Elastic nonwoven pad

• US 4,801,482 A
• Filed: 10/15/1986
• Issued: 01/31/1989
• Est. Priority Date: 10/15/1986
• Status: Expired due to Term

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Corporation
• Inventors: Chester, Stephen O., Goggans, Gary L., Frost, J. Eric, Ozbirn, Monica V., Everhart, Cherie H.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US06/919,298
• Time in Patent Office: 839 Days
• Field of Search: 428/137, 428/138, 428/152, 428/182, 428/184, 428/186, 428/198, 428/284, 428/287, 428/297, 428/298, 428/299, 428/296, 428/903, 428/340, 428/326, 428/53, 428/68, 5/500
• US Class Current: 428/68
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• 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 2555/02 Diapers or napkins
• 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 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 1/559 : 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: Y10S 428/903 : Microfiber, less than 100 micron diameter
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/24446 : Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 428/24694 : Parallel corrugations
• CPC Class Codes: Y10T 428/24711 : Plural corrugated components
• CPC Class Codes: Y10T 428/24727 : with planar component
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• 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.]

Abstract

An elastic pad 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 sheet may be formed from a polyetherester and the nonelastic nonwoven web may be a web of spunlaced hydraulically entangled polyester fibers. The nonelastic nonwoven web may also include rayon or wood pulp fibers.

Claims

1. An elastic pad formed from a composite elastic laminate which includes an elastic nonwoven web and at least one nonelastic web joined to said elastic nonwoven web at least at two areas and with said nonelastic web being gathered between said two areas, said pad comprising

a top;

and

sides depending from said; and

wherein said sides are adapted to retainingly engage an edge of a surface to be covered.

2. The elastic pad of claim 1, wherein said pad is a mattress pad.

3. The elastic pad of claim 1, wherein said pad is a table pad.

4. The elastic pad of claim 1, wherein the composite elastic laminate has an interlayer bonding force of at least 2 kilograms.

5. The elastic pad of claim 4, wherein the interlayer bonding force is from about 2.5 to about 4.5 kilograms.

28. The elastic pad of claim 1, wherein said pad has a substantially rectangular shape.

29. The elastic pad of claim 1, wherein said pad has a substantially circular shape.

30. The elastic pad of claim 1, wherein said pad has a substantially square shape.

31. The elastic pad of claim 1, wherein said pad is capable of stretching at least about 25 percent in at least one direction.

32. The elastic pad of claim 1, wherein said pad is a table pad.

33. The elastic pad of claim 1, wherein said pad is a mattress pad.

34. The table pad of claim 32 having from about 40 percent to about 100 percent stretch in the machine direction and having up to about 40 percent stretch in the cross-machine direction.

35. The mattress pad of claim 33, wherein said pad is capable of stretching at least about 50 percent in at least one direction.

36. The mattress pad of claim 33, wherein said pad is capable of stretching from about 50 percent to about 100 percent in at least one direction.

37. The mattress pad of claim 33, wherein said pad is capable of stretching about 75 percent in at least one direction.

48. The elastic pad of claim 1, wherein said nonelastic web is a nonelastic nonwoven web.

6. An elastic pad formed from a composite elastic laminate which includes an elastic nonwoven web and at least one nonelastic web joined to said elastic nonwoven web at least at two areas and with said nonelastic web being gathered between said two areas, said pad comprising:

a top; and

sides depending from said top; and

wherein said sides are adapted to retainingly engage an edge of a surface to be covered.

7. The elastic pad of claim 6, wherein said elastic sheet is an elastic nonwoven web of meltblown fibers.

8. The elastic pad of claim 7, wherein the basis weight of the elastic nonwoven web is from about 10 grams per square meter to about 200 grams per square meter.

9. The elastic pad of claim 7, wherein the basis weight of the nonelastic web is from about 1 ounce per square yard to about 5 ounces per square yard.

10. The elastic pad of claim 7, wherein said melt-blown fibers are meltblown microfibers.

11. The elastic pad of claim 7, wherein the nonelastic web is apertured.

49. The elastic pad of claim 6, wherein said nonelastic web is a nonelastic nonwoven web.

12. An elastic pad comprising:

a top; and

sides depending from said top that are adapted to retainingly engage an edge of a surface to be covered; and

wherein said elastic pad is formed from a stretch-bonded laminate;

including

an elastic nonwoven web, said elastic web comprising fibers of a polyetherurethane material; and

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

13. An elastic pad comprising:

a top; and

sides depending from said top that are adapted to retainingly engage an edge of a surface to be covered; and

wherein said elastic pad is formed from a stretch-bonded laminate, said laminate including;

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

##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 of spunlaced hydraulically entangled polyester fibers joined to said elastic web at least at two areas and with said nonelastic web being gathered between said two areas.

14. The elastic pad of claim 13, wherein said polyetherester fibers are meltblown fibers.

15. The elastic pad of claim 14, wherein the basis weight of the elastic nonwoven web is from about 10 grams per square meter to about 200 grams per square meter.

16. The elastic pad of claim 14, wherein the basis weight of the nonelastic web is from about 1 ounce per square yard to about 5 ounces per square yard.

17. The elastic pad of claim 14, 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.

18. The elastic pad of claim 14, wherein said meltblown fibers are meltblown microfibers.

19. The elastic pad of claim 14, wherein the nonelastic web is apertured.

20. The elastic pad of claim 14, wherein the nonelastic web further comprises fibers selected from the group consisting of rayon fibers or wood pulp fibers.

21. An elastic pad comprising:

a top; and

sides depending from said top that are adapted to retainingly engage an edge of a surface to be covered; and

wherein said elastic pad is formed from a palindromic stretch-bonded laminate, said laminate including;

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 polyetheresterurethane material having a melt index of from about 5 grams per 10 minutes to about 20 grams per 10 minutes when measured at 190 degrees C. under a 2,160 gram load; 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.

22. An elastic pad comprising:

a top; and

sides depending from said top that are adapted to retainingly engage an edge of a surface to be covered; and

wherein said elastic pad is formed from a palindromic stretch-bonded laminate including;

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;

##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

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.

23. The elastic pad of claim 22, wherein the nonelastic web further comprises fibers selected from the group consisting of rayon fibers or wood pulp fibers.

24. The elastic pad of claim 22, wherein said melt-blown fibers are meltblown microfibers.

25. The elastic pad of claim 22, wherein the nonelastic web is apertured.

26. The elastic pad of claim 22, wherein the composite elastic laminate has an interlayer bonding force of at least 2 kilograms.

27. The elastic pad of claim 26, wherein the interlayer bonding force is from about 2.5 to about 4.5 kilograms.

38. The elastic pad of claim 22, wherein said pad has a substantially rectangular shape.

39. The elastic pad of claim 22, wherein said pad has a substantially rectangular shape.

40. The elastic pad of claim 22, wherein said pad has a substantially rectangular shape.

41. The elastic pad of claim 22, wherein said pad is capable of stretching at least about 25 percent in at least one direction.

42. The elastic pad of claim 22, wherein said pad is a table pad.

43. The elastic pad of claim 22, wherein said pad is a mattress pad.

44. The table pad of claim 42 having from about 40 percent to about 100 percent stretch in the machine direction and having up to about 40 percent stretch in the cross-machine direction.

45. The mattress pad of claim 43, wherein said pad is capable of stretching at least 50 percent in at least one direction.

46. The mattress pad of claim 43, wherein said pad is capable of stretching from about 50 percent to about 75 percent in at least one direction.

47. The mattress pad of claim 43, wherein said pad is capable of stretching about 75 percent in at least one direction.