Elastic laminate web

• US 20020016122A1
• Filed: 06/21/2001
• Published: 02/07/2002
• Est. Priority Date: 12/21/1999
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Strube, John Brian, Curro, John Joseph, Spencer, Anthony Stephen, Benson, Douglas Herrin
• Granted Patent: US 6,830,800 B2
• Time in Patent Office: Days
• US Class Current: 442/381
• CPC Class Codes: A47L 1/15 Cloths, sponges, pads, or the like, e.g. containing cleaning agents
• CPC Class Codes: A47L 13/17 containing cleaning agents A47L13/19 takes precedence ; chemical compositions C11D17/049
• CPC Class Codes: A61F 13/15593 having elastic ribbons fixed thereto; Devices for applying the ribbons
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/15731 Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
• CPC Class Codes: A61F 13/4902 characterised by the elastic material
• CPC Class Codes: A61F 13/51104 the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
• CPC Class Codes: A61F 13/5123 the apertures being formed on a multilayer top sheet
• CPC Class Codes: A61F 13/51464 being stretchable or elastomeric
• CPC Class Codes: A61F 13/51476 being three-dimensional, e.g. embossed, textured, pleated, or with three-dimensional features, like gathers or loops
• CPC Class Codes: A61F 13/51478 being a laminate, e.g. multi-layered or with several layers
• CPC Class Codes: A61F 2013/51165 with the combination of films and nonwovens
• CPC Class Codes: A61F 2013/51182 with non-continuous bonding
• CPC Class Codes: A61F 2013/51322 being elastomeric or stretchable
• CPC Class Codes: A61K 8/0208 Tissues; Wipes; Patches
• CPC Class Codes: A61Q 19/00 Preparations for care of the skin
• CPC Class Codes: A61Q 19/10 Washing or bathing preparations
• CPC Class Codes: B08B 1/143 Wipes
• CPC Class Codes: B26F 1/20 with tools carried by a rotating drum or similar support B26F1/22 takes precedence
• CPC Class Codes: B26F 1/24 Perforating by needles or pins
• CPC Class Codes: B29C 2793/0045 : Perforating
• CPC Class Codes: B29C 55/023 : using multilayered plates or sheets
• CPC Class Codes: B29C 55/18 : by squeezing between surfaces, e.g. rollers
• CPC Class Codes: B29C 59/007 : Forming single grooves or ribs, e.g. tear lines, weak spots by moulding B29C37/0057; folding lines B29C53/06; in metal articles B21D17/00; by cutting B26D3/08
• CPC Class Codes: B29C 59/04 : using rollers or endless belts
• CPC Class Codes: B29C 65/02 : by heating, with or without pressure
• CPC Class Codes: B29C 65/18 : using heated tools
• CPC Class Codes: B29C 65/7437 : the tool being a perforating tool perforating as mechanical pre-treatment B29C66/02242
• CPC Class Codes: B29C 66/1122 : Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/21 : said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/344 : Stretching or tensioning the joint area during joining
• CPC Class Codes: B29C 66/436 : Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats joining through openings B29C66/304
• CPC Class Codes: B29C 66/45 : Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/4722 : Fixing strips to surfaces other than edge faces fixing strips to edge faces B29C63/0026
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/723 : being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/7294 : Non woven mats, e.g. felt
• CPC Class Codes: B29C 66/7392 : characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/7394 : characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/81433 : being toothed, i.e. comprising several teeth or pins comprising a single tooth B29C66/81429, or being patterned
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/83511 : jaws mounted on rollers, cylinders or drums
• CPC Class Codes: B29K 2023/04 : Polymers of ethylene
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/10 : Polymers of propylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2105/0854 : in the form of a non-woven mat
• CPC Class Codes: B29K 2995/0068 : Permeability to liquids; Adsorption
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2031/4878 : Diapers, napkins
• CPC Class Codes: B29L 2031/737 : Articles provided with holes, e.g. grids, sieves nets B29L2028/00
• CPC Class Codes: B29L 2031/7374 : Slotted
• CPC Class Codes: B32B 15/04 : comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 2037/0092 : in which absence of adhesives is explicitly presented as an advantage
• CPC Class Codes: B32B 2038/0028 : Stretching, elongating
• CPC Class Codes: B32B 2038/047 : Perforating
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/065 : Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/067 : Wood fibres
• CPC Class Codes: B32B 2262/12 : Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2264/00 : Composition or properties of particles which form a particulate layer or are present as additives
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2307/202 : Conductive
• CPC Class Codes: B32B 2307/204 : Di-electric
• CPC Class Codes: B32B 2307/31 : Heat sealable
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/726 : Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2479/00 : Furniture
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2555/02 : Diapers or napkins
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/0012 : Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: B32B 38/04 : Punching, slitting or perforating
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/04 : characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B65D 75/30 : Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
• CPC Class Codes: C11D 17/049 : Cleaning or scouring pads; Wipes
• CPC Class Codes: D04H 1/559 : the fibres being within layered webs
• CPC Class Codes: H01B 7/0838 : Parallel wires, sandwiched between two insulating layers
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/234 : including elements cooperating to form cells
• CPC Class Codes: Y10T 428/237 : Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/24041 : Discontinuous or differential coating, impregnation, or bond
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 442/601 : Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/602 : Nonwoven fabric comprises an elastic strand or fiber material
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/671 : Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/679 : Natural or synthetic rubber sheet or film
• CPC Class Codes: Y10T 442/69 : Autogenously bonded nonwoven fabric

Abstract

An elastic laminate web is disclosed. The elastic laminate web can be non-apertured or apertured, and comprises a first web, and a second web joined to the first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2. The first and second webs form an interior region therebetween. An elastic material is disposed between the first and second webs. The elastic material is apertured in regions coincident the bond sites, such that the first and second webs are joined through the apertures. The laminate so produced can be stretched in a predetermined direction, such as by incremental stretching, to produce an apertured elastic laminate.

Claims

1. A non-apertured elastic laminate web comprising:

a) a first web;

b) a second web joined to said first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2, the first and second webs forming an interior region therebetween;

c) an elastic material being disposed between at least a portion of said first and second webs; and

d) said elastic material being apertured in regions coincident said bond sites, such that said first and second webs are joined through said apertures.

2. The laminate web of claim 1, wherein said laminate is joined by bonds in the absence of adhesive.

3. The laminate web of claim 1, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 3:

1.

4. The laminate web of claim 1, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 10:

1.

5. The laminate web of claim 1, wherein said first or second web comprises a nonwoven.

6. A laminate web having a plurality of apertures, said laminate web comprising:

a) first and second extensible webs being joined at a plurality of discrete bond sites;

b) an elastic material disposed between said first and second nonwoven webs; and

c) the first and second extensible webs being in fluid communication via the apertures.

7. The laminate web of claim 6, wherein said laminate is joined by bonds in the absence of adhesive.

8. The laminate web of claim 6, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 3:

1.

9. The laminate web of claim 6, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 10:

1.

10. The laminate web of claim 6, wherein said first or second extensible web comprises a nonwoven.

11. A disposable absorbent article comprising an elastic laminate web having a plurality of apertures, said elastic laminate web comprising:

a) a first web;

b) a second web joined to said first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2, the first and second webs forming an interior region therebetween;

c) an elastic material being disposed between at least a portion of said first and second webs; and

d) said elastic material being apertured in regions coincident said bond sites, such that said first and second webs are joined through said apertures.

12. The disposable absorbent article of claim 11, wherein said first or second extensible web comprises a nonwoven.

13. The disposable absorbent article of claim 11, wherein said elastic laminate web further comprises absorbent gelling material.

15. The article of apparel of claim 14, wherein said first or second extensible web comprises a nonwoven.

17. The method of claim 16, wherein said third web material is provided in an unapertured condition.

18. The method of claim 16, wherein said third web material is involved in said thermal point bonding about a perimeter of a said bond sites.

20. The method of claim 19, wherein said first and second web materials comprise nonwoven fibers.

21. The method of claim 19, wherein said stretching means comprises incremental stretching.

22. The method of claim 19, wherein said protuberances of said thermal point bonder have an aspect ratio of between about 3 and 20.

23. The method of claim 19, wherein said protuberances of said thermal point bonder have an aspect ratio of 10.

14. An article of apparel comprising an elastic laminate web having a plurality of apertures, said article comprising:

a) a first web;

b) a second web joined to said first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2, the first and second webs forming an interior region therebetween;

c) an elastic material being disposed between at least a portion of said first and second webs; and

d) said elastic material being apertured in regions coincident said bond sites, such that said first and second webs are joined through said apertures.

16. A method for forming an elastic laminate web the steps of:

(a) providing first and second web materials comprising thermoplastic material;

(b) providing at least one third elastomeric web material;

(c) providing a thermal point bonder having a plurality of protuberances;

(d) guiding said third elastomeric web material in a stretched condition between at least a portion of said first and second web materials in a face-to-face layered relationship to said thermal point bonder;

(e) displacing said third elastomeric web material with said protuberances at discrete, spaced apart locations to form apertures in said third material; and

(f) thermally point bonding said first and second outer web materials to form bond sites at discrete, spaced apart locations coincident with said protuberances, thereby forming a bonded laminate.

19. A method for forming an apertured elastomeric laminate web comprising the steps of:

(a) providing first and second web materials comprising thermoplastic material;

(b) providing at least one third elastomeric web material;

(c) providing a thermal point bonder having a plurality of protuberances;

(d) guiding said third elastomeric web material in a stretched condition between at least a portion of said first and second web materials in a face-to-face layered relationship to said thermal point bonder;

(e) displacing said third elastomeric web material with said protuberances at discrete, spaced apart locations to form apertures in said third material;

(f) thermally point bonding said first and second outer web materials to form bond sites at discrete, spaced apart locations coincident with said protuberances, thereby forming a bonded laminate; and

(g) stretching said bonded laminate to form apertures in the elastomeric laminate web.