U.S. patent application number 11/997598 was filed with the patent office on 2010-09-02 for stretchable laminate.
Invention is credited to Johannes H. A. de Jong.
Application Number | 20100221496 11/997598 |
Document ID | / |
Family ID | 38654945 |
Filed Date | 2010-09-02 |
United States Patent
Application |
20100221496 |
Kind Code |
A1 |
de Jong; Johannes H. A. |
September 2, 2010 |
STRETCHABLE LAMINATE
Abstract
A stretchable laminate (10) comprising at least one nonelastic
fabric layer (20/30) and an elastic layer (40) laminated thereto.
The fabric layer(s) (20/30) have interruptions (22/32) formed
therein which extend 10% to 99% through the layer thickness thereby
rendering the laminate (10) stretchable. The stretchable laminate
(10) can be incorporated into a diaper component, or it can serve
as an intermediate laminate in a method for making an elastic, or
more elastic, laminate.
Inventors: |
de Jong; Johannes H. A.;
(Lichtaart, BE) |
Correspondence
Address: |
RENNER, OTTO, BOISSELLE & SKLAR, LLP (AVERY)
1621 EUCLID AVE, 19TH FL
CLEVELAND
OH
44115-2191
US
|
Family ID: |
38654945 |
Appl. No.: |
11/997598 |
Filed: |
August 31, 2007 |
PCT Filed: |
August 31, 2007 |
PCT NO: |
PCT/US07/77367 |
371 Date: |
February 1, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60941402 |
Jun 1, 2007 |
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60941431 |
Jun 1, 2007 |
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60941420 |
Jun 1, 2007 |
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60913048 |
Apr 20, 2007 |
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60913059 |
Apr 20, 2007 |
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60912983 |
Apr 20, 2007 |
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60862252 |
Oct 20, 2006 |
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60824261 |
Aug 31, 2006 |
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Current U.S.
Class: |
428/172 ;
156/257 |
Current CPC
Class: |
A61F 13/4902 20130101;
A61F 13/49015 20130101; Y10T 442/601 20150401; A61F 13/5622
20130101; A61F 13/49012 20130101; Y10T 156/1064 20150115; Y10T
428/24314 20150115; Y10T 428/24612 20150115; B32B 3/10 20130101;
B32B 27/12 20130101; A61F 13/49017 20130101 |
Class at
Publication: |
428/172 ;
156/257 |
International
Class: |
B32B 3/30 20060101
B32B003/30; B32B 38/04 20060101 B32B038/04 |
Claims
1. A stretchable laminate (10) comprising a first fabric layer (20)
and an elastic layer (40) laminated thereto; wherein the elastic
layer (40) is made of an elastic material that has recoverable
elongation properties in a direction (C) cross from the machine
direction (M); wherein the first fabric layer (20) has
interruptions (22) formed therein which extend 10% to 99% through
the layer thickness thereby rendering the laminate (10) stretchable
in the cross direction (C).
2. A stretchable laminate (10) as set forth in the preceding claim,
wherein the first fabric layer (20) is a nonelastic fabric
layer.
3. A stretchable laminate (10) as set forth in either of the two
preceding claims, wherein the first fabric layer (20) is a nonwoven
fabric layer.
4. A stretchable laminate (10) as set forth in any of the preceding
claims, further comprising a second fabric layer (30) and wherein
the elastic layer (40) is sandwiched between the first fabric layer
(20) and the second fabric layer (30).
5. A stretchable laminate (10) as set forth in the preceding claim,
wherein the second fabric layer (30) also has interruptions (32)
formed therein which extend 10% to 99% through the layer
thickness.
6. A stretchable laminate (10) as set forth in either of the two
preceding claims, wherein the second fabric layer (30) is a
nonelastic fabric layer.
7. A stretchable laminate (10) as set forth in any of the claims
4-6, wherein the second fabric layer (30) is a nonwoven fabric
layer.
8. A stretchable laminate (10) as set forth in any of the preceding
claims, wherein adjacent interruptions (22/32) are spaced a
distance of between about 1 millimeter and about 10
millimeters.
9. A stretchable laminate (10) as set forth in any of claims 1-8,
wherein interruptions (22/32) are spaced evenly.
10. A stretchable laminate (10) as set forth in any of claims 1-8,
wherein interruptions (22/32) are spaced unevenly.
11. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 20% to
99% through the thickness of the fabric layer (20/30).
12. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 30% to
99% through the thickness of the fabric layer (20/30).
13. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 40% to
99% through the thickness of the fabric layer (20/30).
14. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 50% to
99% through the thickness of the fabric layer (20/30).
15. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 60% to
99% through the thickness of the fabric layer (20/30).
16. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend 70% to
99% through the thickness of the fabric layer (20/30).
17. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) are die-cuts,
kiss cuts, slits, scores, laser cuts, and/or ultrasound cuts.
18. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the interruptions (22/32) extend in a
path non-parallel to the cross direction (C).
19. A stretchable laminate (10) as set forth in claim 18, wherein
interruptions (22/32) extend in a path substantially parallel to
the machine direction (M).
20. A stretchable laminate (10) as set forth in claim 18, wherein
the interruptions (22/32) extend in a path at an acute angle
relative to the machine direction (M).
21. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the paths of respective interruptions
intersect.
22. A stretchable laminate (10) as set forth in any of the claims
17-21, wherein the interruptions (22/32) are substantially
continuously spaced in the cross direction (C).
23. A stretchable laminate (10) as set forth in any of the claims
17-21, wherein the interruptions are noncontinuously spaced in the
cross direction.
24. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein adjacent interruptions (22/32) are spaced
apart a distance between about 1 millimeter and about 10
millimeters in the cross direction (C).
25. A stretchable laminate (10) as set forth in any of claims
17-24, wherein the interruptions (22/32) extend continuously across
the span of the machine direction (M).
26. A stretchable laminate (10) as set forth in any of claims
17-24, wherein the interruptions (22/32) extend noncontinuously
across the span of the machine direction (M).
27. A stretchable laminate (10) as set forth in any of claims 1-26,
wherein the elastic layer (40) is substantially coextensive with
the fabric layer(s) (20/30) in the cross direction (C).
28. A stretchable laminate (10) as set forth in any of claims 1-27,
wherein the elastic layer (40) is substantially coextensive with
the fabric layer(s) (20/30) in the machine direction (M).
29. A stretchable laminate (10) as set forth in any claims 1-26,
wherein the elastic layer (40) is non-coextensive with the fabric
layer(s) (20/30) in the cross direction (C).
30. A stretchable laminate (10) as set forth in the preceding
claim, wherein the elastic layer (40) is coextensive with the
fabric layer(s) (20/30) in the machine direction (M).
31. A stretchable laminate (10) as set forth in any of claims
27-30, wherein the interruptions (22/32) are coextensive with the
elastic layer (40).
32. A stretchable laminate (10) as set forth in any of claims
27-30, wherein the interruptions (22/32) are non-coextensive with
the elastic layer (40).
33. A stretchable laminate (10) as set forth in any of claims
27-30, wherein the interruptions (22/32) do not extend beyond the
extent of the elastic layer (40) in the cross-direction (C).
34. A stretchable laminate (10) as set forth in the preceding
claim, wherein the interruptions (22/32) extend almost, but not
quite the full cross-extent of the elastic layer (40) to leave an
uninterrupted margin aligned each lateral edge of the elastic layer
(40).
35. A stretchable laminate (10) as set forth in the preceding
claim, wherein the uninterrupted margins each have a width in the
range of 2 mm to 20 mm.
36. A stretchable laminate (10) as set forth in any of claims
27-30, comprising interrupted zones (12) and uninterrupted zones
(14), and wherein the interruptions (22/32) are located only in the
interrupted zones (12).
37. A stretchable laminate (10) as set forth in claim 36, wherein
the elastic layer (40) is coextensive with both the interrupted
zones (12) and the uninterrupted zones (14).
38. A stretchable laminate (10) as set forth in claim 36, wherein
the elastic layer (40) is coextensive with only the interrupted
zones (12).
39. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein a skin/liner sublayer(s) (42) is (are)
positioned between the fabric layer(s) (20/30) and the elastic
layer (40).
40. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein an adhesive sublayer(s) (46) is (are)
positioned between the fabric layer(s) (20/30) and the elastic
layer (40).
41. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the fabric layer(s) (20/30) is (are) heat
bonded to the elastic layer (40).
42. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the fabric layer(s) (20/30) is (are)
ultrasonically bonded to the elastic layer (40).
43. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the first fabric layer (20) has tendons
(24) extending from the interruptions (22) through the remaining
percentage of the layer thickness.
44. A stretchable laminate (10) as set forth in any of the
preceding claims, wherein the second fabric layer (30) has a tendon
(34) positioned between the elastic layer (40) and an
elastic-layer-adjacent end of an aligned interruption (32).
45. A stretchable laminate (10) as set forth in either claim 43 or
claim 44, wherein the tendons (24/34) extend from an
elastic-adjacent proximate side of the fabric layer (20/30) and the
interruptions (22/32) extend from the tendons (24/34) to the distal
side of the fabric layer (20/30).
46. A stretchable laminate (10) as set forth in any claims 43-45,
wherein the interruptions (22/32) extend from an elastic-adjacent
proximate side of the fabric layer (20/30) and the tendons (24/34)
extend from the interruptions (22/32) to the distal side of the
fabric layer (20/30).
47. An elastic laminate (18) made from a stretchable laminate (10)
as set forth in any of claims 43-46, wherein the tendons (24/34)
have been interrupted whereby the fabric layer (20/30) comprises
separate fabric segments (28/38) attached to the elastic layer (40)
which diverge upon laminate elongation and converge upon laminate
recovery.
48. An elastic laminate (18) as set forth in the preceding claim,
wherein the elastic layer (40) is visible between the fabric
segments (28/38) upon laminate elongation.
49. An elastic laminate (18) as set forth in either claim 47 or
claim 48, wherein the elastic layer (40) is hidden by the fabric
segments (28/38) upon laminate recovery.
50. An elastic laminate (18) as set forth in any of claims 47-49,
wherein the initial interruptions (22/32) comprise severed fiber
ends.
51. An elastic laminate (18) as set forth in any of claims 47-50,
wherein the tendons (24/34) have been ruptured whereby the tendon
interruptions (26/36) comprise fractured fiber ends.
52. An elastic laminate (18) as set forth in any of claims 47-50,
wherein the tendons (24/34) have been cut, slit, or scored, whereby
the tendon interruptions (26/36) comprise severed fiber ends.
53. An elastic laminate (18) comprising a first fabric layer (20)
and an elastic layer (40) laminated thereto; wherein the elastic
layer (40) is made of an elastic material that has recoverable
elongation properties in a direction (C) cross from the machine
direction (M); wherein the first fabric layer (20) comprises
separate fabric segments (28) attached to the elastic layer (40)
which diverge upon elongation and converge upon recovery; wherein
the separate fabric segments (28) are formed by initial
interruptions (22) which extend through 10% to 99% of the layer
thickness and tendon interruptions (26) which extend from the
interruptions (22) through the remaining 90% to 1% of the layer
thickness.
54. An elastic laminate (18) as set forth in the preceding claim,
wherein the first fabric layer (20) is a nonelastic fabric
layer.
55. An elastic laminate (18) as set forth in either of the two
preceding claims, wherein the first fabric layer (20) is a nonwoven
fabric layer.
56. An elastic laminate (18) as set forth in any of claims 53-55,
further comprising a second fabric layer (30) and wherein the
elastic layer (40) is sandwiched between the first fabric layer
(20) and the second fabric layer (30).
57. An elastic laminate (18) as set forth in the preceding claim,
wherein the second fabric layer (30) has initial interruptions (32)
which extend through 10% to 99% of the layer thickness and tendon
interruptions (36) which extend from the initial interruptions (32)
through the remaining 90% to 1% of the layer thickness.
58. An elastic laminate (18) as set forth in either of the two
preceding claims, wherein the second fabric layer (30) is a
nonelastic fabric layer.
59. An elastic laminate (18) as set forth in any of claims 56-58,
wherein the second fabric layer (30) is a nonwoven fabric
layer.
60. An elastic laminate (18) as set forth in any of claims 53-59,
wherein the tendon interruptions (26/36) extend from the proximal
side of the fabric layer (20/30) and the initial interruptions
(22/32) extend from the tendon interruptions (26/36) to the distal
side of the fabric layer (20/30).
61. An elastic laminate (18) as set forth in any of claims 53-60,
wherein the initial interruptions (22/32) extend from the proximal
side of the fabric layer (20/30) and the tendon interruptions
(26/36) extend from the initial interruptions (22/32) to the distal
side of the fabric layer (20/30).
62. An elastic laminate (18) as set forth in any of claims 53-61,
wherein the initial interruptions (22/32) are die cut, kiss cut,
slit, scored, laser cut, and ultrasound cut, and they comprise
severed fabric ends.
63. An elastic laminate (18) as set forth in any of claims 53-61,
wherein the tendon interruptions (26/36) are ruptured and comprise
fractured fabric ends.
64. An elastic laminate (18) as set forth in any of claims 53-61,
wherein the tendon interruptions (26/36) are cut, slit, or scored
and comprise severed fabric ends.
65. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 20% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 80% to 1% through the thickness of the
fabric layer (20/30).
66. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 30% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 70% to 1% through the thickness of the
fabric layer (20/30).
67. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 40% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 60% to 1% through the thickness of the
fabric layer (20/30).
68. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 50% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 50% to 1% through the thickness of the
fabric layer (20/30).
69. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 60% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 40% to 1% through the thickness of the
fabric layer (20/30).
70. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the initial interruptions (22/32) extend 70% to 99%
through the thickness of the fabric layer (20/30) and the tendon
interruptions (26/36) extend 30% to 1% through the thickness of the
fabric layer (20/30).
71. An elastic laminate (18) as set forth in any of claims 53-70,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) extend in a path non-parallel to the cross
direction (C).
72. An elastic laminate (18) as set forth in claim 71, wherein
initial interruptions (22/32) and the tendon interruptions (26/36)
extend in a path substantially parallel to the machine direction
(M).
73. An elastic laminate (18) as set forth in claim 71, wherein the
initial interruptions (22/32) and the tendon interruptions (26/36)
extend in a path at an acute angle relative to the machine
direction (M).
74. An elastic laminate (18) as set forth in any of the preceding
claims, wherein the paths of respective initial interruptions
(22/32) and tendon interruptions (26/36) intersect.
75. An elastic laminate (18) as set forth in any of claims 71-74,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) are substantially continuously spaced in the
cross direction (C).
76. An elastic laminate (18) as set forth in any of claims 71-74,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) are noncontinuously spaced in the cross
direction (C).
77. An elastic laminate (18) as set forth in any of claims 53-76,
wherein adjacent initial interruptions (22/32) and adjacent tendon
interruptions (26/36) are spaced apart a distance between about 1
millimeter and about 10 millimeters in the cross direction (C).
78. An elastic laminate (18) as set forth in any of claims 71-77,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) extend continuously across the span of the
machine direction (M).
79. An elastic laminate (18) as set forth in any of claims 71-77,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) extend noncontinuously across the span of the
machine direction (M).
80. An elastic laminate (18) as set forth in any of claims 53-79,
wherein the elastic layer (40) is substantially coextensive with
the fabric layer(s) (20/30) in the cross direction (C).
81. An elastic laminate (18) as set forth in the preceding claim,
wherein the elastic layer (40) is non-coextensive with the fabric
layer(s) (20/30) in the cross direction (C).
82. An elastic laminate (18) as set forth in any of claims 53-81,
wherein the elastic layer (40) is substantially coextensive with
the fabric layer(s) (20/30) in the machine direction (M).
83. An elastic laminate (18) as set forth in any of claims 79-82,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) are coextensive with the elastic layer
(40).
84. An elastic laminate (18) as set forth in any of claims 79-82,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) are non-coextensive with the elastic layer
(40).
85. An elastic laminate (18) as set forth in any of claims 79-82,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) do not extend beyond the extent of the
elastic layer (40) in the cross-direction (C).
86. An elastic laminate (18) as set forth in the preceding claim,
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) extend almost, but not quite the full
cross-extent of the elastic layer (40) to leave an uninterrupted
margin aligned each lateral edge of the elastic layer (40).
87. A stretchable laminate (10) as set forth in the preceding
claim, wherein the uninterrupted margins have a width in the range
of 2 mm to 20 mm.
88. An elastic laminate (18) as set forth in any of claims 80-87,
comprising interrupted zones (12) and uninterrupted zones (14), and
wherein the initial interruptions (22/32) and the tendon
interruptions (26/36) are located only in the interrupted zones
(12).
89. An elastic laminate (18) as set forth in claim 88, wherein the
elastic layer (40) is coextensive with both the interrupted zones
(12) and the uninterrupted zones (14).
90. An elastic laminate (18) as set forth in claim 88, wherein the
elastic layer (40) is coextensive with only the interrupted zones
(12).
91. An elastic laminate (18) as set forth in claims 53-90, wherein
a skin/liner sublayer(s) (42) is (are) positioned between the
fabric layer(s) (20/30) and the elastic layer (40).
92. An elastic laminate (18) as set forth in any of claims 53-91,
wherein an adhesive sublayer(s) (46) is (are) positioned between
the fabric layer(s) (20/30) and the elastic layer (40).
93. An elastic laminate (18) as set forth in any of claims 53-92,
wherein the fabric layer(s) (20/30) is (are) heat bonded to the
elastic layer (40).
94. An elastic laminate (18) as set forth in any of claims 53-93,
wherein the fabric layer(s) (20/30) is (are) ultrasonically bonded
to the elastic layer (40).
95. A side panel (50) having a proximal edge (52) for attachment to
a lateral edge of a rear portion (66) of a chassis (62) of an
absorbent article (60), a distal edge (54), an upper edge (56), and
a lower edge (58); wherein the side panel (50) includes the
laminate (10/18) set forth in any of claims 1-94.
96. A side panel (50) as set forth in the preceding claim, wherein
the cross direction (C) is the proximal-distal direction and/or the
machine direction (M) is the upper-lower direction.
97. A side panel (50) as set forth in either claim 95 or claim 96,
wherein the first fabric layer (20) is the next-to-the-skin
layer.
98. A side panel (50) as set forth in the preceding claim, wherein
the second fabric layer (30) is the exposed layer.
99. A side panel (50) as set forth in either claim 95 or claim 96,
wherein the first fabric layer (20) is the exposed layer.
100. A side panel (50) as set forth in the preceding claim, wherein
the second fabric layer (30) is the next-to-the-skin layer.
101. A side panel (50) as set forth in any of claims 95-100,
wherein the lower edge (58) is convexly curved.
102. A side panel (50) as set forth in any of claims 95-100,
wherein the upper edge (56) and the lower edge (58) are parallel
and substantially perpendicular to the proximal edge (52) and/or
the distal edge (54).
103. A disposable absorbent article (60) comprising a chassis (62)
having a front portion (64), a rear portion (66), a crotch portion
(68), and side panels (50), as set forth in any of claims 95-102,
attached to each lateral edge of the rear portion (66).
104. A fastening tape (70) comprising a manufacturer end (72) for
connection to the rear chassis portion (84) or a side panel (88) of
a disposable absorbent article (78), and a user end (74) for
selective attachment to the front portion (82) of the disposable
absorbent article (78) by a user; wherein the fastening tape (70)
comprises the laminate (10/18) set forth in any claims 1-94.
105. A fastening tape (70) as set forth in the preceding claim,
further comprising attachment means (76) adjacent its user end
(74).
106. A disposable absorbent article (78) comprising a chassis (80)
having a front portion (82), a rear portion (84), and a crotch
portion (86); the disposable absorbent article (78) further
comprising the fastening tape (70), set forth in either claim 104
or claim 105, attached to the rear portion (84) of the chassis (80)
or a side panel (88).
107. A belt (90) comprising a manufacturer end (92) for connection
to the rear chassis portion (100) of a disposable absorbent article
(98), and a user end (94); wherein the belt (90) comprises the
laminate (10/18) set forth in any claims 1-94.
108. A belt (90) as set forth in the preceding claim, further
comprising attachment means (96) adjacent its user end (94).
109. A disposable absorbent article (98) comprising a chassis (100)
having a front portion (102), a rear portion (104), and a crotch
portion (106); the disposable absorbent article (108) further
comprising the belt (90), set forth in either claim 107 or claim
108, attached to the rear portion (104) of the chassis (100).
110. A disposable absorbent article (110) comprising a chassis
(112) having a front portion (114), a rear portion (116), and a
crotch portion (118), wherein the chassis (112) comprises the
laminate (10/18) set forth in any of claims 1-95.
111. A disposable absorbent article (90) as set forth in the
preceding claim, wherein the laminate (10/18) forms at least part
of the front portion (114) of the chassis (112).
112. A disposable absorbent article (90) as set forth in the
preceding claim, wherein the laminate (10/18) forms a waist region
of the front portion (114) of the chassis (112).
113. A disposable absorbent article (110) as set forth in any
claims 110-112, wherein the laminate (10/18) forms at least part of
the rear portion (96) of the chassis (92).
114. A disposable absorbent article (110) as set forth in the
preceding claim, wherein the laminate (10/18) forms a waist region
of the rear portion (116) of the chassis (112).
115. A disposable absorbent article (110) as set forth in any of
claims 110-114, wherein the laminate (10/18) forms at least part of
the crotch portion (118) of the chassis (112).
116. A disposable absorbent article (110) as set forth in the
preceding claim, wherein the laminate (10/18) forms leg-opening
regions of the crotch portion (118) of the chassis (112).
117. A method of making the laminate (10/18) set forth in claims
1-95, comprising the steps of: forming the interruptions (22) in
the first fabric layer (20); laminating the first fabric layer (20)
and the elastic layer (40).
118. A method as set forth in claim 117, wherein said
first-fabric-interruption-forming step is performed prior to said
first-fabric-laminating step.
119. A method as set forth in claim 117 or claim 118, wherein,
after said first-fabric-interruption-forming step, the first fabric
layer (20) is assembled into a format suitable for continuous
supply.
120. A method as set forth in any of claims 117-119, further
comprising the step of laminating the second fabric layer (30) to
the elastic layer (40).
121. A method as set forth in the preceding claim, further
comprising the step of forming interruptions (32) in the second
fabric layer (30).
122. A method as set forth in the preceding claim, wherein
second-fabric-interruption-forming step is performed prior to said
second-fabric-laminating step.
123. A method as set forth in either claim 121 or claim 122,
wherein, after said second-fabric-interrupting-forming step, the
second fabric layer (30) is assembled into a format suitable for
continuous supply.
124. A method as set forth in any of claims 117-123, wherein said
interruption-forming step(s) and/or said laminating step(s) are
performed in-line.
125. A method as set forth in any of claims 117-124, wherein said
first-fabric-laminating step and/or said second-fabric-laminating
step comprises bonding a preformed elastic film to the fabric
layer(s) (20/30).
126. A method as set forth in claim 125, wherein the bonding step
comprises adhesively bonding the elastic layer (40) to the fabric
layer(s) (20/30) to form an adhesive sublayer 46 between the
elastic layer (40) and the fabric layer(s) (20/30).
127. A method as set forth in the preceding claim, wherein the
adhesive sublayer (46) comprises a hot melt adhesive.
128. A method as set forth in claim 125, wherein said bonding step
comprises heat bonding the elastic layer (40) to the fabric
layer(s) (20/30).
129. A method as set forth in claim 125, wherein said bonding step
comprises ultrasonically bonding the elastic layer (40) to the
fabric layer(s) (20/30).
130. A method as set forth in any of claims 117-124, wherein said
first-fabric-laminating step and/or said second-fabric-laminating
step comprises extruding an elastic material to form the elastic
layer (40).
131. A method of making an elastic laminate (18) as set forth in
any of claims 47-94, comprising the step of providing a stretchable
laminate (10) as set forth in any of claims 1-46, and forming the
interruptions (26/36) in the tendons (24/34) to form the separate
fabric segments (28/38).
132. A method of making an elastic laminate (18) as set forth in
any of claims 47-94, comprising the step of making a stretchable
laminate (10) according to a method set forth in any of claims
114-127, and forming interruptions (26/36) in the tendons (24/34)
to form the separate fabric segments (28/38).
133. A method as set forth in either claim 131 or claim 132,
wherein said tendon-interrupting step comprises rupturing the
tendons (24/34).
134. A method as set forth in the preceding claim, wherein said
rupturing step comprises breaking or tearing the tendons
(24/34)
135. A method as set forth in any of claims 130-134, wherein said
first-fabric-tendon-interrupting step is performed after said first
fabric (20) is laminated to the elastic layer (40).
136. A method as set forth in any of claims 130-135, wherein said
second-fabric-tendon-interrupting step is performed after said
second fabric (30) is laminated to the elastic layer (40).
137. A method as set forth in claim 131 or claim 132, wherein said
tendon-interrupting step comprises severing the tendons
(24/34).
138. A method as set forth in any of claims 132-137, wherein said
tendon-interrupting step(s) are performed in-line with steps
performed to make the stretchable laminate (10).
139. A method as set forth in any of claims 132-137, wherein said
tendon-interrupting step(s) are performed after said stretchable
laminate (10) has been incorporated into a diaper component
(50/70/90/112).
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.120
to International Application Nos. PCT/US07/77367 filed Aug. 31,
2007; PCT/US07/77349 filed Aug. 31, 2007; PCT/US07/77359 filed Aug.
31, 2007, which claimed priority to U.S. Provisional Patent
Application Nos. 60/941,402 filed Jun. 1, 2007; 60/913,059 filed
Apr. 20, 2007; 60/824,261 filed Aug. 31, 2006; 60/941,420 filed
Jun. 1, 2007; 60/912,983 filed Apr. 20, 2007; 60/862,252 filed Oct.
20, 2006; 60/941,431 filed Jun. 1, 2007; 60/913,048 filed Apr. 20,
2007. The entire disclosures of these international/provisional
applications are hereby incorporated by reference.
BACKGROUND
[0002] A stretchable laminate, comprising an elastic layer and one
or more fabric layers, can be used in a variety of situations where
elasticity is required or desired for one reason or another. For
example, in the field of disposable absorbent articles (e.g.,
diapers, incontinence briefs, etc.), an elastic laminate can be
used as, or incorporated into, a side panel or belt for attachment
to a rear chassis portion. A fastening tape, for attaching a rear
chassis portion to a front chassis portion, can also comprise a
stretchable laminate. A stretchable laminate can be used to form
the diaper/brief chassis itself, or portions/regions thereof (e.g.,
waist regions in a front/rear chassis portion, leg-opening regions
in a crotch chassis portion, etc.) With these and other
applications, it is often necessary or desirable to use a fabric
layer (e.g., a nonwoven fabric layer) as the next-to-the-skin layer
and/or the exposed layer.
SUMMARY
[0003] A stretchable laminate comprises an elastic layer (made of
an elastic material that has recoverable elongation properties) and
at least one fabric layer. Interruptions (e.g., cuts, slits,
scores, etc.) are formed in the fabric layer(s), these
interruptions extending about 10% to about 99% through the
thickness of the fabric layer, thereby rendering the laminate
stretchable. Even with nonelastic fabric layers (e.g., nonelastic
nonwoven layers), the laminate still provides sufficient
stretchability and/or elasticity.
[0004] The stretchability and/or elasticity of the stretchable
laminate is obtained without the need for conventional activation
steps such as stretching, ring rolling, and/or tension-induced
tearing. Thus, the structural deficiencies associated with
activation (e.g., snapping caused by damaged elastic layers,
reduced resiliency/recovery due to pre-elongation, matrix weakness
imposed by breaks/tears, etc.) and the manufacturing complications
caused by activation (e.g., inconvenience of pre-tensioning or
necking steps, clumsy compilation procedures due to layer
elongation, extreme precision necessary to prevent elastic damage,
high elastic extrusion standards to avoid susceptible weak
gel-particle-surrounding spots, time-consuming repetition of ring
rolling steps, etc.) may advantageously be eliminated with the
stretchable laminate.
[0005] That being said, the stretchable laminate with the partial
interruptions may instead serve as an intermediate product in the
production of an elastic, or more elastic, laminate. Specifically,
the tendons forming the uninterrupted extensions of the
interruptions (e.g., uncut extension of cut line, unslit extension
of slit line, unscored extension of score line) can be ruptured in
a further production step. If most and/or all of the tendons are
ruptured, the fabric layer will comprise separate fabric segments
attached to the elastic layer which diverge upon laminate
elongation and converge upon laminate recovery.
DRAWINGS
[0006] FIGS. 1A-1C are a plan view and side views of a stretchable
laminate, the laminate comprising a fabric layer and an elastic
layer, the fabric layer having a series of distal interruptions
extending partially through the fabric layer, the laminate being
shown in a relaxed state in FIGS. 1A and 1B, and in an elongated
state in FIG. 1C.
[0007] FIG. 1D is a close-up view of an interruption in the
stretchable laminate shown in FIGS. 1A-1C.
[0008] FIG. 1E-1G are a plan view and side views of a stretchable
laminate, the laminate comprising a fabric layer and an elastic
layer, the fabric layer having a series of proximal interruptions
which extend partially through the fabric layer, the laminate being
shown in a relaxed state in FIGS. 1E and 1F, and in an elongated
state in FIG. 1G.
[0009] FIG. 1H is a close-up view of an interruption in the
stretchable laminate shown in FIGS. 1E-1G.
[0010] FIGS. 2A-2H are side views of some other possible
interruption patterns.
[0011] FIGS. 3A-3I are plan views of some other possible
interruption patterns.
[0012] FIGS. 4A-4F are close-up views of the stretchable laminate
showing some other possible interruption path geometries.
[0013] FIGS. 5A-5C are schematic views of some possible methods of
making the laminate.
[0014] FIGS. 6A-6E are side views of stretchable laminates
comprising two fabric layers.
[0015] FIGS. 6F and 6G are each a close-up view of an interruption
in the second fabric layer.
[0016] FIGS. 7A-7H are schematic views of some possible methods of
making a two-fabric-layer laminate.
[0017] FIGS. 8A-8Q are schematic views of some further possible
methods of making a two-fabric-layer laminate.
[0018] FIGS. 9A-9L are schematic views of some possible techniques
for laminating the elastic layer and the fabric layer(s).
[0019] FIGS. 10A-10C are a plan view and side views of an elastic
laminate, the laminate comprising a fabric layer and an elastic
layer, the laminate including pairs of aligned proximal and distal
interruptions which together extend through the thickness of the
fabric layer(s), the laminate being shown in a relaxed state in
FIGS. 10A and 10B, and in an elongated state in FIG. 100.
[0020] FIGS. 10D-10G are each close-up views of a pair of the
interruptions in the fabric layer.
[0021] FIGS. 10H and 10I are magnified representations of a
ruptured interruption and a severed interruption, respectively.
[0022] FIGS. 11A-11F are plan views of side panels including a
stretchable laminate, and FIGS. 11G and 11H are plan views of
absorbent disposable articles each of which includes a pair of side
panels.
[0023] FIGS. 12A-12C are plan views of fastening tapes including a
stretchable laminate, and FIGS. 12D and 12E are plan views of
absorbent disposable articles each of which includes a pair of such
fastening tapes.
[0024] FIGS. 13A-13G are plan views of belts including a
stretchable laminate, and FIG. 13F is a plan view of an absorbent
disposable article including a pair of such belts.
[0025] FIG. 14 is a plan view of an absorbent disposable article
including a stretchable laminate.
DETAILED DESCRIPTION
[0026] Referring now to the drawings, and initially to FIGS. 1A-1C
and FIGS. 1E-1G, a stretchable laminate 10 is shown. The laminate
10 comprises a first fabric layer 20 and an elastic layer 40
laminated thereto. The first fabric layer 20 can be a nonelastic
layer and, more particularly, a nonwoven nonelastic layer. The
elastic layer 40 is made of an elastic material that has
recoverable elongation properties in a direction C which is cross
(e.g., substantially perpendicular) to the machine direction M. The
thicknesses of the layers 20 and 40 (and also the fabric layer 30
introduced below) are greatly exaggerated in the drawings for ease
of explanation. The thicknesses of these layers will usually be in
the range of, for example, about 2.5 micrometers to about 100
micrometers or more. If these thicknesses were drawn to scale with
the illustrated lengths, it would be difficult to decipher and/or
number the layers.
[0027] The first fabric layer 20 has interruptions 22 formed
therein which extend only partially through the layer thickness
(i.e., the percentage of the dimension i to the dimension t is less
than 100%). For example, the interruptions 22 may extend 10% to
99%, 20% to 99%, 30% to 99%, 40% to 99%, 50% to 99%, 60% to 99%,
and/or 70% to 99% through the thickness of the fabric layer 20. The
interruptions 22 can be, for example, die cuts, kiss cuts, slits,
scores, laser cuts, and/or ultrasound cuts. The interruptions 22
allow the first fabric layer 20 to expand upon elongation of the
elastic layer 40 (FIG. 1C and FIG. 1G) and contract upon recovery
of the elastic layer 40 (FIG. 1B and FIG. 1F), thereby rendering
the laminate 10 stretchable in the cross direction C.
[0028] If the elastic layer 40 is used as a reference layer, the
fabric layer 20 will have a proximal side located closest to the
elastic layer 40 and a distal side located away from the elastic
layer. The thickness of the fabric layer 20 is the distance between
its proximal and distal sides. In FIGS. 1A-1C, the interruptions 22
are distal interruptions in that they extend through the distal
side of the fabric layer 20, but not the proximal side of this
fabric layer. In FIGS. 1E-1G, the interruptions 22 are proximal
interruptions in that they extend through the proximal side of the
fabric layer 20, but not the distal side of this fabric layer 20.
Although not specifically shown in the drawings, it is possible for
the fabric layer 20 to have both distal interruptions and proximal
interruptions, provided they are not aligned so as cause the
interruptions 22 to extend completely through the fabric
thickness.
[0029] As is best seen by referring additionally to FIGS. 1D and
1H, the first fabric layer 20 has tendons 24 extending from the
interruptions 22 through the remaining percentage of the layer
thickness. For example, if the interruption 22 is a cut/slit/score,
the tendon 24 is an uncut region of the cut/slit/score line. In
FIGS. 1A-1D, the tendons 24 extend from the proximal side of the
fabric layer 20 and to the distal interruptions 22. In FIGS. 1E-1H,
the tendons 24 extend from the distal side of the fabric layer 20
to the proximal interruptions 22.
[0030] FIGS. 1A-1C and FIGS. 1E-1G show one possible pattern for
the interruptions 22. FIGS. 2A-2H and FIGS. 3A-3I showing other
possible interruption patterns. As shown in FIG. 1A-1C and FIGS.
1E-1G, the interruptions 22 can continuously extend across the span
of the cross direction C. (See also FIGS. 3B, 3E, and 3G.) As shown
in FIGS. 2A-2H, the interruptions 22 need not extend continuously
across the span of the cross direction C. (See also FIGS. 3A, 3C,
3F, 3H and 3I.) In either case, adjacent interruptions 22 can be
spaced apart (evenly or unevenly) a distance of between about 1
millimeter and about 10 millimeters in the cross direction C.
Although the second series of drawings specifically show distal
interruptions (e.g., FIGS. 1A-1D), they apply equally to proximal
interruptions (e.g., FIGS. 1E-1H).
[0031] The elastic layer 40 can be coextensive with the first
fabric layer 20 in the cross direction C (FIG. 1A, FIG. 1E, and
FIGS. 2A-2D) or non-coextensive with the first fabric layer 20 in
the cross direction C (FIGS. 2E-2H). The interruptions 22 can be
coextensive with the elastic layer 40 (FIG. 1A, FIGS. 1E and 2E-2H)
or non-coextensive with the elastic layer 40 (FIGS. 2A-2D) in the
cross direction. With particular reference to FIG. 2E and/or FIG.
2H, the interruptions 22 can not extend beyond the extent of the
elastic layer 40 in the cross direction C. The interruptions 22 can
extend almost, but not quite the full cross-extent of the elastic
layer 40 on each side, thereby leaving an uninterrupted margin
aligned with each lateral edge of the elastic layer 40. This latter
option may be desirable to, for instance, securely attach the
elastic layer 40 to the fabric layers 20/30. Margin widths in the
range of 2-20 millimeters, 4-12 millimeters, and/or 6-10
millimeters may be sufficient for this purpose.
[0032] As shown in FIG. 1A, FIG. 1E, and FIGS. 3A, 3D, and 3G, the
interruptions 22 can extend continuously in the machine direction
M. As shown in FIGS. 3B, 3C, 3E, 3F, 3H and 3I, the interruptions
22 need not extend continuously in the machine direction M. The
elastic layer 40 can be coextensive with the fabric layer 20 in the
machine direction M (FIGS. 3A-3D and FIGS. 3G-3I) or the elastic
layer 40 can be non-coextensive with the fabric layer 20 in the
machine direction M (FIG. 3E and FIG. 3F). The interruptions 22 can
be coextensive with the elastic layer 40 (FIGS. 3D, 3E, 3F and 3I)
or the interruptions can be non-coextensive with the elastic layer
40 (FIGS. 3A-3C and FIG. 3H) in the machine direction M.
[0033] The interruptions 22 can elongate and extend in a direction
non-parallel to the cross direction C. For example, the
interruptions 22 can extend substantially parallel to the machine
direction (FIGS. 3A-3F). Alternatively, the interruptions 22 can
extend an acute angle (e.g., about 10.degree. to about 75.degree.,
about 10.degree. to about 60.degree., and/or about 10.degree. to
about)45.degree. relative to the machine direction M (FIGS. 3G-3I)
and these interruptions 22 can (but need not) intersect. Although
not specifically shown in the drawings, the paths of the
interruptions 22 can include both paths substantially parallel to
the machine direction M and paths at an acute angle relative to the
machine direction M. The parallel and angularly offset paths can
(or cannot) intersect.
[0034] In other words, the laminate 10 can have interrupted zones
12 and uninterrupted zones 14 (with the interruptions 22 being
located only in the interrupted zones 12). The elastic layer 40 can
be coextensive with both the interrupted zones 12 and the
uninterrupted zones 14 (FIGS. 2A-2D, FIGS. 3A-3C, and FIG. 3H) or
the elastic layer 40 can be substantially coextensive with only the
interrupted zones 12 in the cross direction C and/or the machine
direction M (FIGS. 2E-2H, FIGS. 3E-3F and FIG. 3I). The earlier
option may ease layer compilation steps in certain situations; the
latter option may reduce material costs.
[0035] In the first through third series of drawings, the
interruptions 22 were illustrated as following a linear path,
however the paths need not always be linear. The interruptions 22
can follow a sinusoidal path (FIGS. 4A-4C) or a zigzag path (FIGS.
4D-4F), with adjacent interruptions being either aligned with each
other (FIGS. 4B and 4E) or offset from each other (FIGS. 4C and
4F). In the case of nonlinear paths, the angle of the interruption
22 relative to the machine direction M can be determined by the
centerline of the path.
[0036] Referring now to FIGS. 5A-5C, some possible methods for
making the stretchable laminate 10 of FIGS. 1A-1C are schematically
shown. (In this fifth series of drawings, the supply of the first
fabric layer 20 is shown in the machine direction M, while the
subsequent interruption forming and/or laminating steps are shown
in the cross direction C for clarity and ease in explanation.) A
method for making the laminate 10 can comprise the steps of forming
the interruptions 22 in the first fabric layer 20 and laminating
the first fabric layer 20 and the elastic layer 40. The
interruption-forming step can be performed prior to the
first-fabric-laminating step (FIG. 5A), or the
first-fabric-laminating step can be performed prior to the
interruption-forming step (FIG. 5B). A cut/slitted/scored fabric
layer 20 can be assembled into a format suitable for continuous
supply (e.g., a roll) and then laminated to the elastic layer 40
(FIG. 5C).
[0037] If proximate interruptions are to be formed in the fabric
layer 20 after lamination (FIG. 5B), such formation would have to
be done without damaging the elastic layer 40. This may prove
difficult with physically-contacting cutting elements, such as
blades, knives, or slitting wheels. However, with the use of laser,
ultrasound, and/or other more precise cutting procedures,
post-laminate formation of the interruptions 22 may be possible and
even preferred. For example, with laser cutting, (e.g., where
carbon dioxide laser beams are delivered via scanner systems with
final focusing optics), the cutting depth can be closely controlled
by altering the power of the laser. For this same reason,
pre-lamination formation of the interruptions 22 with laser,
ultrasound, or other non-contacting cutting techniques may be best
if a facility is accommodated with the necessary equipment.
[0038] If proximate interruptions are to be formed in the fabric
layer 20, (e.g., the stretchable laminate 10 shown in FIGS. 1E-1G)
performing the interruption-forming steps prior to the laminating
step may prove to be most practical. (FIGS. 5A and 5C). That being
said, laser, ultrasound or other sophisticated cutting systems
could conceivably be used to form such proximate interruptions
post-lamination.
[0039] Referring now to FIGS. 6A-6E, the stretchable laminate 10
can comprise a second fabric layer 30, with the elastic layer 40
sandwiched between the first fabric layer 20 and the second fabric
layer 30. Usually, but not necessarily, the second fabric layer 30
will have the same width (i.e., dimension in the machine direction
M) as the first fabric layer 20. If the second fabric layer 30 is
an elastic fabric layer (e.g., an elastic nonwoven layer),
interruptions may not be necessary.
[0040] If the second fabric layer 30 is a nonelastic fabric layer
(e.g. a nonelastic nonwoven layer), interruptions 32 can be
provided to further render the laminate 10 stretchable in the cross
direction C. The interruptions 32 can have the same or similar
features (e.g., thickness, spacing, zoning, coextension, path
geometry, etc.) as the interruptions 22 whereby the fabric 30 could
be mirror form of the fabric 20 relative to the elastic layer 40.
Thus, the fabric 30 could have any or all of the features of the
fabric 20, such as those shown and/or described in connection with
FIGS. 2A-2H. Additionally or alternatively, the interruptions 32
can substantially align with the interruptions 22 (FIGS. 6B-6D),
overlap/underlap the interruptions 22 (FIG. 6C), or staddle the
interruptions 22 (FIG. 6E). Although the interruptions 22/32 are
shown in FIGS. 6A-6E as proximal interruptions either or both could
instead be distal interruptions and/or the fabric layers 20/30
could either or both include both distal interruptions and proximal
interruptions.
[0041] As is best seen by referring additionally to FIGS. 6F and
6G, the fabric layer 30 will include tendons 34 extending from the
interruptions 32 through the remaining percentage the layer
thickness. In FIG. 6F the tendon 34 extends from the proximal side
of the fabric layer 30 to the distal interruption 32. In FIG. 6G,
the tendon 34 extends from the distal side of the fabric layer 30
to the proximal interruption 32.
[0042] Referring now to FIGS. 7A-7H, some possible methods for
making the two-fabric-layer laminate 10 are shown. (Again, the
continuous supply of the fabric layer(s) 20/30 is shown in the
machine direction M, while the subsequent interruption forming
and/or laminating steps are shown in the cross direction C for
clarity and ease in explanation.) The method can comprise the steps
of forming the interruptions 22 in the first fabric layer 20, and
laminating the layers 20/30/40 together. If the second fabric layer
30 is an elastic layer (FIG. 6A), and no interruptions are
necessary, further steps may not be required. If the second fabric
layer 30 is to be interrupted, the method will comprise the further
step of forming interruptions 32 in the second fabric layer 30.
(FIGS. 7A-7H.)
[0043] The interruption-forming steps can be performed prior to
laminating steps (FIG. 7A), before and after the laminating steps
(FIGS. 7B and 7C), or after the laminating steps (FIG. 7D).
(Although, again, interruption-forming steps done after lamination
may prove difficult for proximal interruptions.) The first fabric
layer 20, with the interruptions 22 already formed therein, can be
assembled into a format suitable for continuous supply (e.g., a
roll) (FIGS. 7E and 7F), and the second-fabric-interruption-forming
step can be performed before (FIG. 7E) or after (FIG. 7F) the
laminating steps. Alternatively, the second fabric layer 30, with
the interruptions 32 already formed therein, is assembled into a
format suitable for continuous supply (e.g., a roll) (FIGS. 7G and
7H) and the first-fabric-interruption-forming step can be performed
after (FIG. 7G) or before (FIG. 7H) the laminating steps. The fact
that the interruptions 22/32 extend only partially through the
thickness of the fabric layers 20/30, expedites the
interruption-forming steps and the laminating steps when compared
to, for example, interruptions extending completely through (i.e.,
100%) the fabric layer thicknesses.
[0044] With particular reference to the methods wherein at least
one fabric-interruption-forming step is performed after lamination
(FIGS. 7B-7D, and 7F-7G), the use of laser or ultrasound cutting
methods (wherein cutting depth can be closely controlled) may
minimize the risk of damage to the elastic layer 40. Additionally
or alternatively, such non-contacting cutting techniques can
usually accommodate precise optical registration procedures, which
may be necessary if alignment between the interruptions 22/32 is
desired or necessary.
[0045] Referring now to FIGS. 8A-8Q, more possible methods for
making the two-fabric-layer laminate 10 are shown. In these
methods, the elastic layer 40 can be laminated to one of the fabric
layers 20/30 and the sublaminate 20/40 or 30/40 assembled into a
format suitable for continuous supply (e.g., a roll). As with the
preceding schematic method drawings, the continuous supply of the
sublaminate is shown in the machine direction M, while the
subsequent steps are shown in the cross direction C.
[0046] The method can comprise laminating the first fabric layer 20
to the elastic layer 40 to form a sublaminate 20/40 (FIGS. 8A-8H).
The first fabric layer 20 in the sublaminate 20 can not yet be
interrupted (FIGS. 8A-8E). In this case, the
first-fabric-interruption-forming step can be performed after the
second-fabric-laminating step (FIGS. 8A, 8C, and 8D) or before the
second-fabric-laminating step (FIGS. 8B and 8E). The
second-fabric-interruption-forming step can be performed after the
laminating step (FIGS. 8A and 8B), before the laminating step (FIG.
8C), after the first-fabric-interruption-forming step (FIG. 8B),
and/or before the first-fabric-interruption-forming step (FIG.
8C).
[0047] The first fabric layer 20 in the sublaminate 20/40 can
already be interrupted (FIGS. 8F-8H), in which case the
second-fabric-interruption-forming step can be performed after the
second-fabric-laminating step (FIG. 8F) or before the
second-fabric-laminating step (FIG. 8G). The second fabric 30 can
also be supplied with interruptions 32, in which case the only
remaining step will be laminating the second fabric 30 to the
sublaminate 20/40 (FIG. 8H). FIGS. 8I-8Q show methods similar to
those shown in FIGS. 8A-8H, except that the second fabric layer 30
can be pre-laminated to the elastic layer 40 to form a sublaminate
30/40. Again, the formation of interruption-forming steps on the
laminate 20/30/40 (FIGS. 8A-8D, 8F, 8I, 8K-8O), the sublaminate
20/40 (FIGS. 8B and 8E), and/or the sublaminate 30/40 (FIGS. 8J and
8L), may be best accomplished with laser, ultrasound, and/or other
more precise cutting procedures.
[0048] FIGS. 9A-9F show some possible techniques for laminating the
fabric layer 20 and/or the fabric layer 30 to the elastic layer 40.
One technique is to extrude the elastic layer 40 directly on the
fabric layer 20/30 and then laminate the other layer 30/20 thereon
(FIG. 9A). Alternatively, the elastic layer 40 can be
simultaneously (or substantially simultaneously) extruded onto both
the fabric layer 30 and the fabric layer 40 (FIG. 9B).
[0049] The elastic layer 40 can be provided as a pre-formed film in
a format suitable for continuous supply (e.g., a roll) and the
fabric layers 20 and 30 laminated thereon (FIGS. 9C-9E). With
certain formulations, the elastic layer 40 can be provided as
monolayer (FIG. 9C). Otherwise, the elastic material may be
"sticky" whereby film-to-film contact may cause blocking. To avoid
these "stickiness" and/or "blocking" issues, and still be able to
use preformed elastic film in a continuous form, a skin or thin
fabric sublayer 42 can be laminated to one side of the elastic film
layer 40 (FIG. 9D). Alternatively, a liner 44 can accompany the
elastic film layer 40 on the roll and then be removed prior to
lamination to the fabric layer 30/20 (FIG. 9E).
[0050] Instead of employing a sublayer 42 or a liner 44, one of the
fabric layers 20/30 can be laminated to the elastic layer 40 prior
to assembling it in a format suitable for continuous supply (FIG.
9F). (See also the methods shown in FIGS. 8A-8Q). This eliminates
any "stickiness" and/or "blocking" issues, and allows a continuous
supply of "skinless" or "linerless" elastic without having to
resort to extrusion.
[0051] In extrusion techniques (FIG. 9A-9B), the molten quality of
the elastic material will usually be sufficient to bond the fabric
layers 20/30 to the elastic layer 40 (or sublayer 42) during
lamination. However, in non-extrusion techniques (FIGS. 9C-9F),
additional steps may be necessary.
[0052] In non-extrusion lamination techniques, an adhesive can be
applied to the layer 20/30 prior to lamination (FIG. 9G) whereby an
adhesive sublayer 46 will be positioned between the bonding
surfaces of the fabric layers 20/30 and the elastic layer 40. The
adhesive can comprise hot-melt adhesives (e.g., hot-melt
rubber-based materials or acrylic-based materials) and/or
non-hot-melt adhesives, such as pressure sensitive adhesives,
polyurethane adhesives and structural adhesives. The adhesive
sublayer(s) 46 can extend across the entire bonding area, or can be
applied in intermittent adhesive patterns (e.g., stripes, spots,
swirls, islands, grids, checkerboard, voids, random, semi-random,
etc.). Although not specifically shown in the drawings, an adhesive
sublayer 46 can be positioned only between one fabric layer 20/30
and the elastic layer 40, with the other fabric layer 30/20 being
secured to the elastic layer 40 in another manner. Also, in the
case of the elastic layer having a skin or liner sublayer 42, the
adhesive sublayer 46 would be positioned between the skin/liner and
the fabric layer 20/30.
[0053] Instead of adhesive bonding, radiant heat can be used to
melt the fabric layers 20/30 and/or the elastic layer 40 into a
molten state which will then bond the layers together upon cooling
(FIGS. 9H-9J). For example, heat can be applied upstream of
layer-compiling (FIG. 9H), during layer-compiling (FIG. 9I), or
downstream of layer-compiling (FIG. 9J). With particular reference
to a heat-applying step during layer-compiling (FIG. 9I), the heat
can be supplied, for example, through the laminating rollers.
Although in the illustrated technique heat is applied to both sides
of the laminate 10, in many cases heat application to just one side
may be sufficient.
[0054] Ultrasonic bonding and/or welding can also be used when
laminating the fabric layer(s) 20/30 to the elastic layer 40 (FIGS.
9K and 9L). This ultrasonic step can be performed during layer
compiling (FIG. 9K) or after layer compiling (FIG. 9L). Again,
although ultrasonic energy is being applied to both sides of the
laminate 10 in the illustrated embodiment, one side application may
be sufficient.
[0055] The first fabric layer 20 and the second fabric layer 30
need not be bonded to the elastic layer 40 in the same manner, and
the bonding techniques can be appropriately intermixed. For
example, one fabric layer 20/30 can be joined to the elastic layer
40 through extrusion, while the other fabric layer 30/20 can be
joined to the elastic layer 40 through adhesive, heat, or
ultrasonic procedures. One fabric layer 20/30 can be bonded to the
elastic layer 40 via adhesive bonding and the other fabric layer
30/20 can be bonded to the elastic layer 40 via heat or ultrasonic
bonding.
[0056] At least some of the interruption-forming steps and/or the
laminating steps can be performed in-line for production efficiency
purposes. In an in-line production process, the first fabric layer
20 and the second fabric layer 30 will each usually be provided in
a format (e.g., a roll) suitable for continuous supply. The fabric
layer 40 will usually be supplied in a format (e.g., a roll)
suitable for continuous supply. A further option is for the fabric
layer 20 and/or the fabric layer 30 to be formed by extrusion and,
if so, coextrusion of a plurality of the layers (e.g., layers 20
and 40, layers 30 and 40, and/or layers 20, 30 and 40) is also
possible. With this option, the interruption-forming steps would be
formed downstream of the extrusion laminating steps for the
relevant fabric layer(s) 20/30, unless the extruding step
incorporates an interruption-forming step.
[0057] The stretchable laminate 10 can be a finished product ready
for incorporation into a diaper component (e.g., side panel 50
introduced below, fastening tape 70 introduced below, and/or diaper
chassis 92). In such a case, the interruptions 22/32 extending
partially through the fabric thicknesses provides sufficient
stretchability and/or elasticity for the given diaper situation.
Alternatively, the stretchable laminate 10 can serve as an
intermediate product when making an elastic (or more elastic)
laminate 18 such as the one shown in FIGS. 10A-10C.
[0058] In the elastic laminate 18, interruptions are formed in the
tendons 24/34. The tendon interruptions 26/36 are best seen in
FIGS. 10D-10G and, as shown, these tendon interruptions 26/36 and
the initial interruptions 22/32 in the intermediate laminate 10,
together extend completely through the thickness of the fabric
layer(s) 20/30. If the initial interruptions 22/32 are distal
interruptions, the tendon interruptions 26/36 will be proximal
interruptions (interruptions 22/26 and 32/36 in FIG. 10D,
interruptions 22/26 in FIG. 10F and interruptions 32/36 in FIG.
10G). If the intermediate interruptions 22/32 are proximal
interruptions, the tendon interruptions 26/36 will be distal
interruptions (interruptions 22/26 and 32/36 in FIG. 10E,
interruptions 32/36 in FIG. 10F, and interruption 22/26 in FIG.
10G.)
[0059] The tendon-interrupting step results in the fabric layers
20/30 comprising separate fabric segments 28/38. The fabric
segments 28/38 are attached to the elastic layer 40 and diverge
upon laminate elongation (FIG. 10C) and converge upon laminate
recovery (FIG. 10B). The elastic layer 40 can be visible between
the fabric segments 28/38 when the laminate 10 is elongated and/or
can be hidden by the fabric segments 28/38 when the laminate 10 is
not elongated.
[0060] If the tendon interruptions 26/36 are formed by rupturing
the tendons 24/34, this interruption will be defined by primarily
fractured fabric strand ends, that is, fabric strand ends which
have been broken roughly and/or unevenly, as shown schematically in
FIG. 10H. If the initial interruptions 22/32 are die-cut, kiss-cut,
slit, scored, laser-cut, ultrasound cut, or otherwise sharply
split, they will be defined by primarily severed fabric strand
ends, that is, fabric strand ends which have been severed cleanly
and neatly, as shown schematically in FIG. 10I.
[0061] The rupturing can be accomplished by applying an integrative
rupturing force over the laminate width or portions thereof (e.g.,
tentering or zone-stretching), by applying a series of discrete
rupture-inducing forces (e.g., corrugated rupturing rolls), or by
any other suitable technique. The tendon interruptions 26/36 can
instead be formed by other separating methods (e.g., cutting,
slitting, scoring, sawing, etc.), if care is taken to insure that
this separation step does not seriously flirt with the danger of
damaging the elastic layer 40. In the latter case, laser,
ultrasound, and/or other accurate non-contacting cutting techniques
may remove the risk of elastic-related casualties.
[0062] The tendon-interrupting step can be performed immediately
following and/or in-line with the steps for making the stretchable
laminate 10. If an elastic laminate 18 is to be incorporated into a
diaper component, the tendon-interrupting step can be before or
after the intermediate laminate 10 is incorporated into the diaper
component and/or before or after this component is installed in the
diaper. The diaper can be provided to the end user with the tendons
24/34 intact (and thus including the stretchable laminate 10) and
the tendon interrupting steps can be performed by the end user of
the diaper. For example, such a force could be applied during the
initial fitting of the diaper. Subsequent and/or hybrid
tendon-interrupting steps could also be applied at different stages
of diaper incorporation. For an example, the tendon 24/34 could be
partially ruptured prior to incorporation of the diaper component
and then completely ruptured during assembly/installation of the
diaper component. For another example, the tendon 24/34 could be
partially ruptured prior to use of the diaper and then completely
ruptured by the end user. Also, the tendons 24/34 of one fabric
layer 20/30 could be ruptured prior to use of the diaper, and the
tendons 34/24 of the fabric layer 30/20 left at least partially
intact for rupture by the end user.
[0063] Referring now to FIGS. 11A-11F, a side panel 50 including
the stretchable laminate 10 or the elastic laminate 18 is shown.
The side panel 50 comprises a proximal edge 52, a distal edge 54,
an upper edge 56, and a lower edge 58. In an absorbent disposable
article 60 (comprising a chassis 62 having a front portion 64, a
rear portion 66, a crotch portion 68), the proximal edge of 52 of a
side panel 50 is joined to each lateral edge of the chassis rear
portion 66 (FIGS. 11G and 11H). The chassis 62 can (or cannot) also
incorporate the stretchable laminate 10 (e.g., chassis 92
introduced below).
[0064] With a baby diaper (FIG. 11G), the lower edge 58 of the side
panel 50 can be convexly curved (FIGS. 11A-11C). With an adult
incontinence brief (FIG. 11H), the upper edge 56 and the lower edge
58 can be parallel and substantially perpendicular to the proximal
edge 52 and/or the distal edge 54 (FIGS. 11D-11F). The first fabric
layer 20 can be the next-to-the-skin layer and/or the second fabric
layer 30 can be the exposed layer. Alternatively, the first fabric
layer 20 can be the exposed layer and/or the second fabric layer 30
can be the next-to-the-skin layer.
[0065] With the side panel 50, the cross direction C corresponds to
the proximal-distal direction. The machine direction M corresponds
to the upper-lower direction. Thus, the side panel 50 is
stretchable in the proximal-distal direction and the interruptions
22/32 extend in the upper-lower direction.
[0066] The side panel 50 can carry a fastener for attaching its
distal edge 54 to the front chassis portion 64 during the diapering
process. The fastener can comprise a fastening tape (with
attachment means) attached to the side panel 40 and projecting
beyond its distal edge 54. Additionally or alternatively,
attachment means can be situated on the side panel 50 itself,
adjacent the distal edge 54. The attachment means can comprise, for
example, mechanical fastening elements (e.g., hooks/loops),
adhesive/cohesive area (s), magnetic connections, etc. If the side
panel 50 carries a fastening tape, this fastening tape can (or
cannot) also incorporate the stretchable laminate 10 (e.g., the
fastening tape 70 introduced below).
[0067] Referring now to FIGS. 12A-12C, a fastening tape 70, having
a manufacturer end 72 and a user end 74, includes a stretchable
laminate 10 and/or an elastic laminate 18. The fastening tape 70
can comprise attachment means 76 (e.g., mechanical elements such as
hook/loops, adhesive/cohesive area(s), magnetic connections etc.)
adjacent its user end 74. When used on an absorbent disposable
article 78 (comprising a chassis 80, having a front portion 82, a
rear portion 84, and a crotch portion 86, and possible side panels
88), the manufacturer end 72 is joined to the rear chassis portion
84 or the side panel 88 (FIGS. 12D and 12E.) The user end 74 is for
selective attachment to the front portion 82 of the disposable
absorbent article 78 via the attachment means 76. The chassis 80
and/or the side panel 88 can (or cannot) also incorporate the
stretchable laminate 10 (e.g., the chassis 112 introduced below
and/or the side panel 50 discussed above). The cross direction C in
the tape 70 can correspond to its length (i.e., direction between
the manufacturer end 72 and the user end 74) and the machine
direction M can correspond to its width.
[0068] Referring now to FIGS. 13A-13G, one or more belts 90 can
include a stretchable laminate 10 and/or an elastic laminate 18.
The belt's cross direction C can correspond to its length (i.e.,
direction between the manufacturer end 92 and the user end 94) and
the machine direction M can correspond to its width. The laminate
10/18 can span the entire belt length (FIGS. 13A and 13B) and/or
the elastic layer 40 can span the entire belt length (FIGS.
13A-13D). The laminate 10/18 can span only a portion of the belt
length (FIGS. 13C-13F), and can be situated centrally, towards the
manufacturer's end 92 (as shown) or towards the user's end 94.
[0069] At least one belt 90 (FIGS. 13B, 13D, and 13F) can comprise
attachment means 96 (e.g., mechanical elements such as hook/loops,
adhesive/cohesive area(s), magnetic connections etc.) adjacent its
user end 94. When used on an absorbent disposable article 98
(comprising a chassis 100, having a front portion 102, a rear
portion 104, and a crotch portion 106), the manufacturer end 92 of
each belt 90 is joined to the rear chassis portion 104. (FIG. 13G.)
One belt 90 (FIGS. 13A, 13C, and 13E) can be folded around the
user's waist and the other belt 90 (FIGS. 14B, 14D, and 14F) can be
folded thereover. The belts 90 are held in position by the
attachment means 96. The chassis 100 can (or cannot) also
incorporate the stretchable laminate 10 (e.g., the chassis 112
introduced below).
[0070] Referring now to FIG. 14, a disposable absorbent article 110
is shown, the article 110 comprising a chassis 112 (having a front
portion 114, a rear portion 116, and a crotch portion 118)
including a stretchable laminate 10 and/or an elastic laminate 18.
The laminate 10/18 can form at least part of the front portion 114
of the chassis 112 (e.g., a waist region), at least part of the
rear portion 116 of the chassis 112 (e.g., a waist region), and/or
at least part of the crotch portion 118 of the chassis 112 (e.g.,
leg-opening regions). The article 110 can (or cannot) include a
side panel incorporating the laminate 10/18 (e.g., the side panel
50 introduced above), a fastening tape incorporating the laminate
10/18 (e.g., the fastening tape 70 introduced above), and/or belts
incorporating the laminate 10/18 (e.g., the belts 90 introduced
above).
[0071] In the side panel 50, the tape 70, the belt 90, and the
absorbent disposable article 110, the laminate 10/18 can include,
or not include, any of the features discussed above. For example,
the interruptions 22/32 can be continuously spaced (or not) in the
cross direction C, the interruptions 22/32 can completely (or only
partially) extend the span of the machine direction M, the elastic
layer 40 can be coextensive (or not) with the fabric layers 20/30
and/or the elastic layer 40 can only be coextensive with the
interruptions 22/32.
[0072] If the fabric layer(s) 20/30 are nonwoven layers (e.g.,
nonelastic nonwoven layers), they can be, for example, polyolefin,
such as polyethylene and/or its copolymers, or polypropylene and/or
its copolymers, or mixtures of the aforementioned polyolefins,
polyurethanes, polyester, polyether or polymide. The nonwoven
materials can comprise, for example, spunbonded webs, meltblown
webs, air laid layer webs, bonded carded webs, hydroentangled webs,
wet-formed webs or any combination thereof. The nonwoven layers can
have a weight of about 10 gsm to about 100 gsm and the layers 20/30
can vary in weight.
[0073] The layers 20/30 can be fabric monolayers, that is a single
layer of fabric rather than a laminate of a plurality of sublayers.
For example, a monolayer structure wherein fibers or other
filaments are fused or otherwise integrated into a single substrate
layer, can be employed. While monolayer constructions will be
preferred in many situations, the layers 20/30 could alternatively
have a multilayer construction (i.e., a compilation or lamination
of layers wherein different layers are distinguishable and/or
separable).
[0074] The elastic layer 40 can comprise an elastomer selected from
the group consisting of styrene block copolymers, polyurethanes,
polyesters, polyethers, and polyether block copolymers.
Additionally or alternatively, the elastic layer 40 can comprise a
vinyl arene-containing block copolymer (e.g., a block copolymer
comprising SBS and/or SEBS). The term "elastic" (or related terms
such as "elasticized" and "elasticity") means that the layer tends
to recover to or near its original size and shape after removal of
a force causing a deformation. For example, an elastic material or
composite can be elongated by at least 50% of its relaxed length
and which will recover, upon release of the applied force, at least
40% of its elongation. For example, the elastic layer 40 can be
capable of being elongated by at least 100% to 300% of its relaxed
length and recover, upon release of an applied force, at least 25%
to 50% of its elongation.
[0075] The machine direction M refers to the production direction
of the laminate 10. This may (or may not) be different than the
machine direction when producing the side panels 50, the fastening
tape 70, the belts 90, or the chassis 112 of the disposable article
110. The machine direction M may (or may not) be different than the
machine direction joining the side panels 50 to the absorbent
disposable article 60, securing the tape 70 to the chassis 80 (or
side panel 88) of the disposable article 78, or attaching the belts
90 to the absorbent article 98.
[0076] One may now appreciate that the stretchable laminate 10 can
be provided for use in a diaper component. The stretchable laminate
10 can be incorporated into the diaper component and/or it can
serve as an intermediate product for making an elastic (or more
elastic) laminate 18 for incorporation into the diaper
component.
* * * * *