Embossed Stretchable Elastic Laminate and Method of Production

Abstract

A stretchable embossed elastic laminate including at least one nonwoven fabric layer, and at least one elastomeric material extruded as a melt onto a major surface of the nonwoven fabric to form an elastic layer bonded to the surface of the nonwoven fabric. The elastic laminate is embossed with a deep embossing pattern to provide an embossed laminate having good tensile strength and excellent resistance to delamination. Also disclosed is a method of forming a stretchable embossed laminate wherein at least one melted elastic material is extruded onto a major surface of the nonwoven fabric, and the elastic material and the nonwoven fabric are conveyed through a nip formed by a layon roll and an embossing roll having a deep embossing pattern.

Description

RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60 / 818,066, filed on Jun. 30, 2006. The disclosure of which is hereby incorporated by reference.BACKGROUND OF THE INVENTION [0002] The presently described technology relates generally to stretchable elastic laminates. More specifically, the present technology relates to embossed stretchable elastic laminates formed from an elastic melt layer and a non-woven layer and having a deep emboss pattern that allows for improved resistance to delamination of the nonwoven from the elastic layer. [0003] Disposable absorbent articles (e.g., disposable diapers for children or adults) often include elastic features designed to provide enhanced and sustainable comfort and fit to the wearer by conformably fitting to the wearer over time. Examples of such elastic features may include, for example, elastic waistbands, elastic leg cuffs, elastic side tabs, or elastic side panels so that the absorbe...

AI Technical Summary

Benefits of technology

[0013] The presently described technology is directed to a stretchable laminate that has improved stretch properties such as improved elongation to break and low permanent deformation, as well as high tensile strength, high delamination resistance and aesthetic appeal.

[0015] In another aspect, the present technology is directed to an embossed stretchable laminate that includes a nonwoven fabric that is stretchable in at least one direction, and an elastic material applied as a melt to a major surface of the nonwoven fabric via a roll having a deep embossing pattern which is utilized during formation of a laminate to give the laminate an improved resistance to delamination.

[0018] In another aspect, the present technology is directed to a method of perforating the laminate or film within the laminate to improve its breathability.

[0019] In another aspect, the present technology is directed to a method of minimizing the stretch in selected zones of the laminate to facilitate a secure attachment to nonstretchy films, laminates or hooks in a disposable garment.

Problems solved by technology

Stretching the nonwoven web in one direction not only causes necking in the other direction, but may also cause the nonwoven web to become thicker.

A variation in thickness may require more complicated set-up procedures and additional processing equipment when utilizing the nonwoven web in different manufacturing operations, thus resulting in increased manufacturing costs.

Moreover, necking of the nonwoven web may cause orientation of the fibers which may result in a striated appearance that may not be aesthetically pleasing.

Employing a secondary bonding operation, such as those described in the '097 patent and the '687 publication, to form the stretchable laminate typically increases the production cost of the stretchable elastic laminate.

The use of such secondary stretching operations typically increases the production cost of the stretchable elastic laminate.

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