Laminated composites
First Claim
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1. A laminated elastic composite, comprising:
- (a) a first nonwoven web layer having a machine direction and a cross direction;
(b) a scrim layer adjacent to the first nonwoven web layer comprising spaced-apart, nonelastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction;
(c) an elastic layer adjacent to the scrim layer comprising a series of substantially parallel, spaced-apart elastic filaments wherein the length of the elastic filaments are oriented substantially in the machine direction;
(d) a fibrous pressure sensitive adhesive layer adjacent the elastic layer; and
(e) a second nonwoven web layer adjacent to the fibrous pressure sensitive adhesive layer.
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Abstract
A laminated composite suitable for use in medical products such as tapes and wraps. The composite includes, for example, a first nonwoven fiber layer, an elastic layer, a melt blown adhesive fiber layer, and a second nonwoven fiber layer. A scrim layer serves as a deadstop, or stretch limit, to prevent over stretching. The non-woven fiber layer(s) and/or the scrim layer form suitable loops for a hook and loop fastening system. The scrim layer in some embodiments is employed to make the composite finger tearable. The melt blown adhesive layer, nonwoven web layer and elastic layer form a breathable, porous elastic composite. Methods of manufacturing the composite are also disclosed.
123 Citations
91 Claims
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1. A laminated elastic composite, comprising:
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(a) a first nonwoven web layer having a machine direction and a cross direction;
(b) a scrim layer adjacent to the first nonwoven web layer comprising spaced-apart, nonelastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction;
(c) an elastic layer adjacent to the scrim layer comprising a series of substantially parallel, spaced-apart elastic filaments wherein the length of the elastic filaments are oriented substantially in the machine direction;
(d) a fibrous pressure sensitive adhesive layer adjacent the elastic layer; and
(e) a second nonwoven web layer adjacent to the fibrous pressure sensitive adhesive layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A laminate composite, comprising:
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(a) a first nonwoven web layer;
(b) a scrim layer adjacent to the first nonwoven web layer comprising spaced-apart, non-elastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented in the cross-direction; and
(c) a fibrous pressure sensitive adhesive layer adjacent the scrim layer. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A laminated composite, comprising:
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(a) a scrim layer comprising spaced-apart filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction. (b) an elastic layer comprising a series of substantially parallel, spaced-apart elastic filament wherein the elastic filaments are oriented substantially in the machine direction; and
(c) a fibrous pressure sensitive adhesive layer adjacent the elastic layer. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38)
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39. A method of making an elastic laminate composite, comprising the steps of:
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(a) providing a melt blowing apparatus comprising a die and a rotating collector drum;
(b) providing a first nonwoven web overlaying the collector drum, wherein the nonwoven web comprises a material selected from the group consisting of a melt blown nonwoven material, a spunbond nonwoven material, a spun laced nonwoven material, a staple carded web, an air laid web and a wet laid web;
(c) providing a series of substantially parallel, spaced-apart elastic filaments overlaying the nonwoven web on the collector drum, wherein the elastic filaments are oriented substantially in the machine direction and wherein the elastic filaments are stretched beyond their relaxed length;
(d) advancing the first nonwoven material and the overlaying elastic filaments to a position beneath the melt blowing die by rotating the collector drum;
(e) melt blowing fibers comprising a pressure-sensitive adhesive from the die onto the elastic filaments;
(f) providing a second nonwoven web downstream from the die wherein the second nonwoven web comprises a material selected from the group consisting of a melt blown nonwoven material, a spunbond nonwoven material, a spun laced nonwoven material, a staple carded web, an air laid web and a wet laid web;
(g) pressure laminating the second nonwoven web onto the blown fiber adhesive filaments, the elastic filaments and the first nonwoven web, by advancing the layers through a nip formed between the collector drum and a calender roll to form an elastic laminate composite comprising the first nonwoven web, the elastic filaments, the blown fiber pressure-sensitive adhesive web and the second nonwoven web; and
(h) collecting the elastic laminate composite on a winder roll. - View Dependent Claims (40)
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41. A method of making a laminate composition, comprising the steps of:
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(a) providing a melt blowing apparatus comprising a die and a rotating collector drum;
(b) providing a nonwoven web overlaying the collector drum, wherein the nonwoven web comprises a material selected from the group consisting of melt blown nonwoven materials, spunbond nonwoven materials, spun laced nonwoven materials, staple carded webs, air laid webs and wet laid webs;
(c) providing a scrim overlaying the nonwoven web and the collector drum comprising spaced-apart filaments oriented substantially in the machine direction that are perpendicular to spaced-apart filaments oriented substantially in the cross direction;
(d) advancing the scrim and the nonwoven web to a position beneath the melt blowing die by rotating the collector drum;
(e) melt blowing fibers comprising pressure-sensitive adhesive from the die onto the scrim;
(f) pressure laminating the blown fiber adhesive filaments and underlying scrim and nonwoven web, by advancing the layers through a nip formed between the collector drum and a calender roll to form a laminate composite comprising the first nonwoven web, the elastic filaments, the blown fiber pressure-sensitive adhesive web and the second nonwoven web; and
(g) collecting the laminate composite on a winder roll. - View Dependent Claims (42)
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43. A method of making a laminate composition, comprising the steps of:
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(a) providing a melt blowing apparatus comprising a die and a rotating collector drum;
(b) providing a first nonwoven web overlaying the collector drum, wherein the first nonwoven web comprises a material selected from the group consisting of melt blown nonwoven materials, spunbond nonwoven materials, spun laced nonwoven materials, staple carded webs, air laid webs and wet laid webs;
(c) providing a scrim overlaying the first nonwoven web and the collector drum comprising spaced-apart filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross direction;
(d) advancing the scrim and the first nonwoven web to a position beneath the melt blowing die by rotating the collector drum;
(e) melt blowing fibers comprising a pressure-sensitive adhesive from the die onto the scrim;
(f) providing a second nonwoven web downstream from the die wherein the second nonwoven web comprises a material selected from the group consisting of melt blown nonwoven materials, spunbond nonwoven materials, spun laced nonwoven materials, staple carded webs, air laid webs and wet laid webs;
(g) pressure laminating the second nonwoven web onto the blown fiber adhesive filaments and underlying scrim and first nonwoven web, by advancing the layers through a nip formed between the collector drum and a calender roll to form a laminate composite comprising the first nonwoven web, the scrim, the blown fiber pressure-sensitive adhesive web and the second nonwoven web; and
(h) collecting the elastic laminate composite on a winder roll. - View Dependent Claims (44)
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45. A method of making an elastic laminate composite, comprising the steps of:
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(a) providing a melt blowing apparatus comprising a die and a rotating collector drum;
(b) providing a series of substantially parallel, spaced-apart elastic filaments overlaying the nonwoven web on the collector drum, wherein the elastic filaments are oriented substantially in the machine direction and the elastic filaments are stretched beyond their relaxed length;
(c) advancing the elastic filaments to a position beneath the melt blowing die by rotating the collector drum;
(d) melt blowing fibers comprising a pressure-sensitive adhesive from the die onto the elastic filaments;
(e) pressure laminating the blown fiber adhesive filaments onto the underlying elastic filaments, by advancing the layers through a nip formed between the collector drum and a calendar roll to form an elastic laminate composite comprising the elastic filaments and the blown fiber pressure-sensitive adhesive web; and
(f) collecting the elastic laminate composite on a winder roll. - View Dependent Claims (46)
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47. A method of making an elastic laminate composite, comprising the steps of:
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(a) providing a melt blowing apparatus comprising a die and a rotating collector drum;
(b) providing a first nonwoven web overlaying the collector drum, wherein the nonwoven web comprises a material selected from the group consisting of a melt blown nonwoven material, a spunbond nonwoven material, a spun laced nonwoven material, a staple carded web, an air laid web and a wet laid web;
(c) providing a scrim overlaying the nonwoven web and the collector drum comprising spaced-apart filaments oriented substantially in the machine direction that are perpendicular to spaced-apart filaments oriented substantially in the cross direction;
(d) providing a series of substantially parallel, spaced-apart elastic filaments overlaying the nonwoven web and scrim on the collector drum, wherein the elastic filaments are oriented substantially in the machine direction and wherein the elastic filaments are stretched at least 50% beyond their relaxed length;
(e) advancing the first nonwoven material, scrim and the overlaying stretched elastic filaments to a position beneath the melt blowing die by rotating the collector drum;
(f) melt blowing fibers comprising a pressure-sensitive adhesive from the die onto the elastic filaments;
(g) providing a second nonwoven web downstream from the die wherein the second nonwoven web comprises a material selected from the group consisting of a melt blown nonwoven material, a spunbond nonwoven material, a spun laced nonwoven material, a staple carded web, an air laid web and a wet laid web;
(h) pressure laminating the second nonwoven web onto the blown fiber adhesive filaments, the elastic filaments and the first nonwoven web, by advancing the layers through a nip formed between the collector drum and a calender roll to form an elastic laminate composite comprising the first nonwoven web, the elastic filaments, the blown fiber pressure-sensitive adhesive web and the second nonwoven web; and
(i) allowing the stretched elastic filaments to relax and collecting the elastic laminate composite on a winder roll. - View Dependent Claims (48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59)
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60. A laminated elastic composite, comprising:
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a first nonwoven web layer having a machine direction and a cross direction;
a scrim layer adjacent to the first nonwoven web layer comprising spaced-apart, nonelastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction;
an elastic layer adjacent to the scrim layer comprising a series of substantially parallel, spaced-apart elastic filaments wherein the length of the elastic filaments are oriented substantially in the machine direction;
a fibrous adhesive layer adjacent the elastic layer; and
a second nonwoven web layer adjacent to the fibrous adhesive layer;
wherein at least one of the nonwoven web layers comprises loops. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74)
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75. A laminated composite, comprising:
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a first nonwoven web layer;
a scrim layer comprising spaced-apart, non-elastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced apart filaments oriented in the cross-direction; and
a fibrous adhesive layer between the scrim layer and the first nonwoven web layer;
wherein the scrim layer comprises loops. - View Dependent Claims (76, 77, 78, 79, 80, 81, 82, 83)
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84. A laminated composite, comprising:
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a scrim layer comprising spaced-apart filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction;
an elastic layer comprising a series of substantially parallel, spaced-apart elastic filaments wherein the elastic filaments are oriented substantially in the machine direction; and
a fibrous adhesive layer adjacent the elastic layer;
wherein the scrim layer comprises loops. - View Dependent Claims (85, 86, 87, 88, 89)
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90. A laminated elastic composite, comprising:
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a scrim layer comprising spaced-apart, nonelastic filaments oriented substantially in the machine direction that are substantially perpendicular to spaced-apart filaments oriented substantially in the cross-direction;
an elastic layer adjacent to the scrim layer comprising a series of substantially parallel, spaced-apart elastic filaments wherein the length of the elastic filaments are oriented substantially in the machine direction;
a fibrous adhesive layer adjacent the elastic layer; and
a nonwoven web layer adjacent to the fibrous adhesive layer;
wherein the scrim layer comprises loops. - View Dependent Claims (91)
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Specification