Start a New Era in Polymer Synthesis", by Ann M. Thayer, Chemical and Engineering News, September 11, 1995, page 15.

As used herein, the term "non-woven fabric" or "non-woven material" means a material having a structure of individual fibers or yarns which are interleaved but not in a repetitive and identifiable manner. Non-woven materials or fabrics have been formed by a variety of processes such as, for example, meltblowing processes, spinning processes, air laying processes, co-forming processes and processes woven carded and united.

As used herein, the term "film side" when referring to a non-woven fabric or a non-woven material means a surface of the fabric or non-woven material that can be attached, attached or attached to an elastomeric sheet to form a laminate. The term "fabric side" when referring to a non-woven material or fabric means a surface opposite to the side of the film.

As used herein, the term "microfibers" means small diameter fibers having an average diameter of no more than about 100 microns, for example, having a diameter of from about 0.5 microns to about 50 microns, more specifically microfibers which may also have an average diameter of from about 4 microns to about 40 microns.

As used herein, the term "carded and bonded fabric" refers to fabrics that are made of short fibers which are sent through a combing or carding unit, which separates or breaks and aligns the short fibers in the fabric. direction of the machine to form a fibrous nonwoven fabric oriented in the direction of the machine generally. Such fibers are usually purchased in bales which are placed in a mixer / opener or collector which separates the fibers before the carding unit. Once the tissue is formed, it is then joined by one or more of the various known joining methods. One such joining method is a powder binding wherein a powder adhesive is distributed through the fabric and then is usually activated by heating the fabric and the adhesive with hot air. Another suitable joining method is pattern bonding where heated calendering rolls or ultrasonic bonding equipment are used to join the fibers together, usually in a localized bonding pattern, even when the fabric can be bonded through its full surface if desired. 11 Another suitable and well-known joining method, particularly when short bicomponent fibers are used, is the bonding via air.

As used herein, the term "meltblown fibers" means fibers formed by extruding a molten thermoplastic material through a plurality of capillary matrix vessels, usually circular and thin as melted threads or filaments in a gas stream (for example of air) at high speed which attenuates the filaments of melted thermoplastic material to reduce their diameters, which can be to a microfiber diameter. Then, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a meltblown and randomly dispersed fiber fabric. Such a process is described, for example, in US Pat. No. 3,849,241 issued to Butin, the disclosure of which is incorporated herein by reference.

As used herein, the term "spunbond fibers" refers to fibers of small diameter which are formed by extruding a melted thermoplastic material as filaments from a plurality of fine capillary vessels, usually circular in a spin organ with the diameter of the extruded filaments then being rapidly reduced, for example, by eductive pulling or other well-known spinning mechanism. The production of the non-woven fabrics bonded with yarn is illustrated in the patents such as, for example, United States of America patents number 4,340,563 granted to Appel et al., And 3,692,618 issued to Dorschner et al. The descriptions of these patents are incorporated herein by reference.

As used herein, the term "interfiber bonding" means the bond produced by the thermal or entangled bond between the individual nonwoven fibers to form a coherent fabric structure. Fiber entanglement is inherent in the meltblowing process but can be generated or augmented by such processes, for example, hydraulic entanglement or piercing with needles. One or more thermal bonding steps are employed in most processes to form the fabrics bonded with spinning. Alternatively and / or additionally, a binding agent can be used to increase the desired bond and to maintain the structural coherence of the fabric. For example, powder binding agents and chemical solvent binding can be used.

As used, the term "inherently extensible nonwoven material" refers to a nonwoven material that can be stretched at least 50 percent in at least one direction without additional processing such as creping or creping. 13 As used herein, the term "constricted material" refers to any material that is restricted in at least one dimension by processes such as, for example, pulling or gathering.

As used herein, the term "narrowable material" means any material which can be narrowed.

As used herein, the term "reversibly constricted material" refers to a narrowed material that has been treated while being tapered to impart memory to the material so that, when a force is applied to extend the material to its pre-stretched dimensions, the narrowed and treated parts will generally recover to their narrowed dimensions upon termination of the force. One form of treatment is the application of heat. Generally speaking, the extent of the reversibly constricted material is essentially limited to the extent of its pre-narrowed dimensions. Therefore, unless the material is elastic, extension too far beyond its pre-stretched dimensions will result in material failure. A reversibly constricted material may include more than one layer, for example multiple layers of a spunbonded fabric, multiple layers of a meltblown fabric, multiple layers of a carded and bonded fabric or any other suitable combination or mixtures thereof. , as described in U.S. Patent No. 4,965,122 issued to Morman, which is incorporated herein by reference.

As used herein, the term "down-tapering percent" refers to the ratio determined by measuring the difference between the pre-narrowed dimension (width) and the narrowed (wide) dimension of a narrowable material and then dividing the difference by the pre-narrowed dimension of the narrow material X 100.

As used herein, the term "extensible laminate" refers to a material having an elastomeric sheet bonded to a material expandable in at least two locations (e.g., a single-side extensible laminate). The elastomeric sheet can be attached to the extension material at intermittent points or can be completely attached thereto. The joint is achieved while the elastomeric sheet and the extensible material are in a juxtaposed configuration. An extendable laminate may include more than two planes. For example, the elastomeric sheet may have an extensible material attached to both of its sides so that a three-layer extensible laminate is formed having a structure of extensible material / sheet material / extensible material (eg a two-sided extensible laminate). ). Additional elastic or elastomeric sheets, layers of constricted material 15, and / or inherently extensible materials such as carded and bonded fabrics may be added. Other combinations of elastomeric sheets and extensible materials may be used, for example as indicated in United States of America patents jointly assigned numbers 5,114,781 and 5,116,662 issued to Morman and 5,336,545 issued to Morman et al., Which is incorporated herein by reference.

As used herein, the term "interfacial plane" refers to a two-dimensional plane defined by the width dimension and the length dimension of a laminate between two adjacent sheets, fabrics or layers of a single-face or extendable laminate. a two-dimensional plane defined by the width dimension and the length dimension of a laminate between the two outer sheets, the fabrics or the layers of a two-sided extendable laminate including three or more sheets, fabrics or layers.

As used herein, the term "cycling test" refers to a method, using a constant extension cup tension tester, such as, for example, the Sintech 2 apparatus, Model 3397-139, available from Sintech Corporation, Cary, North Carolina, to determine the level of elasticity in the transverse direction of an extensible laminate. Specifically, a sample of an extensible material is cut to a dimension of 4.5 by 3 inches, the 4.5 inches 16 being in the transverse direction. The 3-inch-long sample is gripped between two pneumatic jaws so that the measurement length (jaw spacing) is 2 inches, and the pulling direction is in the transverse direction. The pulling speed is 20 inches per minute. The test is done during two extension / retraction cycles. The sample is first pulled at 100% elongation (jaw spacing of 4 inches) and is immediately returned (retracted) to the starting measurement length. The extension-retraction cycle is then repeated. Finally, the sample is pulled to an extension where it breaks, at which time the test stops. Strength and extension are measured by an appropriate load cell and other sensors. The data is recorded and analyzed by a computer program. The samples are characterized by the load (force) measured at an elongation of 30% during the first cycle extension cycle (pulled) and the load at 30% elongation during the second cycle retraction mode. The elasticity measurement is reported as a ratio of retraction force to extension force.

As used herein, the terms "transverse direction elasticity" and "elasticity measurement" refer to the ratio between the retraction force and the extension force as determined by the cycle test.

As used herein, the terms "binding coverage" and "binding coverage percent" refer to the amount of the interfacial plane that is covered by intermittent adhesive bonds and / or thermal junctions.

As used herein, the terms "intermittent joints" or "intermittent joint" refer to discrete areas of clamping between two or more layers of material. The layers in the area surrounding the intermittent joints remain essentially not clamped together allowing independent movement of each of the layers.

As the term was used herein, "intermittent adhesive bonds" refers to the intermittent joints formed by applying a discontinuous or random pattern of adhesive to parts of a first sheet of material, film or fibrous material and passing the first sheet and the second sheet of the fabric, film or fibrous material through a pressure point between the two pressure point rollers so that the parts of the first sheet are selectively adhered to the areas of the second sheet. The level of intermittent adhesive bonding coverage is determined at least on the part of the amount of adhesive applied and the pattern of application.

As used herein, the term "thermal point junctions" refers to intermittent joints formed through the use of heat and / or pressure. For example, thermal bonding points 18 can be formed by using a patterned calendering roll and heated to the thrust portions of a first sheet of cloth, film or fibrous material in a second sheet of cloth, film or material fibrous so that the parts of the second sheet encapsulate areas of the first sheet and join thereto. Alternatively, the point-junctions can be formed by the use of a patterned ultrasonic horn to create localized areas of heat so that when the materials to be joined are passed between the ultrasonic connecting horn and the anvil of Ultrasonic bonding The combination of heat and pressure forms discrete joints between materials. Thermal point junctions can have a variety of shapes. Thermal point junctions may appear as discrete points that are, for example, circular or electrical, or that may appear as stars, animals, line segments, or other shapes. Various thermal point joining shapes can be combined to create thermal point joining patterns such as, for example, H & P and amisch wire weave patterns. The level of thermal point junction coverage is determined at least in part by the size and number of the thermal point junctions.

As used herein, the terms "selectively" embrace the terms "only" and "to a great extent." 19 As agui was used, the term "consisting essentially of" does not exclude the presence of additional materials or process steps which do not significantly affect the desired characteristics of a product composition. Exemplary materials of this class will include, without limitation, pigments, antioxidants, stabilizers, surfactants, waxes, flow promoters, solvents, particles and aggregates to improve the processing of the composition.

As used herein, the term "comprising" opens the claim to the inclusion of additional materials or additional process steps than those recited above.

These terms can be defined with additional language in the remaining parts of the description.

Synthesis of the Invention The present invention is directed to extensible laminates having improved elastic properties in the transverse direction. The extensible laminate includes both intermittent adhesive bonds and thermal point bonds with non-clamping regions therebetween. The non-clamping regions between the joints preserve the independent movement of the layers of the laminate thus maximizing the elastic properties of the extensible laminate 20. Desirably, the extensible laminates have an elasticity measurement of more than about 0.22 ratio of extension force / retraction force. By using both the intermittent adhesive joints and the thermal point joints, the stretch laminate having a desirable surface aesthetics can be produced faster while the peel strength and internal cohesion are maintained.

In an embodiment of the present invention, an extensible laminate includes a sheet of an extensible nonwoven material, a sheet of an elastomeric material and an adhesive. The adhesive is applied to at least a portion of a film side of the extensible nonwoven material so that the extensible nonwoven material is selectively held to the elastomeric sheet by a plurality of intermittent adhesive bonds. The extendable nonwoven material is further selectively fastened to the elastomeric sheet by a plurality of thermal point seams so that the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the extendable nonwoven material and the elastomeric sheet than the seams. of thermal point.

In another embodiment, an extensible laminate includes a first sheet of an extensible nonwoven material, a second sheet of an extensible nonwoven material and a sheet of an elastomeric material placed between the first and second sheets of extensible nonwoven material. An adhesive is applied to at least a part of the film side of the first sheet of extendable nonwoven material and / or of the second sheet of extendable nonwoven material so that the first sheet and / or the second sheet of the material Expandable nonwoven is selectively bonded to the sheet of elastomeric material by a plurality of intermittent adhesive bonds. The first and / or the second sheet of extendable nonwoven material is further selectively fastened to the sheet of elastomeric material by one. plurality of thermal point junctions, such that the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the first and second sheets of a narrowed nonwoven material than the thermal point joints. Desirably, at least about 50 percent of the interfacial plane is free from both the thermal dot and the intermittent adhesive joints.

A process for making an extensible laminate includes the steps of: providing a fabric of an extensible nonwoven material; provide a fabric of an elastomeric material; applying an adhesive in a discontinuous or random pattern to at least a portion of a film side of an expandable non-woven fabric; selectively fastening the non-woven fabric expandable to the elastomeric fabric by a plurality of intermittent adhesive bonds; and selectively securing the expandable non-woven fabric to the elastomeric fabric by a plurality of thermal point seams, whereby the intermittent adhesive seams 22 cover a greater percentage of an interfacial plane between the expandable non-woven fabric and the elastomeric fabric than the seams of thermal point.

In another embodiment, a process for making an extensible laminate includes the steps of: providing the first fabric of an expandable nonwoven material having one side to the film and one side to the fabric; applying an adhesive in a discontinuous pattern to the side of the film of the first stretch non-woven material; provide a fabric of an elastomeric material; selectively holding the first nonwoven fabric extendable to the elastomeric fabric by a plurality of intermittent adhesive bonds; providing a second fabric of extendable nonwoven material; and selectively bonding the second non-woven fabric extendable to the elastomeric fabric by a plurality of thermal point junctions, whereby the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the first and second tissues of the material that has not been extensible than the fibers. thermal point junctions.

Brief Description of the Drawings Figure 1 is a detailed view of a single-side extensible laminate of the present invention.

Figure 2 is a detailed view of an intermittent adhesive bonding pattern. 2. 3 Figure 3 is a detailed view of a thermal point attachment pattern.

Figure 4 is a detailed view of an intermittent adhesive and the thermal point attachment pattern.

Figures 5 and 6 are detailed views of two extendable two-sided laminates of the present invention.

Figures 7, 8 and 9 are schematic views of a process for making the extensible laminates of the present invention.

Description of Preferred Additions The present invention provides an extensible laminate having areas of discrete intermittent joints and areas of non-union between the layers. Both intermittent adhesive joints and thermal point joints are used to selectively clamp one or more of the extensible layers to an elastomeric layer. Intermittent adhesive bonds, however, cover a greater percentage of an interfacial plane between the expandable nonwoven layer and the elastomeric layer than the thermal point junctions. The thermal spot joints impart an aesthetically desirable pattern to the surface of the laminate. It also provides a process to make the laminate extensible.

The use of the intermittent adhesive joints in combination with the thermal point joints provide both greater flexibility properties in manufacturing and an improved cross directional stretch. The thermal point joint has been found to be an effective means for joining the individual layers of an extensible laminate having extension in the transverse direction. However, at commercial production speeds, heated calendered calender rolls need to be heated to a higher temperature in order to produce the necessary level of bonding. Unfortunately, the higher temperature detrimentally impacts the softness and fluffiness of the tensile non-woven layers resulting in a less desirable stretch laminate.

It has been found that higher production speeds can be achieved without detrimentally affecting the extendable laminate. By using both the intermittent adhesive joints and the thermal point joints, the heated calendered pattern rolls can be maintained at a temperature that does not destroy or degrade the non-woven extensible layers while the desired peel strength and internal cohesion of the resultant extensible laminate are maintained because the intermittent adhesive bonds complement the thermal point junctions.

Generally, intermittent interfacial adhesive bonds should cover at least 5 percent more of the total interfacial plane than interfacial thermal junctions. For example, if the thermal spot junctions cover 20 percent of the flat area between the film and the non-woven layer, the intermittent adhesive bonds must cover at least 25 percent of the interfacial plane. Suitably, the intermittent adhesive joints must cover at least 10 percent more of the interfacial plane than the thermal point junctions. By "interfacial junctions" we mean only the joints between the layers excluding the joints between fibers in the non-woven fabric.

In one embodiment, shown in Figure 1, an extensible laminate 10 includes a first sheet of an expandable nonwoven material 12 and a second sheet of an elastomeric material 14. The expandable nonwoven sheet 12 has a side of the film 15 oriented towards the elastomeric sheet 14 and one side to the fabric 18. An adhesive is applied to at least a side portion to the film 16 of the expandable non-woven sheet 12 so that the plurality of intermittent adhesive bonds 20 selectively bonds the sheet non-stretch fabric 12 to the elastomeric sheet 14. The expandable non-woven sheet 12 is further selectively clamped to the elastomeric sheet 26 by a plurality of thermal point joints 24. The intermittent adhesive bonds 20 cover a greater percentage of an interfacial plane 22 between the expandable non-woven sheet 12 and the elastomeric sheet 14 than the thermal knit joints 24. The intermittent adhesive bonds 20 may coincide with the joints of thermal point 24, but such a coincidence is not essential.

The extensible laminate has an extension in the transverse direction due to the influence of the extensible nonwoven material. When the extension force in the transverse direction is removed, the laminate will essentially return to its fabricated configuration due to the influence of the elastomeric material. As shown in Figure 1, the expandable non-woven sheet 12 is essentially unattached to the elastomeric sheet 14 in portions of the interfacial plane 22 not covered by the intermittent adhesive bonds 20 and / or the thermal spot junctions 24. As a result, the laminate has improved transverse direction elasticity due to the independence of the movement of the extensible nonwoven sheet 12 and the elastomeric sheet 14 between the point junctions 20 and 24 allows a less restricted stretch and the recovery of the elastomeric sheet 14 Desirably, the laminate 10 has a measure of elasticity in the transverse direction 26 of greater than about 0.22 ratio of retraction force / extension force 27. The elasticity of the laminate 10 is measured according to the method described in the above "DEFINITION" of elasticity in the transverse direction.

Properly, the extendable nonwoven material 12 can be an inherently extensible nonwoven material, such as, for example, a bicomponent and crimped yarn bonded material as described in U.S. Patent No. 5,418,045 issued to Pike et al., Which is incorporated herein by reference. by reference or a cloth carded and joined and oriented.

Other suitable extensible non-woven materials include biaxially extensible nonwoven materials such as a spun / stretch and shrink-bonded. The nonwoven material extendable in the transverse direction and in the machine direction can be provided by stretching a fibrous nonwoven fabric in a machine direction to cause narrowing (and extension) in the transverse direction. Alternatively, the non-woven material can be a collection of very loose fibers discontinuously joined in the transverse direction so that the material can be stretched in the transverse direction. The same material with the extension in the transverse direction imparted may be crimped or creped in the machine direction to cause extension in the machine direction.

The expandable non-woven material 12 can also be a narrow non-woven material such as, for example, a knitted and narrowed woven fabric, a narrowed meltblown fabric or a bonded, bonded knitted fabric. If the tapered non-woven material is a fabric of meltblown fibers it may include meltblown microfibers. The tapered non-woven material can be made of any material that can be stretched by tension and spread, with the application of a force to extend the tapered material, to its pre-tapered dimensions. Certain polymers such as, for example, polyolefins, polyesters and polyamides can be heat treated under suitable conditions to impart such memory. Exemplary polyolefins include one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers and butane copolymers. Polypropylenes that have been found useful include, for example, polypropylene available from Himont Corporation of ilmington, Delaware under the trade designation PF-304, polypropylene available from Exxon-Mobil Chemical Company of Baytown, Texas under the registered trademark ESCORENE PD-3445 , and polypropylene available from Shell Chemical Company of Houston, Texas under the trade designation DX 4A09. The polyethylenes can also be used including ASPUN 5811A and linear low density polyethylenes 2553 from Dow Chemical Company of Midland, Michigan, as well as various high density polyethylenes. The chemical characteristics of these materials are available from their respective manufacturers.

In one embodiment of the present invention, the expandable nonwoven material 12 can be a multi-layer material having, for example, at least one layer of a spunbonded fabric attached to at least one layer of meltblown fabric, a carded and bonded fabric or other suitable material. For example, the expandable nonwoven material 12 can be a multi-layer material having a first layer of spin-bonded polyolefin (having a basis weight of from about 6.8 to about 271.3 grams per square meter (gsm)), a meltblown polyolefin layer (having a basis weight of from about 3.4 to about 113.4 grams per square meter), and a second layer of spin-bonded polyolefin having a basis weight (from about 6.8 to about 271.3 grams per square meter).

Alternatively, the expandable nonwoven material 12 may be a single layer of material such as, for example, a spunbonded fabric having a basis weight of from about 6.8 to about 339.1 grams per square meter or a meltblown fabric which has a basis weight of from about 6.8 to about 271.3 grams per square meter. Suitably the expandable nonwoven material 12 can have a constriction percent of from about 30 from 15% to about 75%. Desirably, the extendable nonwoven material 12 can have a constriction percent of from about 25% to about 70%.

The extendable nonwoven material 12 may also include a composite material made of a mixture of two or more different fibers or a mixture of fibers and particles. Such mixtures can be formed by adding fibers and / or particles to a gas stream in which the meltblown fibers are carried such that an intimate entanglement of the meltblown fibers and other materials (e.g. wood pulp, short fibers or particles such as, for example, super-absorbent materials) prior to harvesting the fibers on a collection device to form a coherent fabric of meltblown and randomly dispersed fibers and other materials as described above. described in U.S. Patent No. 4,100,324 issued to Anderson et al. which is incorporated herein by reference.

The fibers of the extendable nonwoven material 12 can be joined by interfiber bonding using one or more of the bonding processes described in the above "DEFINITION" of interfiber bonding.

The elastomeric sheet 14 can be made of any material that can be manufactured in the form of a sheet. The elastomeric sheet 14 may be a non-woven elastomeric fabric. For example, the non-woven elastomeric fabric can be formed by meltblowing a suitable resin or mixtures containing the same to provide a non-woven elastomeric fabric. A specific example of a non-woven elastomeric fabric is described in U.S. Patent No. 4,663,220 issued to Wisneski et al., Which is incorporated herein by reference.

Alternatively, the elastomeric sheet 14 can be an elastomeric film formed by extrudate, setting or the like of any suitable film-forming resins or mixtures containing the same. For example, the elastomeric film can be made of elastic block copolymers having the general formula ABA 'wherein A and Al' are thermoplastic polymer end blocks which contain a styrenic moiety such as poly (vinyl arene) and wherein B is a middle block of elastomeric polymer such as a conjugated diene or a lower alkene polymer. The elastomeric film can be formed of, for example, block copolymers (polystyrene / poly (ethylenebutylene) / polystyrene) available from KRATON Polymers of Houston, Texas under the trademark KRATON G. One such block copolymer can be, for example , KARATON G-1657. Suitable mixtures containing the block copolymers include, for example KRATON G-2755, KRATON G-2760, KRATON D6659 and KRATON RP6578. 32 Other exemplary materials which may be used include polyurethane elastomeric materials such as for example those available under the trademark Estane Ninth, Inc., Cleveland, Ohio, polyamide elastomeric materials such as, for example, those available under the trademark PEBAX from TOFINA Chemical Company of Piladelfia, Pennsylvania, and elastomeric polyester materials such as, for example, those available under the trademark HYTREL from EI duPont De Nemours & Company of Wilmington, Delaware. The formation of the elastic sheets of the polyester elastic materials is described in, for example, U.S. Patent No. 4,741,949 issued to Morman et al., And incorporated herein by reference.

The elastomeric film can be a mixture of an elastomeric polymer and a polymer with limited elastic properties. For example, the polymer or elastomeric polymers can be blended with single site catalyzed polymers such as the "metallocene" polymers produced according to a metallocene process. The term "metallocene-catalyzed polymers" as used herein includes those polymer materials that are produced by the polymerization of at least ethylene using metallocenes or constrained geometry catalysts, a class of organometallic complexes, as catalysts. For example, a common metallocene is ferrocene, a metal complex between two ligands of 33 cyclopentadienyl (Cp). Process catalysts metallocene include bis (n-butylcyclopentadienyl) titanium dichloride, bis (n-buticiclopentadienil) zirconium, bis (cyclopentadienyl) scandium chloride, bis (indenyl) zirconium dichloride, bis (methylcyclopentadienyl) titanium , bis (methylcyclopentadienyl) zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl dichloride (cyclopentadienyl, -1-fluoroenyl) zirconium, molybdocene dichloride, niquelocene, niobocene dichloride, ruthenocene, titanocene dichloride , zirconocene chloride hydride, zirconocene dichloride, among others. A more exhaustive list of such compounds is included in U.S. Patent No. 4,374,696 issued to Rosen et al. And assigned to the Dow Chemical Company. Such compounds are also discussed in U.S. Patent No. 4,064,802 to Stevens et al., Also assigned to Dow.

Desirably, the metallocene polymers are selected from copolymers of ethylene and 1-butene, copolymers of tylene and 1-hexene, copolymers of tylene and 1-octene and combinations thereof. Such metallocene polymers are available from Exxon-Mobil Chemical Company of Baytown, Texas under the trademark designation EXXPOL for polymers based on polypropylene and EXACT for polymers based on polyethylene. DuPont Dow Elastomers, L.L.C of 34 Wilmington, Delaware has polymers commercially available under the trademark ENGAGE. Metallocene polymers are also available under the trademark AFFINITY from the Dow Chemical Company of Midland Michigan. Metallocene polymers suitable for use in the present invention include, for example, ENGAGE EG8200 and AFFINITY XUS48380.01L.

Elastomeric polymers including polypropylene, alone or in combination with other elastomeric polymers or less elastic materials, are also suitable for forming the elastomeric film. For example, the elastomeric film can be formed of an elastomeric polypropylene homopolymer, an elastomeric polypropylene copolymer or a combination thereof.

A polyolefin can be used alone to form an extension film or it can be mixed with an elastomeric polymer to improve the processing of the film composition. The polyolefin can be a, which when subjected to an appropriate combination of elevated temperature and high pressure conditions is extrudable, alone or in a mixed form. Useful polyolefin materials, for example, polyethylene, polypropylene and polybutene, including ethylene copolymers, propylene copolymers and butane copolymers. A particularly useful polyethylene can be obtained from U.S.I. Chemical Company under the trademark PETROTHENE NA601. Two or more of the polyolefins may be used. Extrudable blends of elastomeric polymers and polyolefins are disclosed in, for example, U.S. Patent No. 4,663,220 issued to Isneski et al., And incorporated herein by reference.

The elastomeric film can also be a multilayer material in the sense that it can include two or more coherent fabrics or sheets. Additionally, the elastomeric film can be a multi-layer material in which one or more of the layers contains a mixture of elastic and non-elastic fibers or particles. An example of the latter type of elastic fabric is described in U.S. Patent No. 4,209,563 issued to Sisson, and incorporated herein by reference in which the elastomeric and non-elastomeric fibers are ground to form a coherent fabric of fibers dispersed at random.

Exemplary elastomeric films for use in the present invention include blends of (poly / poly (ethylenebutylene) / polystyrene) block copolymers, metallocene-derived polymers and polyolefins. For example, the elastomeric film can be formed from a blend of from about 15 percent to about 75 percent of a metallocene-derived polyolefin, from about 10 percent to about 60 percent block copolymers. (polystyrene / poly (ethylenebutylene) / polystyrene), and 36 from from O to about 15 percent of a low density polyethylene.

In another aspect, the elastomeric sheet 14 can be an elastomeric foam material. A suitable elastomeric foam material is an elastomeric polyurethane foam.

The elastomeric sheet 14 can be formed by any number of conventionally known processes, including, but not limited to, flat die extrusion, blown film (tubular) set, melt blown and the like processes. Desirably, the elastomeric sheet 14 is a set film that has been formed on a chill roll and has been substantially cooled prior to laminating to the extendable nonwoven material 12. This dictates an additional undesirable bond between the extendable nonwoven material 12 and the sheet elastomeric 14 which can decrease the extension force / retraction force ratio of the expandable laminate 10. Suitably, the elastomeric sheet 14 can have a basis weight of about 5 to about 100 grams per square meter, more suitably about 25 to around 60 grams per square meter.

As noted above, the extensible nonwoven material 12 is selectively held to the elastomeric sheet 14 by a plurality of intermittent adhesive joints 20. The 37 use of the inelastic and / or elastic adhesives is suitable for this invention. An example of a suitable adhesive is a meltblown adhesive containing from about 54.5 percent to about 57.5 percent by weight of petroleum hydrocarbon resins; from about 18.5 percent to about 21.5 percent by weight of a mixture of various mineral oils; from about 22.5 percent to about 27.5 percent by weight of styrene-butadiene-styrene block copolymers; from about 0.1 percent to about 0.9 percent by weight of polyethylene and ethylene vinyl acetate; and from about 0.2 percent to about 1.8 percent by weight of an antioxidant and stabilizers. A specific example of an adhesive suitable for use in the present invention is NS34-5610, available from National Starch and Chemical Company of Bridgewater, New Jersey.

The adhesive may be applied to the side of the film 16 of the expandable nonwoven material 12 by any method known in the art, including, but not limited to, meltblowing, spraying, intermittent slot coating, combing and / or printing with roll with engraving with pattern. Alternatively or additionally, the adhesive may be applied to at least a portion of a surface of the elastomeric sheet 14. Desirably, the adhesive is applied in a melted or liquid state. Suitably, the adhesives applied in the melted state 38 should not thermally degrade and / or melt the expandable nonwoven material 12. Alternatively, the adhesive may be applied to individual strands, filaments or cords having a solid or semi-solid form that are heated and / or activated with pressure to effect the union.

The amount of adhesive applied to the side of the film 16 of an extensible nonwoven material 12 and / or to the elastomeric sheet 14 can be varied depending on the type of adhesive, the application method, the application pattern, the desired binding coverage, of elastomeric film type and type of extendable nonwoven material. For example, the adhesive can be applied by a melt blown process at an aggregate level of from about 2 grams per square meter to about 10 grams per square meter to achieve a bonding coverage of about 10 percent a about 70 percent of the interfacial plane 22 between the expandable nonwoven sheet 12 and the elastomeric film 14.

Desirably, the adhesive is applied in a random and / or discontinuous pattern. More desirably, the adhesive is applied in a pattern that is discontinuous in the transverse direction 26. More desirably, as shown in Figure 1, the adhesive is applied in a pattern that is discontinuous in both, the transverse direction 26 and the direction of the machine 28. 39 Referring to Figure 2, a suitable discontinuous pattern of adhesive application includes a plurality of individual points 30. Desirably, the dots have a diameter of from about 1 millimeter to about 2 millimeters and an area of about 0.8 millimeters square to around 3.1 square millimeters. More desirably, as shown in Figure 2, the points 30 are arranged in a checkerboard pattern on the side of the film 16 of the extensible nonwoven material 12. Suitably, the points 30 are spaced apart from one another by a distance "d" of from about 5 millimeters about 8 millimeters measured from center to center and provide a cell size of about 25 square millimeters to about 64 square millimeters. Such a pattern can provide a binding coverage of from about 1.25 to about 12.5 percent (calculated as [dot area / cell size] x 100).

Advantageously, if the adhesive is inelastic, the intermittent adhesive bonds 20 can cover from about 10 percent to about 50 percent of the interfacial plane 22 between the sheet of the expandable nonwoven material 12 and the elastomeric film 14. More advantageously , intermittent inelastic adhesive bonds 20 can cover from -about 10 to about 40 percent of the interfacial plane 22. Desirably, at least about 50 percent to about 90 percent of the interfacial plane 22 is free of intermittent inelastic adhesive joints 20.

Suitably, if the adhesive is elastomeric, the intermittent adhesive bonds 20 can cover from about 10 percent to about 70 percent of the interfacial plane 22. More suitably, the elastomeric intermittent adhesive links 20 can cover up to about 10 percent. percent to about 65 percent of the interfacial plane 22. More suitably, the elastomeric intermittent adhesive junctions 20 can cover from about 10 percent to about 50 percent of the interfacial plane 22. Desirably, at least about 30 percent about 70 percent of the interfacial plane is free of intermittent elastomeric adhesive bonds.

As shown in Figure 1, the sheet of expandable nonwoven material 12 is further selectively bonded to the elastomeric sheet 14 by a plurality of thermal point junctions 24. The thermal point bonds 24 can be formed through the use of heat and pressing to force portions of the expandable nonwoven sheet 12 to the areas of the elastomeric sheet 14 so that the portions of the expandable nonwoven sheet are encapsulated by the areas of the elastomeric sheet 14. 41 Such thermal point joints are formed, generally by passing the two sheets of material through a pressure point between a pair of heated rolling rolls. At least one of the rolling rolls is engraved so that it has a pattern of protuberances or bolts that form the knit joints when the sheets are pressed between the rolls. The other roller laminator can be smooth or this can also have a pattern. If the second roller has a pattern, the pattern can match the first roller pattern so that the thermal point joints on each side of the laminate lie on top of each other. Alternatively, the patterns may be offset so that the two sides of the laminate exhibit different bonding patterns. The two rollers can also have spiral patterns with an opposite inclination so that the joint occurs only where the spirals are.

In the alternative, the thermal spot junctions 24 can be formed using ultrasonic bonding or welding techniques. Generally, this type of thermal point bond is formed by passing the two sheets of material through a pressure point between an ultrasonic bonding horn and an ultrasonic bonding anvil. At least one of the horn and the anvil is engraved or has a pattern so that it has protuberances that form the thermal point junctions when the sheets are exposed to the ultrasonic sound waves. 42 The thermal point junction coverage can be calculated by multiplying the bolt density, expressed as bolts per area, by the area of the bolts. For example, a pattern roller that includes a plurality of bolts that has an area of 0.01 square centimeters per bolt and that has a bolt density of 30 bolts per square centimeter will provide a thermal point joint coverage of 0.30 or 30 hundred.

The thermal point junctions 24 can be placed in the interfacial plane between the intermittent adhesive junctions 20. Alternatively, as shown in Figure 1, at least a portion of the thermal point junctions 24 can lie on at least one part of the intermittent adhesive joints 20. Suitably, the thermal point junctions 24 can cover from about 5 percent to about 50 percent of the interfacial plane. More suitably, the thermal point junctions 24 can cover from about 10 percent to about 40 percent of the interfacial plane 22. Advantageously, at least about 50 percent of the interfacial plane 22 is free of thermal point junctions. 24 In another embodiment, the intermittent adhesive junctions 20 and the thermal spot junctions 24 can be placed on the interfacial plane 22 as alternate strips or bands of thermal spot junctions and intermittent adhesive bonds 43 as shown in Figure 4. Strips or strips may be oriented in the transverse direction, in the machine direction or on a diagonal across the interfacial plane or other suitable pattern. The individual strips or strips may have the same or different dimensions such as length and / or width. Additionally, the individual strips or bands of joints may be spaced apart from one another by a strip or free band of junction in the interfacial plane 22. The strips or bands may be configured in any suitable pattern to provide the desired joint coverage. .

Referring to Figure 1, the intermittent adhesive junctions 20 cover a greater percentage of the interfacial plane 22 than the thermal point junctions 24. At least about 30, suitably, at least about 50 percent of the interfacial plane is free of both inelastic intermittent adhesive joints and thermal point joints (when the adhesive is inelastic). More suitably, at least about 60 percent of the interfacial plane is free both inelastic intermittent adhesive junctions and thermal point junctions. Desirably, at least about 30 percent of the interfacial plane is free of both intermittent elastomeric adhesive joints and thermal point bonds (when the adhesive is elastic). More desirably, at least about 35 percent of the interfacial plane is free of both intermittent elastomeric adhesive junctions 44 and thermal point junctions. More desirably, at least about 50 percent of the interfacial plane is free of both the elastomeric intermittent adhesive junctions and the thermal point junctions. When a combination of elastic and inelastic adhesives is used, at least about 30 percent of the interfacial plane 22 must be free of all adhesive and thermal bonds.

In addition to contributing to the peel strength and the internal cohesion of the extendable laminate, the thermal point joints 24 impart a surface pattern to the side of the fabric 18 of the extensible nonwoven material 12 which is aesthetically desirable. The bonding pattern can be applied either evenly or unevenly to the side of the fabric 18 of the extensible nonwoven material 12. A uniformly applied bonding pattern contributes to more consistent material properties across the surface of the resulting extensible laminate, while A unevenly applied bonding pattern can affect material properties such as the level of retraction force.

Many patterns for the calendering rolls have been developed. As will be understood by those skilled in the art, joint covers are, by necessity described in approximations or ranges, that the joint bolts are normally tapered and wear out over time. Those skilled in the art will also recognize that references to "bolts / square inch" or "joints per square inch" are somewhat interchangeable since the bolts will create the joints in the substrate in essentially the same sizes and surface ratio as the bolts on the roller. There may be a number of discrete union patterns that can be used. See, for example, United States of America patent number 4,041,203 granted to Brock et al. Which is incorporated herein by reference. An example of a pattern is the Hansen Pennings pattern or "H &P" with about 200 joints per square inch as taught in United States Patent No. 3,855,046 issued to Hansen and Pennings. The H &P pattern has square points or bolt joint areas where each bolt can have a side dimension of 0.965 centimeters, for example, resulting in a pattern that has a joint coverage of about 30 percent. Another typical point union pattern is the expanded Hansen and Pennings junction pattern or "EHP" which produces a binding coverage of about 15% to about 18% which may have a square bolt having a lateral dimension of 0.94 millimeters, for example a bolt density of about 100 bolts per square inch. Other common patterns include the "Ramisch" diamond pattern with repetitive diamonds that have a binding coverage of from about 8 percent to about 14 percent and 52 bolts per square inch and an "S" wave pattern as described in commonly assigned U.S. Patent No. 5,964,742 to cCormack et al., which is incorporated herein by reference. Additional patterns include, for example, the lines in the transverse direction, the lines in the machine direction, or other extensible patterns known in the art. One such extensible pattern suitable for use in the present invention known as "wire weave" has a binding coverage of from about 15 percent to about 20 percent and 302 bolts per square inch. As shown in Figure 3, the wire-fabric bonding pattern 32 includes diamond-shaped pattern elements that create a pattern that looks like a window grid. Each pattern element can be defined by four elliptical point junctions 34.

In another embodiment, as shown in Figure 5, an extensible laminate 10 includes a first sheet of an expandable nonwoven material 12 having one side of the film 16 and one side to the fabric 18, a second sheet of a non-material expandable fabric 36 having one side to the film 38 and one side to the fabric 40, and a sheet of an elastomeric material 14 having a first surface 17 and a second surface 37 placed between the sheets 12 and 36 of a non-woven material extensible. A first adhesive is applied to at least a side of the film 16 of the first sheet of the expandable nonwoven material 12 and / or at least a portion of a first surface 17 of the elastomeric sheet 14 (not shown) of so that the first sheet of the non-stretchable fabric material 47 is selectively bonded to the elastomeric sheet 14 by a plurality of intermittent adhesive bonds 20. A second adhesive is applied to at least one side portion to the film 38 of the second a non-woven material sheet 36 and / or at least a portion of a second surface 37 of the elastomeric sheet 14 (not shown) so that the second sheet of extensible nonwoven material 36 is selectively held to the elastomeric sheet 14 by a plurality of intermittent adhesive joints 20 '. The first sheet of extensible nonwoven material 12 and the second sheet of narrow nonwoven material 36 are further selectively bonded to the elastomeric sheet 14 by a plurality of thermal point junctions 24 and 24 '. The intermittent adhesive joints 20 and 20 'cover a greater percentage of an interfacial plane 42 between the first sheet of the extensible nonwoven material 12 and the second sheet of the extensible nonwoven material 36 than the thermal bonding points 24 and 24'.

The first sheet of extendable nonwoven material 12 and the second sheet of extendable nonwoven material 36 may be the same material or may be different materials. For example, the first sheet 12 may be a spunbond fabric while the second sheet 36 may be a spunbonded fabric, a meltblown fabric, a bonded and bonded fabric or a multilayer composite thereof. In addition, the first sheet 12 can be an extendable nonwoven material having a basis weight to the second sheet 36 can be an extendable nonwoven material having the same or a different basis weight.

Similarly, the first and second adhesives may be the same or different. For example, the first and second adhesives can be a meltblown adhesive as described above. Alternatively, the first adhesive may be a meltblown adhesive while the second adhesive may be a hot melt sprayed adhesive such as, for example, a styrene-isoprene-styrene-based adhesive available under the trade designation Findley 2525A from Ato -Findley Adhesives, Inc. of Wauwatosa, Wisconsin. Additionally, the first and second adhesives can be applied in the same or different discontinuous and / or random patterns.

A further embodiment is shown in Figure 6. An extendable laminate 10 includes a first sheet of an expandable nonwoven material 12 having one side to the film 16 and one side to the fabric 18, a second sheet of an extendable nonwoven material 36 and a sheet of an elastomeric material 14 having a first surface 17. The elastomeric sheet 14 is positioned between the first sheet 12 and the second sheet 36 of an extensible nonwoven material. An adhesive is applied to at least a side portion of the film 16 of the first sheet of the expandable nonwoven material 12 and / or at least a portion of the first surface 17 of the elastomeric sheet 14 (not shown) of So that the first sheet of the expandable non-woven material 12 is selectively bonded to the elastomeric sheet 14 by a plurality of intermittent adhesive bonds 20. The second sheet of extensible nonwoven material 35 is selectively attached to the elastomeric sheet 14 by a plurality of thermal point junctions 24. The intermittent adhesive bonds 20 cover a greater percentage of an interfacial plane 42 between the first sheet of extensible nonwoven material 12 and the second sheet of extensible nonwoven material 36 than the thermal point bonds 24.

The extensible laminate 10 of the invention can be incorporated into any suitable absorbent article. Examples of absorbent articles that may include an extensible laminate 10 include absorbent garments such as underpants, diapers, diaper briefs, women's hygiene products, swimwear, incontinence products. , other garments for health care and personal care, including medical garments or similar. As used herein, the term "incontinence products" includes absorbent underwear for children, absorbent garments for children or young adults with special needs such as autistic children or others with bowel / bladder control problems as a result of physical disabilities, as well as absorbent garments for older incontinent adults. fifty A process for making an extensible laminate 10 is shown in Figure 10. The process includes the steps of: providing an expandable nonwoven fabric 12 having one side to the film 16 and one side to the fabric 18; provide an elastomeric fabric 14. An adhesive 44 is applied in a discontinuous pattern to at least a side portion to the film 16 of the expandable non-woven fabric 12. Alternatively or additionally, an adhesive may be applied to a first surface 17 of the elastomeric fabric 14 (not shown) . The stretchable non-woven fabric 12 is selectively bonded to the elastomeric fabric 14 by a plurality of intermittent adhesive links 20 (not shown). The intermittent adhesive joints 20 are formed by passing the fabric through a first pressure point 46 between a first smooth pressure point roll 48 and a second smooth pressure point roll 50. The fabric of nonwoven material Extendable 12 is selectively bonded to the elastomeric fabric 14 by a plurality of thermal point seams 24 (not shown). The thermal point bonds 24 are formed by passing the stretchable nonwoven fabric 12 and the elastomeric fabric 14 through a second pressure point 52 between a smooth anvil roll 54 and a heated pattern calender roll 56. Desirably, the side to the fabric 18 of the expandable nonwoven fabric 12 is oriented towards the heated pattern calender roll 56 so that the thermal point bonds 24 create an aesthetically desirable pattern on the non-woven extendable surface of the laminate extensible 10.

The calendering roller with heated pattern 56 has a plurality of spaced and spaced studs or protuberances 58 on its surface. The protuberances 58 are commonly known as engraving points. The protuberances 58 make contact with the side of the fabric 18 of an expandable nonwoven fabric 12 and selectively force the elastomeric film fabric 14 inside the fiber structure sideways to the film 16 of the tensile nonwoven fabric 12 by encapsulating thus, and joining parts of the stretchable nonwoven fabric 12 to the elastomeric film fabric 14 at a plurality of thermal bonding points 24. In areas between the thermal spot junctions 24 and the intermittent adhesive joints 20, the expandable nonwoven fabric 12 and the elastomeric fabric 14 are not joined to each other and can move independently with respect to each other. The structure which leaves the second pressure point 52 is now an extensible laminate 10 of the present invention and can be wound onto a take-up roller for storage or transport for further processing. The calendering roller with heated pattern 56 makes contact with the side of the fabric 18 of the stretchable nonwoven fabric 12, to prevent the elastomeric fabric 14 from adhering to the protrusions 58. There may, however, be some circumstances where it is desirable that the patterned and heated calender roll 52 contacts the elastomeric fabric 14.

The temperature at which the pattern calendering roller 56 is heated will depend on the properties of the elastomeric fabric 14 and / or the expandable nonwoven fabric 12, but are usually in the range of from about 100 ° to about 275 °. F (around 38 ° to around 135 ° C). The binding characteristics are determined, in part by a number of factors, including but not limited to, the composition of fabrics 12 and 14, the presence of wetting agents, the temperature of the elastomeric sheet 14 and the expandable nonwoven material. 12 at the thermal bonding points 24, the temperature of the heated smooth anvil roller 54 and the calendering roller with heated pattern 56, and the like. Additionally, the design and construction of the protuberances 58 will have an impact on the joint. Such factors include, but are not limited to the height, geometry, density, width and pattern of the protuberances 58, the size of the second pressure point 52 and the like.

Optionally, the elastomeric fabric 14 can be formed inline during production. For example, the first smooth pressure point roll 48 can be a cooling roll wherein the elastomeric polymer or the polymer blend can be extruded to form an elastomeric film fabric set prior to adhesive lamination to the nonwoven fabric. extensible.

It should be understood that more than two layers of material can be laminated together to form an extensible laminate of the present invention, such as but not limited to a spin-bonded elastomer-bonded laminate, a spin-elastomer-blown laminate. with fusion, and the like. Figures 8 and 9 show alternate embodiments of processes for forming the extensible laminates of the present invention.

Figure 8 shows a process for making an extensible laminate of the present invention including two layers of extendable nonwoven material. The process includes the steps of providing a first fabric of an extendable nonwoven material 12 having one side to the film 16 and one side to the fabric 18; applying an adhesive 44 in a discontinuous pattern to at least a portion of the side to the film 16 of the first fabric of extendable nonwoven material 12; providing a fabric of an elastomeric material 1; and selectively joining the first non-stretchable fabric 12 to the elastomeric fabric 14 by a plurality of intermittent adhesive links 20 (not shown). The intermittent adhesive joints 20 are formed by passing the fabrics 12 and 14 through a first pressure point 46 between a first smooth pressure point roll 48 and a second smooth pressure point roll 50. It provides a second fabric of an extensible nonwoven material 36 having one side to the film 38 and one side to the fabric 40. The second extensible nonwoven fabric 36 is selectively attached to the elastomeric fabric 14 by a plurality of thermal point bonds 24 (not shown). The thermal point bonds 24 are formed by passing the first extensible nonwoven fabric, the elastomeric material and the second nonwoven fabric extendable through the second pressure point 52 between the smooth anvil roll 54 and the patterned calender roll. heated 56, wherein the calendered roller with heated pattern is set aside to the fabric 40 of the second expandable nonwoven fabric 36.

Optionally, the process may include the additional steps of applying an adhesive in a discontinuous pattern to the side to the film 38 of the second extensible nonwoven fabric 36, selectively joining the second extensible nonwoven fabric 36 to the elastomeric fabric 14 by a plurality of joints 20 'intermittent adhesives and / or selectively holding the first stretch nonwoven fabric 12 to the elastomeric fabric 14 by a plurality of thermal point junctions 24'. In addition, the adhesive can be applied to at least a portion of a first surface 17 and / or of a second surface 37 of the elastomeric fabric 14.

Figure 9 shows a further process for forming an extensible laminate that includes two fabrics of a 55 non-woven extensible material. The process includes the steps of: providing a first fabric of extendable nonwoven material 12; applying an adhesive 44 in a discontinuous pattern to the side to the film 16 of the first extensible non-woven fabric 12; provide an elastomeric fabric 14; and selectively joining the first fabric of extensible nonwoven material 12 to the elastomeric fabric 14 by a plurality of intermittent adhesive joints 20 (not shown) to form a first composite 60. The intermittent adhesive joints 20 are formed by passing the first non-woven fabric extendable 12 having the side to the film 16 facing the elastomeric fabric 14 and the elastomeric fabric 14 through a first clamping point 46 between a first smooth clamping point roll 48 and a second smooth pressure point roll 50. The process further includes providing a second fabric of extendable nonwoven material 36 having one side to the film 38 and one side to the fabric 40; applying an adhesive 44 'in a discontinuous pattern to the side to the film 38 of the second extensible non-woven fabric 36; and selectively joining the second extensible nonwoven fabric 36 to the elastomeric fabric 14 by a plurality of intermittent adhesive bonds 29 '(not shown) to form a second composite 62. The intermittent adhesive joints 20' are formed by passing the first compound 60 and the second expandable nonwoven fabric 36 having the side to the film 38 facing the elastomeric fabric 14 of the first composite 60 through a second pressure point 64 between the second pressure point roller 50 and the third point roller. pressure 66. The process also includes selectively holding the first stretch non-woven fabric 12 to the elastomeric fabric 14 by a plurality of thermal point joints 24 (not shown) and selectively joining the second non-woven fabric expandable to the elastomeric fabric 14 by a plurality of thermal point junctions 24 '(not shown). The thermal spot junctions 24 which hold the first stretchable nonwoven fabric 12 to the elastomeric fabric 14 are formed by passing the second compound 62 through a pressure point 52 between a first smooth anvil roll 54 positioned on one side of the second extensible non-woven fabric 36 and a heated pattern first calender roll 56 positioned on one side of the first extensible non-woven fabric 12. The thermal point bonds 24 'hold the second stretchable non-woven fabric 36 to the elastomeric fabric 14 and are formed by passing the second compound 62 through a pressure point 68 between a second smooth anvil roll 70 positioned on one side of the first extensible nonwoven fabric 12 and the second heated pattern calendering roll 72 placed on one side of the second extensible nonwoven fabric 36.

Alternatively, in Figs. 7, 8 and 9, the smooth anvil rollers 52 and / or 70 can be ultrasonic bonding anvils and patterned and heated calender rolls 56 and / or 72 can be standard ultrasonic bonding horns.

Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications to example embodiments are possible without materially departing from the novel teachings or the advantages of this. invention. Therefore, all such modifications are intended to be included within the scope of this invention as defined in the following claims.

It should be noted that any patents or publications mentioned herein are incorporated by reference in their entirety.

Claims

58 R E I V I N D I C A L I O N S

1. An extensible laminate comprising: a sheet of an extendable nonwoven material having one side to the film and one side to the fabric; a sheet of an elastomeric film; an adhesive applied to at least a side portion to the film of the expandable nonwoven material such that the sheet of the expandable nonwoven material is selectively bonded to the elastomeric film sheet by a plurality of intermittent adhesive bonds, wherein the first sheet of extensible nonwoven material is further selectively bonded to the sheet of elastomeric film by a plurality of thermal point joints, and the intermittent adhesive thermal bond joints cover a greater percentage of an interfacial plane between the sheet of the material non-stretchable fabric and elastomeric film sheet that thermal junction points.

2. The extensible laminate as claimed in clause 1, characterized in that the sheet of extensible nonwoven material is essentially not attached to the sheet of elastomeric film in the portions of the interfacial plane 59 between the intermittent adhesive joints and the point connections. thermal.

3. The extensible laminate as claimed in clause 1, characterized in that the intermittent adhesive joints cover at least 5 percent more of the interfacial plane than the thermal point junctions.

4. The extensible laminate as claimed in clause 1, characterized in that the intermittent adhesive joints cover at least 10 percent more of the interfacial plane than the thermal point junctions.

5. The extensible laminate as claimed in clause 1, characterized in that the intermittent adhesive joints cover at least 20 percent more of the interfacial plane than the thermal point junctions.

6. The extensible laminate as claimed in clause 1, characterized in that the laminate has an elasticity measurement of more than about 0.22 ratio of retraction force / extension force.

7. The extensible laminate as claimed in clause 1, characterized in that the thermal point junctions are placed in the interfacial plane between the intermittent adhesive bonds. 60

8. The extensible laminate as claimed in clause 1, characterized in that at least a portion of the thermal point junctions lie on at least a portion of the intermittent adhesive bonds.

9. The extensible laminate as claimed in clause 1, characterized in that the adhesive is an inelastic adhesive.

10. The extensible laminate as claimed in clause 9, characterized in that the intermittent adhesive joints cover from about 5 percent to about 50 percent of the interfacial plane.

11. The extensible laminate as claimed in clause 1, characterized in that the adhesive is an elastomeric adhesive.

12. The extensible laminate as claimed in clause 11, characterized in that the intermittent adhesive bonds cover up to about 70 percent of the interfacial plane.

13. An absorbent article comprising the extensible laminate as claimed in clause 1.

14. An extensible laminate comprising: a first sheet of an extendable nonwoven material having one side to the film and one side to the fabric; a sheet of an elastomeric film; Y a first adhesive applied in a discontinuous pattern to the side of the film of the first sheet of the extensible nonwoven material so that the first sheet of extensible nonwoven material is selectively bonded to the sheet of elastomeric film by a first plurality of adhesive joints intermittent, wherein the first sheet of the expandable nonwoven material is further selectively bonded to the sheet of the elastomeric film by a first plurality of thermal point bonds so that the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the first sheet of extendable nonwoven material and the elastomeric film sheet that the thermal point junctions and at least about 50 percent of the interfacial plane are free of intermittent adhesive bonds.

15. The extensible laminate as claimed in clause 14, characterized in that the laminate 62 has an elasticity measurement greater than about 0.22 ratio of retraction force / extension force.

16. The extensible laminate as claimed in clause 14, characterized in that at least about 50 percent of the interfacial plane is free of intermittent adhesive junctions and thermal point junctions.

17. The extensible laminate as claimed in clause 14, characterized in that it also comprises: a second sheet of an extendable nonwoven material having a first side and a second side; Y a second adhesive applied in a discontinuous pattern to the film side of the second sheet of an extensible nonwoven material so that the second sheet of the expandable nonwoven material is selectively held to the elastomeric film sheet by a second plurality of intermittent adhesive bonds , wherein the first and second plurality of intermittent adhesive joints cover a greater percentage of an interfacial plane between the sheets of first and second extensible nonwoven material than the thermal point bonds.

18. The extensible laminate as claimed in clause 17, characterized in that the second sheet of extensible nonwoven material is further selectively bonded to the elastomeric film sheet by a second plurality of thermal point bonds so that the pluralities First and second of the intermittent adhesive joints cover a greater percentage of the interfacial plane between the first and second sheets of the extensible nonwoven material than the first and second pluralities of the thermal point junctions.

An extensible laminate comprising a first sheet of an extendable nonwoven material having one side to the film and one side to the fabric; a sheet of an elastomeric film; an adhesive applied in a discontinuous pattern next to the film of the first sheet of extensible nonwoven material so that the first sheet of extensible nonwoven material is selectively held to the sheet of the elastomeric film by a plurality of intermittent adhesive bonds; and a second sheet of extensible nonwoven material selectively fastened to the elastomeric film sheet by a plurality of thermal point bonds, wherein the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the first and second sheets of the extensible nonwoven material than the thermal point joints, at least about 50 percent of the interfacial plane is free of joints of Adhesive intermittent and thermal bond joints and laminate have a measured elasticity of more than about 0.22 retraction force ratio / extension force.

20. A process for making an extensible laminate comprising the steps of: providing a fabric of an extensible nonwoven material having one side to the film and one side to the fabric; provide an elastomeric film fabric; applying an adhesive in a discontinuous pattern to the side to the fabric film of expandable nonwoven fabric; selectively joining the tissue of the extensible nonwoven material to the elastomeric film fabric by a plurality of intermittent adhesive bonds; and 65 selectively joining the tissue of the extensible nonwoven material to the fabric of the elastomeric film by a plurality of thermal point junctions; whereby the intermittent adhesive bonds cover a greater percentage of an interfacial plane between the expandable nonwoven fabric and the elastomeric film fabric than the thermal point junctions.

21. The process as claimed in clause 20, characterized in that the laminate has an elasticity measurement of more than about 0.22 ratio of retraction force / extension force.

22. The process as claimed in clause 20, characterized in that the intermittent adhesive joints cover at least about 5 percent more of the interfacial plane than the thermal point junctions.

23. The process as claimed in clause 20, characterized in that the intermittent adhesive joints cover at least about 10 percent more of the interfacial plane than the thermal point junctions.

2 . The process as claimed in clause 20, characterized in that the intermittent adhesive joints 66 cover at least about 20 percent more of the interfacial plane than the thermal point junctions.

25. The process as claimed in clause 20, characterized in that the thermal point joints are formed by passing the fabric of the extensible nonwoven material and the fabric of the elastomeric film through a pressure point between an anvil roller. and a calendering roller with heated pattern.

26. The process as claimed in clause 20, characterized in that the thermal point junctions are formed by passing the fabric of the extensible nonwoven material and the elastomeric film fabric through a pressure point between an ultrasonic bonding anvil and an ultrasonic bonding horn with pattern.

27. The process as claimed in clause 20, characterized in that the adhesive is applied as a plurality of individual points.

28. The process as claimed in clause 27, characterized in that the individual points have a diameter of from about 1 millimeter to about 2 millimeters. 67

29. The process as claimed in clause 28, characterized in that the individual points form a checkerboard pattern.

30. The process as claimed in clause 29, characterized in that the individual points are spaced apart from one another by a distance of from about 5 millimeters to about 8 millimeters measured from center to center.

31. A process for making an extensible laminate comprising the steps: providing a first fabric of an extensible nonwoven material having one side to the film and one side to the fabric; applying an adhesive in a discontinuous pattern to the side to the film of the first fabric of extensible nonwoven material; provide a fabric of an elastomeric film; selectively joining the first fabric of nonwoven material expandable to the elastomeric film fabric by a plurality of intermittent adhesive bonds; 68 providing a second fabric of an extendable nonwoven material having one side to the film and one side to the fabric; Y selectively joining the second fabric of expandable nonwoven material to the elastomeric film fabric by a plurality of thermal point bonds; whereby the intermittent adhesive joints cover a greater percentage of an interfacial plane between the first and second webs of the non-woven material than the thermal point joints.

32. The process as claimed in clause 31, characterized in that it comprises 1 step of selectively joining the first non-woven fabric stretchable to the elastomeric film fabric by a plurality of thermal point junctions.

33. The process as claimed in clause 31, characterized in that it further comprises the steps of: applying an adhesive in a discontinuous pattern to the side to the film of the second fabric of extendable nonwoven material; and selectively attaching the second fabric of extendable nonwoven material to the elastomeric film fabric by a plurality of intermittent adhesive bonds. 69

34. The process as claimed in clause 32, characterized in that it further comprises the steps of: applying an adhesive in a discontinuous pattern to the side to the film of the second fabric of extendable nonwoven material; and selectively joining the second fabric of the expandable nonwoven material to the elastomeric film fabric by a plurality of intermittent adhesive bonds. 70 R E S U E N An extensible laminate includes a sheet of an extendable nonwoven material having one side to the fabric and one side to the film, a sheet of an elastomeric film and an adhesive. The adhesive is applied to at least a part of the side to the film of the expandable nonwoven material. The expandable non-woven material is selectively bonded to the elastomeric film by a plurality of intermittent adhesive bonds. The extensible nonwoven material is further selectively bonded to the elastomeric film by a plurality of thermal point junctions. The intermittent adhesive bonds cover a greater percentage of an interfacial plane between the expandable nonwoven material and the elastomeric film material than the thermal point junctions. A process for making the laminate extensible is also described.