Composite webs with reinforcing polymeric regions and elastic polymeric regions

• US 6,875,710 B2
• Filed: 11/05/2001
• Issued: 04/05/2005
• Est. Priority Date: 11/05/2001
• Status: Expired due to Fees

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Wood, Leigh E., Eaton, Bradley W., Jackson, Byron M., Tuman, Scott J.
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): Salvatore, Lynda
• Application Number:
  US10/012,698
• Publication Number:
  US 20030087098A1
• Time in Patent Office: 1,247 Days
• Field of Search: 442/66, 428/134, 428/136, 428/137, 428/141, 428/100, 428/167
• US Class Current: 442/66
• CPC Class Codes: A61F 13/4902 characterised by the elastic material
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/28 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 3/16 secured to a flexible backing
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/15 with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
• 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: Y10T 428/24017 Hook or barb
• CPC Class Codes: Y10T 428/24298 Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 Slit or elongated
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2049 : Each major face of the fabric has at least one coating or impregnation
• CPC Class Codes: Y10T 442/2057 : At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3024 : Including elastic strand or strip

Abstract

Methods of manufacturing composite webs including a substrate with one or more reinforcing discrete polymeric regions located on or within the composite web are disclosed. Molten nonelastomeric thermoplastic material of the discrete polymeric region is forced against the substrate by a transfer roll. If the substrate is porous, fibrous, etc., a portion of the nonelastomeric thermoplastic composition may infiltrate the substrate and/or encapsulate fibers of the substrate. The composite webs also include elastomeric thermoplastic material in discrete polymeric regions on or within the composite web.

Claims

1. An elastic article comprising:

a substrate comprising first and second major surfaces;

one or more reinforcing discrete polymeric regions attached to the substrate, wherein each reinforcing discrete polymeric region of the one or more reinforcing discrete polymeric regions comprises a nonelastomeric thermoplastic composition that infiltrates a portion of substrate; and

one or more elastic elements attached to the substrate, wherein each elastic element of the one or more elastic elements comprises an elastic discrete polymeric region comprising an elastomeric thermoplastic composition that infiltrates a portion of the substrate.

2. An article according to claim 1, wherein the substrate comprises a laminated substrate comprising a first substrate and a second substrate, wherein each elastic element of the one or more elastic elements is located between the first substrate and the second substrate.

3. An article according to claim 1, wherein at least one elastic element of the one or more elastic elements is located on the first major surface of the substrate.

4. An article according to claim 1, wherein at least one elastic element of the one or more elastic elements is located on the second major surface of the substrate.

5. An article according to claim 1, further comprising an elongation axis, wherein each elastic element of the one or more elastic elements comprises a length greater than a width, and wherein the length of each elastic element of the one or more elastic elements is aligned with the elongation axis.

6. An article according to claim 5, wherein the amount of elastomeric thermoplastic in each elastic element of the one or more elastic elements increases when moving away from the one or more reinforcing discrete polymeric regions along the elongation axis.

7. An article according to claim 1, wherein at least one reinforcing discrete polymeric region of the one or more reinforcing discrete polymeric regions comprises an opening formed through the substrate within a surrounding ring formed of the nonelastomeric thermoplastic composition of the at least one reinforcing discrete polymeric region.

8. An article according to claim 1, further comprising one or more slits formed through the substrate, wherein at least one of the one or more elastic elements spans at least one slit of the one or more slits.

9. An article according to claim 1, further comprising one or more pleats formed in the substrate, wherein at least one of the one or more elastic elements spans at least one pleat of the one or more pleats.

10. An article according to claim 9, wherein at least some elastic elements of the one or more elastic elements spans only one pleat of the one or more pleats.

11. An article according to claim 9, at least some elastic elements of the one or more elastic elements span two or more pleats of the one or more pleats.

12. A composite web comprising:

a substrate comprising first and second major surfaces;

a plurality of nonelastomeric discrete polymeric regions attached to the substrate, wherein each nonelastomeric discrete polymeric region of the plurality of nonelastomeric discrete polymeric regions comprises a nonelastomeric thermoplastic composition that infiltrates a portion of substrate;

a plurality of elastomeric discrete polymeric regions attached to the substrate, wherein each elastomeric discrete polymeric region of the plurality of elastomeric discrete polymeric regions comprises an elastomeric thermoplastic composition that infiltrates a portion of the substrate; and

one or more lines of separation in the composite web, wherein the one or more lines of separation define boundaries of a plurality of distinct articles in the composite web, and wherein each article of the plurality of articles comprising at least one nonelastomeric discrete polymeric region of the plurality of nonelastomeric discrete polymeric regions and at least one elastomeric discrete polymeric region of the plurality of elastomeric discrete polymeric regions.

13. A composite web according to claim 12, wherein the substrate comprises a laminated substrate comprising a first substrate and a second substrate, wherein each elastomeric discrete polymeric region of the plurality of elastomeric discrete polymeric regions is located between the first substrate and the second substrate.

14. A composite web according to claim 12, wherein the substrate comprises a laminated substrate comprising a first substrate and a second substrate, wherein each elastomeric discrete polymeric region of the plurality of elastomeric discrete polymeric regions is located on the first major surface or the second major surface of the substrate.

15. A composite web according to claim 12, wherein the substrate comprises a laminated substrate comprising a first substrate and a second substrate, wherein each nonelastomeric discrete polymeric region of the plurality of nonelastomeric discrete polymeric regions is located between the first substrate and the second substrate.

16. A composite web according to claim 12, wherein the substrate comprises a laminated substrate comprising a first substrate and a second substrate, wherein each nonelastomeric discrete polymeric region of the plurality of nonelastomeric discrete polymeric regions is located on the first major surface or the second major surface of the substrate.