Stretch Composites and Methods of Making the Composite

• US 20100116418A1
• Filed: 12/03/2009
• Published: 05/13/2010
• Est. Priority Date: 11/05/2001
• Status: Active Grant

• Current Assignee: Fred Naval Desai, Mark William Hamersky, Steven Daryl Smith, Urmish Popatlal Dalal
• Original Assignee: Fred Naval Desai, Mark William Hamersky, Steven Daryl Smith, Urmish Popatlal Dalal
• Inventors: Dalal, Urmish Popatlal, Smith, Steven Daryl, Hamersky, Mark William, Desai, Fred Naval
• Granted Patent: US 8,067,063 B2
• Time in Patent Office: Days
• US Class Current: 156/163
• CPC Class Codes: A61F 13/15593 having elastic ribbons fixed thereto; Devices for applying the ribbons
• CPC Class Codes: A61F 13/4902 characterised by the elastic material
• CPC Class Codes: A61F 2013/15284 characterized by quantifiable properties
• CPC Class Codes: B29C 55/08 transverse to the direction of feed
• CPC Class Codes: B29C 55/18 by squeezing between surfaces, e.g. rollers
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 53/025 modified
• CPC Class Codes: D06N 3/045 with polyolefin or polystyrene (co-)polymers
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component

Abstract

A stretch composite having one or more elastomeric members disposed on at least one region of an extensible fibrous substrate to provide stretch properties to a targeted region of the substrate. The composite has been incrementally stretched to at least partially break up the structure of the substrate in order to reduce its resistance to stretch. The stretch composites are useful for disposable and durable articles, such as disposable absorbent articles including diapers, pull-on diapers, training pants, incontinence briefs, catamenial garments, baby bibs, and the like, and durable articles like garments including sportswear, outerwear and the like. The present invention also relates to methods of forming such stretch composites.

Claims

1. A process for making a stretch composite comprising the steps of:

a. providing at least one inelastic substrate;

b. applying a tensioning force to the inelastic substrate to form a necked, inelastic substrate;

c. providing an application device, said device including at least one patterned print roll; and

d. printing at least two differing elastomeric members by means of said patterned print roll, onto said substrate to form a stretch composite, said elastomeric members differing in a property selected from the group consisting of differing width dimensions between said elastomeric members, differing mechanical properties between said elastomeric members, differing elastomeric compositions between said elastomeric members and differing visual appearance between said elastomeric members, and wherein said elastomeric members comprise a thermoplastic elastomer and a phase change solvent having the general formula;

R′

-L_y-(Q-L_x)_n-1-Q-L_y-R;

 

 

(I)

R′

-L_y-(Q-L_x)_n-R;

 

 

(II)

R′

-(Q-L_x)_n-R;

 

 

(III)

R′

-(Q-L_x)_n-1-Q-L_y-R;

 

 

(IV)

R′

-(Q-L_x)_n-1-Q-R;

or 

 

(V)

a mixture thereof;

wherein Q is a para-ring substituted difunctional aromatic moiety, and wherein the substitutions are in the 1,4 positions;

L is CH₂;

R and R′

are the same or different and are independently selected from H, CH3, COOH, CONHR₁, CONR₁R₂, NHR₃, NR₃R₄, hydroxy, or C1-C30 alkoxy;

wherein R₁, R₂, R₃ and R₄ are the same or different and are independently selected from H or linear or branched alkyl from C1-C30;

x is an integer from 1 to 30;

y is an integer from 1 to 30; and

n is an integer from 3 to 7;

wherein the phase change solvent has a phase change in a temperature range from 40°

C. to about 250°

C.

2. The process of claim 1, further comprising a step of bonding a second inelastic substrate to the stretch composite.

3. The process of claim 1, wherein the inelastic substrate is incrementally stretched, at least in one or more portions, prior to applying a tensioning force.

4. The process of claim 1, wherein said elastomeric members have a melt viscosity of from about 1 to about 400 Pa·

s, measured at 175°

C. and 1 s<sup>−

1</sup> strain rate.

5. The process of claim 1, wherein said elastomeric members are selected from the group consisting of rectilinear stripes, curvilinear stripes, triangles, trapezoids, squares, parallelograms, polygons, ellipses, circles and combinations thereof.

6. The process of claim 5, wherein said elastomeric members are spaced apart with respect to each other.

7. The process of claim 1, wherein the stretch composite comprises one or more elasticized regions of an absorbent article.

8. The process of claim 7, wherein the one or more elasticized regions of the absorbent article is selected from the group consisting of an elasticized waist region, an elasticized cuff region, an elasticized side panel, an elastic ear portion, an elasticized outercover, an elasticized topsheet, a fastener system, and combinations thereof.

9. The process of claim 1, wherein said thermoplastic elastomer and said phase change solvent have a weight ratio of from about 10:

1 to about 1;

1.

10. The process of claim 1, wherein said elastomeric members have a width dimension of at least about 2.0 mm.