Spunlaced polyester-meltblown polyetherester laminate

• US 4,781,966 A
• Filed: 10/15/1986
• Issued: 11/01/1988
• Est. Priority Date: 10/15/1986
• Status: Expired due to Term

• Current Assignee: The University Of Tennessee Research Corporation (University of Tennessee)
• Original Assignee: Kimberly-Clark Corporation
• Inventors: Taylor, Jack D.
• Primary Examiner(s): CANNON, JAMES
• Application Number:
  US06/919,273
• Time in Patent Office: 748 Days
• Field of Search: 428/152, 428/198, 428/200, 428/287, 428/288, 428/296, 428/302, 428/303, 428/339, 428/340
• US Class Current: 428/152
• CPC Class Codes: A61F 13/49007 Form-fitting, self-adjusting disposable diapers
• CPC Class Codes: A61F 13/51 characterised by the outer layers wicking or transfer layers A61F13/537
• CPC Class Codes: A61F 2013/15821 characterized by the apparatus for manufacturing
• CPC Class Codes: A61F 2013/49042 with only stretchable part, i.e. part being not elastic but only extensible with not a full recovery of its original length
• CPC Class Codes: A61F 2013/51078 being embossed
• CPC Class Codes: A61F 2013/530131 being made in fibre but being not pulp
• CPC Class Codes: A61F 2013/5395 with thermoplastic agent, i.e. softened by heat
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/516 mono-axially
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2432/00 Cleaning articles, e.g. mops, wipes personal care B32B2555/00
• CPC Class Codes: B32B 2437/00 Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 27/00 : Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/285 : comprising polyethers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• 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 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• 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 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 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• 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: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: D04H 1/435 : Polyesters
• CPC Class Codes: D04H 1/492 : by fluid jet D04H1/49 takes precedence
• CPC Class Codes: D04H 1/559 : the fibres being within layered webs
• CPC Class Codes: D04H 1/56 : in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: D06M 17/00 : Producing multi-layer textile fabrics
• CPC Class Codes: Y10T 428/24446 : Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 428/24843 : with heat sealable or heat releasable adhesive layer
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/27 : Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
• CPC Class Codes: Y10T 442/601 : Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/621 : Including other strand or fiber material in a different layer not specified as having microdimensions
• CPC Class Codes: Y10T 442/68 : Melt-blown nonwoven fabric
• CPC Class Codes: Y10T 442/681 : Spun-bonded nonwoven fabric

Abstract

A laminate which is elastic in at least one direction, includes an elastic sheet having at least one nonelastic nonwoven web joined thereto at least at two areas. The nonelastic web is gathered between the two areas. The elastic sheet is formed from a polyetherester and the nonelastic nonwoven web includes spunlaced hydraulically entangled polyester fibers. The nonelastic nonwoven web may also include rayon or wood pulp fibers.

Claims

1. A laminate which is elastic in at least one direction, said laminate comprising:

an elastic sheet comprising a polyetherester material having the following formula;

##STR3## where "G" is selected from the group including;

poly(oxyethylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

at least one nonelastic nonwoven web comprising spunlaced hydraulically entangled polyester fibers joined to said elastic sheet at least at two areas, said nonelastic web being gathered between said two areas.

2. The laminate of claim 1, wherein said elastic sheet is an elastic nonwoven web of meltblown fibers.

3. The laminate of claim 2, wherein the basis weight of the elastic nonwoven web is from about 10 grams per square meter to about 200 grams per square meter.

4. The laminate of claim 2, wherein the basis weight of the nonelastic web is from about 1 ounce per square yard to about 5 ounces per square yard.

5. The laminate of claim 2, wherein said polyetherester material has a melt flow of from about 5.0 to about 6.0 grams per 10 minutes when measured in accordance with ASTM D-1238 at 190°

C. under a 2,160 gram load.

6. The laminate of claim 2, wherein said meltblown fibers are meltblown microfibers.

7. The laminate of claim 2, wherein the nonelastic web is apertured.

8. The laminate of claim 2, wherein the nonelastic web further comprises fibers selected from the group consisting of rayon fibers or wood pulp fibers.

9. An elastic stretch-bonded laminate adapted to stretch at least about 50 percent in at least one direction, said laminate comprising:

an elastic nonwoven web comprising fibers of a polyetherester material having the formula of;

##STR4## where "G" is selected from the group including;

poly(oxyethylene)alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

at least one nonelastic nonwoven web comprising spunlaced hydraulically entangled polyester fibers joined to said elastic web at least at two areas, said nonelastic web being gathered between said two areas.

10. The stretch-bonded laminate of claim 9, wherein said polyetherester fibers are meltblown fibers.

11. The stretch-bonded laminate of claim 10, wherein the basis weight of the elastic nonwoven web is from about 10 grams per square meter to about 200 grams per square meter.

12. The stretch-bonded laminate of claim 10, wherein the basis weight of the nonelastic web is from about 1 ounce per square yard to about 5 ounces per square yard.

13. The stretch-bonded laminate of claim 10, wherein said polyetherester material has a melt flow of from about 5.0 to about 6.0 grams per 10 minutes when measured in accordance with ASTM D-1238 at 190°

C. under a 2,160 gram load.

14. The stretch-bonded laminate of claim 10, wherein said meltblown fibers are meltblown microfibers.

15. The stretch-bonded laminate of claim 10, wherein the nonelastic web is apertured.

16. The stretch-bonded laminate of claim 10, wherein the nonelastic web further comprises fibers selected from the group consisting of rayon fibers or wood pulp fibers.

17. An elastic palindromic stretch-bonded laminate adapted to stretch at least about 50 percent in at least one direction, said laminate comprising:

an inner elastic nonwoven web having a basis weight of from about 20 grams per square meter to about 100 grams per square meter, said elastic web comprising meltblown fibers of a polyetherester material having the formula of;

##STR5## where "G" is selected from the group including;

poly(oxyethylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

two outer nonelastic nonwoven webs comprising spunlaced hydraulically entangled polyester fibers, said nonelastic webs each having a basis weight of from about 1 ounce per square yard to about 5 ounces per square yard.

18. The palindromic stretch-bonded laminate of claim 17, wherein the nonelastic web further comprises fibers selected from the group consisting of rayon fibers or wood pulp fibers.

19. The palindromic stretch-bonded laminate of claim 17, wherein said meltblown fibers are meltblown microfibers.

20. The palindromic stretch-bonded laminate of claim 17, wherein the nonelastic web is apertured.

21. A laminate which is elastic in at least one direction, said laminate comprising:

an elastic sheet comprising a polyetherester material having the following formula;

##STR6## where "G" is selected from the group including;

poly(oxyethylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

at least one nonelastic nonwoven web comprising spunlaced hydraulically entangled polyester fibers joined to said elastic sheet at least at two areas, said nonelastic web being gathered between said two areas; and

wherein said spunlaced hydraulically entangled polyester nonwoven web has;

a machine direction sheet grab tensile of from about 10 pounds to 75 pounds;

a cross-machine direction sheet grab tensile of from about 5 to 50 pounds;

a machine direction trapezoid tear of from about 3 pounds to about 40 pounds;

a cross-machine trapezoid tear of from bout 2 pounds to about 45 pounds;

a thickness of from about 10 mils to about 45 mils; and

a basis weight of from about 1 to 5 ounces per square yard.

22. An elastic stretch-bonded laminate adapted to stretch at least about 50 percent in at least one direction, said laminate comprising:

an elastic nonwoven web comprising fibers of a polyetherester material having the formula of;

##STR7## where "G" is selected from the group including;

poly(oxyethylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

at least one nonelastic nonwoven web comprising spunlaced hydraulically entangled polyester fibers joined to said elastic web at least at two areas, said nonelastic web being gathered between said two areas

wherein said spunlaced hydraulically entangled polyester nonwoven web has;

a machine direction sheet grab tensile of from about 10 pounds to 75 pounds;

a cross-machine direction sheet grab tensile of from about 5 to 50 pounds;

a machine direction trapezoid tear of from about 3 pounds to about 40 pounds;

a cross-machine trapezoid tear of from bout 2 pounds to about 45 pounds;

a thickness of from about 10 mils to about 45 mils; and

a basis weight of from about 1 to 5 ounces per square yard.

23. An elastic palindromic stretch-bonded laminate adapted to stretch at least about 50 percent in at least one direction, said laminate comprising:

an inner elastic nonwoven web having a basis weight of from about 20 grams per square meter to about 100 grams per square meter, said elastic web comprising meltblown fibers of a polyetherester material having the formula of;

##STR8## where "G" is selected from the group including;

poly(oxythylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers; and

two outer nonelastic nonwoven webs comprising spunlaced hydraulically entangled polyester fibers, said nonelastic webs each having a basis weight of from about 1, ounce per square yard to about 5 ounces per square yard

wherein said spunlaced hydraulically entangled polyester nonwoven web has;

a machine direction sheet grab tensile of from about 10 pounds to 75 pounds;

a cross-machine direction sheet grab tensile of from about 5 to 50 pounds;

a machine direction trapezoid tear of from about 3 pounds to about 40 pounds;

a cross-machine trapezoid tear of from bout 2 pounds to about 45 pounds;

a thickness of from about 10 mils to about 45 mils; and

a basis weight of from about 1 to 5 ounces per square yard.

24. An elastic palindromic stretch-bonded laminate adapted to stretch at least about 50 percent in at least one direction, said laminate comprising:

an inner elastic nonwoven web having a basis weight of from about 20 grams per square meter to about 100 grams per square meter, said elastic web comprising meltblown fibers of a polyetherester material having the formula of;

##STR9## where "G" is selected from the group including;

poly(oxyethylene)-alpha,omega-diol poly(oxypropylene)-alpha,omega-diol poly(oxytetramethylene)-alpha,omega-diol and

"a", "m" and "n" are positive integers;

an outer nonelastic nonwoven web comprising spunlaced hydraulically entangled polyester fibers, said spunlaced nonelastic web having;

a machine direction sheet grab tensile of from about 10 pounds to 75 pounds;

a cross-machine direction sheet grab tensile of from about 5 to 50 pounds;

a machine direction trapezoid tear of from about 3 pounds to about 40 pounds;

a cross-machine trapezoid tear of from bout 2 pounds to about 45 pounds;

a thickness of from about 10 mils to about 45 mils; and

a basis weight of from about 1 to 5 ounces per square yard; and

an outer nonelastic web of dry laid polyester staple fibers having a length of from about 1.0 to about 2.0 inches joined by a hot melt polyester-based, powder-form adhesive, said dry laid web having a basis weight of from about 5 grams per square meter to about 50 grams per square meter.