Elastic laminates and methods for making the same

• US 6,090,234 A
• Filed: 08/21/1997
• Issued: 07/18/2000
• Est. Priority Date: 07/15/1996
• Status: Expired due to Term

• Current Assignee: Wyeth (Pfizer Inc.)
• Original Assignee: The Procter & Gamble Company
• Inventors: Ouellette, William Robert, Barone, Daniel Louis
• Primary Examiner(s): YAO, SAMCHUAN CUA
• Application Number:
  US08/915,831
• Time in Patent Office: 1,062 Days
• Field of Search: 156/177, 156/178, 156/179, 156/292, 156/296, 156/244.15, 156/441, 156/308.2, 264/DIG. 81, 428/110
• US Class Current: 156/177
• CPC Class Codes: B29C 70/224 the structure being a net B29C70/688 takes precedence
• CPC Class Codes: B29C 70/504 using rollers or pressure bands for corrugating B29C53/22
• CPC Class Codes: B29K 2105/0809 Fabrics
• CPC Class Codes: B29K 2105/108 arranged in parallel planes and crossing at substantial angles B29K2105/206 takes precedence
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2459/00 Nets, e.g. camouflage nets
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 37/04 characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/206 Laminating a continuous layer between two continuous plastic layers
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• 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 7/04 Interconnection of layers
• CPC Class Codes: D04H 1/559 the fibres being within layered webs
• CPC Class Codes: D04H 3/04 : in rectilinear paths, e.g. crossing at right angles
• CPC Class Codes: Y10T 428/24099 : On each side of strands or strand-portions

Abstract

The present invention relates to elastic laminate structures comprising an open cell polymeric mesh integrally thermal bonded between two fabric carrier layers and methods for manufacturing such laminates.

Claims

1. A method of manufacturing elastic laminate structures comprises the steps of:

a) providing a first carrier layer;

b) providing a second carrier layer;

c) providing a mesh, disposed between said first and second carrier layers, having a plurality of first strands intersecting a plurality of second strands, said first and second strands having a softening temperature at an applied pressure, wherein said softening temperature of said second strands, at said applied pressure, is greater than said softening temperature of said first strands at said applied pressure;

d) heating said mesh to said softening temperature of said first strands and less than said softening temperature of said second strands;

e) applying a bonding pressure to said first strands; and

f) integrally bonding from about 10% to about 100% by weight, of said first strands to said first and second carrier layers.

2. A method of manufacturing elastic laminate structures according to claim 1 wherein at least about 50% by weight, of said first strands are integrally bonded to said first and second carrier layers.

3. A method of manufacturing elastic laminate structures according to claim 2 wherein at least about 90% by weight, of said first strands are integrally bonded to said first and second carrier layers.

4. A method of manufacturing elastic laminate structures according to claim 1 wherein the outer surface of said first strands penetrate at least about 10% of the structural thickness of said first and second carrier layers.

5. A method of manufacturing elastic laminate structures according to claim 4 wherein the outer surface of said first strands penetrate at least about 50% of the structural thickness of said first and second carrier layers.

6. A method of manufacturing elastic laminate structures according to claim 5 wherein the outer surface of said first strands penetrate at least about 75% of the structural thickness of said first and second carrier layers.

7. A method of manufacturing elastic laminate structures according to claim 1 wherein said softening temperature of said first strands is at least 10°

C. lower, at said applied pressure, than said softening temperature of said second strands.

8. A method of manufacturing elastic laminate structures according to claim 7 wherein said softening temperature of said first strands is at least 20°

C. lower, at said applied pressure, than said softening temperature of said second strands.

9. A method of manufacturing elastic laminate structures according to claim 1 wherein at least about 50% by weight, of said integrally bonded first strands are deformed to a flat shape and are coplanar with said first and second carrier layers.

10. A method of manufacturing elastic laminate structures according to claim 9 wherein at least about 75% by weight, of said integrally bonded first strands are deformed to a flat shape and are coplanar with said first and second carrier layers.

11. A method of manufacturing elastic laminate structures according to claim 1 wherein at least 25% by weight, of said second strands are deformed to a substantially elliptical cross-sectional shape.

12. A method of manufacturing elastic laminate structures according to claim 11 wherein at least 50% by weight, of said second strands are deformed to a substantially elliptical cross-sectional shape.

13. A method of manufacturing elastic laminate structures according to claim 12 wherein at least 75% by weight, of said second strands are deformed to a substantially elliptical cross-sectional shape.

14. A method of manufacturing elastic laminate structures according to claim 1 wherein said first carrier layer is juxtaposed said mesh which is juxtaposed said second carrier layer, wherein said juxtaposed first carrier layer, mesh, and second carrier layer pass over a substantially non-resilient first surface, and a substantially non-resilient second surface, wherein said surfaces are provided in the form of rollers.

15. A method of manufacturing elastic laminate structures according to claim 14 wherein said first and second surfaces are heated to a temperature sufficient to raise the temperature of said first strands to said softening temperature of said first strands.

16. A method of manufacturing elastic laminate structures according to claim 15 wherein said first surface is spaced adjacent said second surface forming a gap therebetween such that said juxtaposed first carrier layer, mesh, and second carrier layer pass easily therethrough said gap.

17. A method of manufacturing elastic laminate structures according to claim 16 wherein said second surface is positioned adjacent a substantially resilient third surface forming an interference nip therebetween such that from about 10% to about 100% of said first strands are integrally bonded to said first and second carrier layers when said juxtaposed first carrier layer, mesh, and second carrier layer pass through said nip.