Three-dimensional highly elastic film/non-woven composite

• US 6,537,930 B1
• Filed: 05/18/2000
• Issued: 03/25/2003
• Est. Priority Date: 05/18/2000
• Status: Expired due to Term

• Current Assignee: Fitesa Film Products LLC
• Original Assignee: Tredegar Film Products Corporation (Tredegar Corporation)
• Inventors: Bruce, Steve D., Middlesworth, Jeff A., Cree, James W.
• Primary Examiner(s): Cole, Elizabeth M.
• Assistant Examiner(s): TORRES VELAZQUEZ, NORCA LIZ
• Application Number:
  US09/574,657
• Time in Patent Office: 1,041 Days
• Field of Search: 442/328, 442/329, 442/366, 442/370, 442/382, 442/394, 442/401, 428/196, 428/198, 428/137
• US Class Current: 442/39
• CPC Class Codes: A61F 13/5146 having apertures of perforations
• CPC Class Codes: A61F 13/51464 being stretchable or elastomeric
• 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 7/04 Interconnection of layers
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 442/166 Cellulose acetate film or sheet
• CPC Class Codes: Y10T 442/601 Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/602 Nonwoven fabric comprises an elastic strand or fiber material
• CPC Class Codes: Y10T 442/643 Including parallel strand or fiber material within the nonwoven fabric
• CPC Class Codes: Y10T 442/654 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/66 Additional nonwoven fabric is a spun-bonded fabric
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/681 Spun-bonded nonwoven fabric

Abstract

A three-dimensional highly elastic film/non-woven composite having a fluid and air impervious core layer and a first and second consolidated layer. The consolidated layers have unidirectional and non-unidirectional fibers. The composite is formed by laminating the air and fluid impermeable elastic core layer between the two layers of consolidated non-wovens. The resulting composite stretches only in the cross-machine direction due to the unidirectional properties of the consolidated non-woven material. The layers are then point bonded or welded together. Preferably the layers are welded by passing the composite between an ultrasonic horn and an ultrasonic bond roll having raised areas for effecting the weld points. A thin inelastic membrane is formed at each of the weld points. The welded composite may then be pre-stretched to rupture the membranes, thereby creating apertures, which makes the composite permeable.

Claims

1. A three dimensional highly elastic film/non-woven composite, comprising:

a fluid and air impervious core film layer having a first side and a second side;

a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer;

a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer; and

wherein said weld points are substantially inelastic and the weld points rupture to form apertures when the composite is stretched in a cross-machine direction to an elongation of about 200% or less.

2. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said core layer comprised of a material selected of a group consisting of an elastomeric film, a foam, and a multi-layer film.

3. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of bicomponent fibers that have at least two distinct meltpoints.

4. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of blended fibers that have at least two distinct meltpoints.

5. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second consolidated layer are comprised of unidirectional fibers and non-unidirectional fibers; and

said first non-woven layer is comprised of fibers that are anisotropic.

6. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first consolidated layer and said second consolidated layer are comprised of unidirectional fibers and non-unidirectional fibers; and

said second consolidated layer is comprised of fibers that are anisotropic.

7. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said weld points occupy between about 2% to about 10% of a total surface area of the film/non-woven composite.

8. The three-dimensional highly elastic film/non-woven composite of claim 1, further comprising:

membranes formed in said weld points wherein said membranes rupture to form apertures when the composite is stretched in a transverse direction to an elongation greater than about 50%.

9. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

the composite provides sufficient resistance to forces greater than about 1500 grams per inch to prevent tearing of the composite.

10. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

the composite has an ultimate tensile direction elongation percentage in the range of about 400% to about 650%.

11. The three-dimensional highly elastic film/non-woven composite of claim 1, further comprising:

stretchable regions and non-stretchable regions.

12. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and

said unidirectional and non-unidirectional fibers of said first non-woven layer have a tensile to break ratio in a machine direction to a cross direction in the range of about 3;

1 to about 1.8;

1.

13. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and

wherein a tensile to break ratio for said unidirectional and non-unidirectional fibers in a machine direction to a cross direction of said first non-woven layer is about 1.8;

1.

14. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and

wherein a tensile to break ratio for said unidirectional and non-unidirectional fibers in a machine direction to a cross direction of said first non-woven layer is about 3;

1.

15. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and

wherein the tensile to break ratio for said first non-woven layer for a machine direction to a cross direction is about 1.8;

1.

16. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

the tensile to break ratio forces of said first non-woven layer in a machine direction to a cross direction is about 3;

1.

19. The three-dimensional highly elastic film/non-woven composite of claim 5, wherein:

said first consolidated layer is comprised of bicomponent fibers that have at least two distinct meltpoints.

20. The three-dimensional highly elastic film/non-woven composite of claim 5, wherein:

said first consolidated layer is comprised of blended fibers that have at least two distinct meltpoints.

21. The three-dimensional highly elastic film/non-woven composite of claim 1, wherein:

the weld points rupture to form apertures when the composite is stretched in a cross-machine direction to an elongation of at least about 20%.

17. A three-dimensional highly elastic film/non-woven composite, comprising:

a fluid and air impervious core film layer having a first side and a second side;

a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer, said first non-woven layer having unidirectional fibers and non-unidirectional fibers, wherein said unidirectional and non-unidirectional fibers of said first non-woven layer have a tensile to break ratio for a machine direction to a cross direction in the range of about 3;

1 to about 1.8;

1;

a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer, said second non-woven layer having unidirectional fibers and non-unidirectional fibers; and

a plurality of bond regions formed by said weld points that bond said first non-woven layer, said second non-woven layer and said core layer together;

inelastic membranes within said bond regions, said membranes adapted to tear upon stretching of the composite, thereby forming apertures.

18. The three-dimensional highly elastic film/non-woven composite of claim 17, wherein:

the unidirectional fibers and non-unidirectional fibers have a tensile to break ratio of a machine direction to a cross direction in the range of about 3;

1 to about 1.8;

1, wherein the unidirectional fibers of said second consolidated layer are oriented in the same direction as the unidirectional fibers of said first consolidated layer fibers.