Breathable non-woven composite material

Abstract

A breathable elastic non-woven composite is described that contains an elastic film laminated to one or more non-woven web materials. The elastic film is fed to a bonding and perforating apparatus while stretching the film to form a laminate. The laminate is then held in a stretched state after the laminate exits the bonding and perforating apparatus for better control of air permeability.

Description

BACKGROUND OF THE INVENTION

[0001] Elastomeric materials are commonly incorporated into garments and personal care products worn on or around the body to improve the fit of the product and its ability to conform to the contours of the body in motion. Examples of such products include diapers, training pants, adult incontinence garments, personal protective clothing, bandages, and the like. However, elastomeric materials often exhibit an undesirable hand, such as a sticky or rubbery feel. Thus, in garments and personal care products, elastomeric materials are typically used between one or more outer facing materials that exhibit a pleasant hand. For example, in personal care products, one or more nonwoven fabrics having a desired hand are typically laminated to the elastomeric material as an outer facing layer such that the elastomeric laminate feels more pleasant to the touch. In one practice, the nonwoven fabric is attached to the elastomeric film when the elastomeric film is in a stretched state such that when the elastomeric film contracts, the nonwoven fabric gathers between the locations where it is bonded to the elastomeric film and forms pleats. The resulting elastomeric laminate is stretchable at least to the extent that the nonwoven fabric can be extended by flattening the pleats located between the bond points. Examples of such stretch-bonded elastomeric laminates are disclosed in many references, including, for example, U.S. Patent No. 4,720,415 to Vander Wielen et al. and U.S. Patent No. 5,385,775 to Wright et al.

[0002] To support skin health, it is also desirable that such elastomeric laminates permit the escape of water vapor trapped between the skin of the wearer and the laminate. These are commonly referred to as "breathable" materials. Most elastomeric polymer films have a very low water vapor transmission rate and are not considered breathable. Thus, it has become common to perforate such elastomeric laminates to permit the escape of water vapor trapped on the skin. Examples of such perforated elastomeric laminates include those described in U.S. Patent No. 7,803,244 to Siqueira et al., U.S. Patent No. 8,241,542 to O'Donnell et al., U.S. Patent No. 8,292,865 to Hutson et al., and EP1397101B1 to Curro et al., which are incorporated herein by reference.

[0003] In one method, a perforated composite material is formed by passing an elastomeric film through a nip to bond the film to a nonwoven web material. While the bond is being formed, holes are also formed in the elastomeric film. The holes have a size sufficient to provide a desired level of texture, softness, hand, and / or aesthetic appeal to the composite material without a significant adverse effect on the elastic properties. For example, such methods are disclosed in U.S. Patent No. 9,011,625 and U.S. Patent No. 11,220,085, both of which are incorporated herein by reference. The products made by the above methods have provided great advances in the art. However, in some cases, after the elastic composite material is formed, the desired level of breathability is not obtained or the desired level of breathability is impaired. Accordingly, there remains a need for a method of producing an elastic composite material that provides better control of the breathability of the composite material when it is formed. SUMMARY OF THE INVENTION

[0004] The present disclosure generally relates to a method of simultaneously melt-fusing and perforating a film-based elastic laminate in a manner that better controls the resulting breathability of the laminate. By the method of the present disclosure, a breathable elastic laminate including a facing layer can be formed, which in the past had a tendency to interfere with the breathability of the laminate after perforation. For example, in the past, it has been difficult to control the breathability of a laminate that contains a nonwoven web having high-density fibers and / or ultrafine fibers. Problems have also been experienced in the past in controlling the breathability of a laminate that contains a facing layer of a polymer having a relatively low melting point. However, the method of the present disclosure provides better control of the breathability and results in the production of an elastic laminate having unique properties, including improved breathability.

[0005] For example, in one aspect, the present disclosure relates to a method of forming a nonwoven composite material. The method includes feeding an elastomeric film and a nonwoven web material through a bonding and perforating apparatus to simultaneously bond or melt-fuse the film to the nonwoven web material and form holes in the film while the film is under a longitudinal draw ratio of about 1.5 or greater, such as a draw ratio of about 2.5 to about 12. According to the present disclosure, the film is held under tension such that after the holes have been formed and the film has been melt-fused to the nonwoven web material, the film shrinks longitudinally by no more than about 60%, such as no more than about 50%, such as no more than about 30%, such as no more than about 20%, such as no more than about 10%. Thereafter, the nonwoven composite material can fully shrink or shrink such that less than 20% of the draw is retained longitudinally in the film before or during winding onto a roll. During the method, the length of at least one of the holes formed in the elastomeric film is from about 200 microns to about 5,000 microns. The resulting nonwoven composite material has a breathability greater than about 10 CFM, such as greater than about 25 CFM, such as greater than about 30 CFM, such as greater than about 50 CFM, such as greater than about 80 CFM.

[0006] According to the method of the present disclosure, after the holes have been formed and the film has been melt-bonded to the nonwoven web material, the film can be held under tension for at least about 0.1 second, such as at least about 0.2 second, such as at least about 0.3 second, and less than about 10 seconds. After the holes have been formed and the film has been melt-bonded to the nonwoven web material, the film can be held under tension by a downstream tension device. The downstream tension device can include a nip formed between two rollers, or can include an S-shaped winding configuration of guide rollers.

[0007] In one aspect, the bonding and perforating device can include intermeshing grooved rollers that melt-bond the nonwoven web and the elastic film and cause the film to rupture in a controlled manner. Alternatively, the bonding and perforating device can include a nip formed between at least one patterned roller that results in spot bonding and melt-bonding. Although the elastic film is open-pored during the method, in one aspect, the nonwoven web material is pore-free after being melt-bonded to the film. In one aspect, additional nonwoven web material can pass through the bonding and perforating device such that the elastic film is positioned between two nonwoven web materials to form a laminate.

[0008] By the method of the present disclosure, various unique nonwoven composites can be formed. For example, a facing material can be incorporated into a nonwoven composite containing a low-temperature polymer and / or containing dense fibers and / or ultrafine fibers while still producing a composite having a desired breathability.

[0009] In one aspect, the nonwoven composite can include an elastic film containing an elastomeric polymer. The elastic film can be positioned adjacent to the nonwoven web material and melt-bonded to the nonwoven web material such that the elastic film adheres to the nonwoven web material at a plurality of discrete bond points. The elastic film can define a plurality of holes, and the corresponding discrete bond points are generally located around the perimeter of the holes. The length of at least one of these holes can be from about 200 microns to about 5,000 microns. According to the present disclosure, the nonwoven web material contains fibers comprising a low-temperature polymer. The nonwoven material can be pore-free in the region adjacent to the holes in the film and can be unbonded to the film except at the corresponding discrete bond points. According to the present disclosure, the breathability of the resulting nonwoven composite can be greater than about 10 CFM, such as greater than about 25 CFM, such as greater than about 30 CFM, for example greater than about 50 CFM, such as greater than about 70 CFM, for example greater than about 90 CFM, such as greater than about 120 CFM.

[0010] The fibers contained in the nonwoven web material can be spunbond fibers, meltblown fibers, staple fibers, or combinations thereof. The melting point of the low-temperature polymer can be below about 150 °C, such as below about 140 °C, such as below about 130 °C, such as below about 120 °C, such as below about 110 °C, such as below about 100 °C. The melting temperature can be determined using DSC, such as by using ASTM test D3418-21. In one aspect, the low-temperature polymer can include polyethylene polymers, poly(lactic acid) polymers, polyhydroxyalkanoate polymers, poly(ethylene adipate) polymers, poly(ethylene oxide) (PEG) polymers, plastomers, random copolymers, or polymer blends containing plasticizers. In another embodiment, the low-temperature polymer can include elastomers, such as polyolefin elastomers.

[0011] In yet another embodiment, the present disclosure relates to a nonwoven composite material comprising an elastic film containing an elastomeric polymer and at least one skin layer. The skin layer can comprise the low-temperature polymer as described above. The elastic film can be positioned adjacent to and melt-bonded to the fiber-containing nonwoven web material opposite the skin layer along the surface of the film such that the elastic film adheres to the nonwoven web material at a plurality of discrete bond points. The elastic film can define a plurality of holes, and the corresponding discrete bond points are generally located around the perimeter of the holes. The length of at least one of these holes can be from about 200 microns to about 5,000 microns. On the other hand, the nonwoven web material can be pore-free in the region adjacent to the holes in the film and can be non-bonded to the film except at the corresponding discrete bond points. The air permeability of the nonwoven composite material can be greater than about 10 CFM, such as greater than about 25 CFM, such as greater than about 30 CFM, such as greater than about 50 CFM, such as greater than about 70 CFM, such as greater than about 90 CFM.

[0012] The breathable elastic nonwoven composite material of the present disclosure can be used in a variety of applications. In one embodiment, for example, the material can be incorporated into absorbent articles.

[0013] Other features and aspects of the present disclosure are discussed in more detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The full and enabling disclosure of the present disclosure is set forth more specifically in the remainder of the specification and with reference to the drawings, in which:

[0015] Figure 1 is a schematic illustration of one embodiment of a method for forming an elastic laminate according to the present disclosure;

[0016] Figure 2 is another schematic illustration of an embodiment of a method for forming an elastic laminate according to the present disclosure;

[0017] Figure 3 is another exemplary embodiment schematically illustrated of a method for forming an elastic laminate according to the present disclosure;

[0018] Figure 4 is a cross-sectional view of one embodiment of an elastic film containing a skin layer, which elastic film can be used to produce an elastic laminate according to the present disclosure; and

[0019] Figure 5 is a perspective view of one embodiment of an absorbent article incorporating a composite elastic laminate manufactured according to the present disclosure.

[0020] The repeated use of reference numerals in this specification and the drawings is intended to represent the same or analogous features or elements of the invention.

[0021] Definitions

[0022] Throughout this specification and the claims, the discussion of articles and / or their individual components has the understanding set forth below.

[0023] The term "comprising" or "including" or "having" is inclusive or open-ended and does not exclude additional unrecited elements, components, or method steps. Thus, the term "including" or "comprising" or "having" encompasses the more restrictive terms "consisting essentially of" and "consisting of".

[0024] As used herein, the term "hole" means a continuous and unbroken hole or opening through the entire thickness of a layer, or, where the context implies, through the entire thickness of a laminate.

[0025] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers such as block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modified forms thereof. In addition, unless specifically limited otherwise, the term "polymer" shall include all possible geometric configurations of the molecule. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetry.

[0026] As used herein, "propylene polymer" means a polymer having a propylene content greater than 50% (mole percent).

[0027] As used herein, "ethylene polymer" means a polymer having an ethylene content greater than 50% (mole percent).

[0028] As used herein, "olefin polymer" means a polymer having an olefin content greater than 50% (mole percent).

[0029] As used herein, the term "fabric" refers to a cohesive fibrous sheet material, including woven, knitted, and non-woven materials.

[0030] As used herein, the term "non-woven web" means a structure or web of material formed without using traditional fabric-forming processes such as weaving or knitting to produce a structure of individual fibers or filaments that are entangled or interlaced but not in a recognizable repeating pattern.

[0031] As used herein, "spunbond" fibers and "spunbond" non-woven webs include a continuous fibrous web formed by extruding a molten thermoplastic material in the form of molten filaments from a plurality of fine capillary tubes into a converging high-velocity stream of hot air, which stream fines the filaments of the molten thermoplastic material to reduce their diameter. The eductive drawing of the spunbond process also serves to impart a degree of crystallinity to the resulting polymeric fibers, which provides a web with relatively increased strength. As non-limiting examples, spunbond fiber non-woven webs and methods of making the same are disclosed in U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 5,382,400 to Pike et al., U.S. Patent No. 8,246,898 to Conrad et al., U.S. Patent No. 8,333,918 to Lennon et al., and the like.

[0032] As used herein, "meltblown" fibers and "meltblown" non-woven webs generally refer to those formed by a method in which a molten thermoplastic material is extruded in the form of molten fibers through a plurality of fine, generally circular die capillaries into a converging high-velocity stream of gas (e.g., air), which stream fines the fibers of the molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers are carried by the high-velocity gas stream and deposited on a collecting surface to form a randomly dispersed meltblown fiber web. As non-limiting examples, meltblown fiber non-woven webs and methods of making the same are disclosed in U.S. Patent No. 3,849,241 to Butin et al., U.S. Patent No. 4,775,582 to Abba et al., U.S. Patent No. 4,707,398 to Wisneski et al., U.S. Patent No. 5,652,048 to Haynes et al., U.S. Patent No. 6,972,104 to Haynes et al., and the like.

[0033] As used herein, the term "longitudinal" or "MD" refers to the direction of travel of the film in the manufacturing process.

[0034] As used herein, the term "cross-machine direction" or "CD" refers to a direction that is substantially perpendicular to the longitudinal direction as defined above.

[0035] As used herein, the terms "elastomer" and "elastic" refer to materials that can be stretched in at least one direction (such as the MD direction) after the application of a tensile force and contract / return to approximately their original dimensions after the release of the tensile force. For example, the stretched material can have a stretched length that is at least 50% greater than its relaxed, unstretched length, and will recover at least 50% of its stretched dimension (i.e., the stretched length minus the original relaxed length) after the release of the tensile force. A hypothetical example would be a one (1)-inch sample of material that can be stretched to at least 1.50 inches and will return to a length of no less than 1.25 inches after the release of the tensile force. Advantageously, the material contracts or recovers greater than 60%, 65%, 70%, 75%, and even more advantageously greater than 80% of the stretched length.

[0036] As used herein, "personal care products" or "absorbent articles" refer to any and all articles or products used for personal health or hygiene, including diapers, adult incontinence garments, absorbent pants and absorbent clothing, tampons, feminine pads and liners, body wipes (e.g., baby wipes, perineal wipes, hand wipes, etc.), bibs, changing pads, bandages, and their components.

[0037] As used herein, "protective articles" refer to all articles designed to protect the user or device from contact with or exposure to external substances, including, for example, face masks, protective gowns and aprons, gloves, caps, shoe covers, device covers, sterile wrappings (e.g., for medical devices), vehicle covers, etc.

[0038] As used herein, the term "hot melt bonding" generally refers to a process performed, for example, by passing a material between a patterned roll (e.g., a calender roll) and another roll that may or may not be patterned (e.g., an anvil roll). Typically, one or both of the two rolls are heated.

[0039] As used herein, "low-temperature polymers" refer to polymers with a melting point below 150 °C (unless otherwise specified), or with a Vicat softening temperature below approximately 125 °C (unless otherwise specified). The melting point of the low-temperature polymer can be below approximately 140 °C, such as below approximately 130 °C, such as below approximately 125 °C, such as below approximately 120 °C, such as below approximately 115 °C, such as below approximately 110 °C, such as below approximately 105 °C, such as below approximately 100 °C, such as below approximately 95 °C, such as below approximately 90 °C. The Vicat softening temperature of the low-temperature polymer can be below approximately 120 °C, such as below approximately 110 °C, such as below approximately 100 °C, such as below approximately 90 °C, such as below approximately 80 °C, such as below approximately 70 °C, such as below approximately 60 °C, such as below approximately 50 °C, and above approximately 40 °C. Optionally, the Shore A hardness of the low-temperature polymer can be below approximately 125, such as below approximately 110, such as below approximately 100, such as below approximately 95, such as below approximately 90, and above approximately 50, as opposed to above approximately 65.

[0040] As used herein, the melting point, glass transition temperature, and percent crystallinity of the polymer can be determined by differential scanning calorimetry (DSC). The differential scanning calorimeter can be a THERMAL ANALYST 2910 differential scanning calorimeter equipped with a liquid nitrogen cooling accessory and THERMAL ANALYST 2200 (version 8.10) analysis software program, both of which are available from T.A. Instruments Inc. of New Castle, Del. To avoid direct handling of the sample, tweezers or other tools are used. The sample is placed in an aluminum pan and weighed on an analytical balance to an accuracy of 0.01 mg. A crimp cap is placed over the pan on top of the material sample. Typically, resin pellets are placed directly on the weighing pan, and fibers are cut to fit on the weighing pan and covered with a lid.

[0041] As described in the operating manual of the differential scanning calorimeter, the differential scanning calorimeter is calibrated using an indium metal standard and a baseline correction is performed. The material sample is placed in the test chamber of the differential scanning calorimeter for testing, and an empty pan is used as the reference. All tests are run with a purge of nitrogen (industrial grade) at 55 cubic centimeters per minute over the test chamber. For resin pellet samples, the heating and cooling program is a 2-cycle test that starts by equilibrating the chamber to -25°C, followed by a first heating cycle at a heating rate of 10°C per minute to a temperature of 200°C, then equilibrating the sample at 200°C for 3 minutes, followed by a first cooling cycle at a cooling rate of 20°C per minute to a temperature of -25°C, then equilibrating the sample at -25°C for 3 minutes, and then a second heating cycle at a heating rate of 10°C per minute to a temperature of 200°C. For fiber samples, the heating and cooling program is a 1-cycle test that starts by equilibrating the chamber to -25°C, followed by a heating cycle at a heating rate of 20°C per minute to a temperature of 200°C, then equilibrating the sample at 200°C for 3 minutes, and then a cooling cycle at a cooling rate of 10°C per minute to a temperature of -25°C. All tests are run with a purge of nitrogen (industrial grade) at 55 cubic centimeters per minute over the test chamber.

[0042] The results are then evaluated using the THERMAL ANALYST 2200 analysis software program, which identifies and quantifies the glass transition temperature (T of the inflection point g) Absorption peaks and exothermic peaks, as well as the areas under the peaks on the DSC graph. The glass transition temperature is determined as the region where the slope of the graph changes significantly, while the melting temperature is determined using automatic inflection point calculation. The area under the peaks on the DSC graph is measured in joules per gram of sample (J / g). For example, the heat of fusion of a resin or fiber sample is determined by integrating the area of the absorption peak. The area value is determined by converting the area under the DSC graph (e.g., the absorption area) into units of joules / gram (J / g) using computer software. The % crystallinity is calculated as follows:

[0043] % crystallinity = 100 * (A - B) / C

[0044] where

[0045] A is the sum of the areas of the absorption peaks (J / g);

[0046] B is the sum of the areas of the exothermic peaks (J / g); and

[0047] C is the heat of fusion value of the selected polymer, where such a polymer has 100% crystallinity (J / g). For polylactic acid, C is 93.7 J / g (Cooper-White, J.J. and Mackay, M.E., Journal of Polymer Science, Polymer Physics Edition, page 1806, volume 37 (1999)). Any area under the exothermic peak encountered due to insufficient crystallization in the DSC scan is subtracted from the area under the absorption peak to appropriately represent the crystallinity.

[0048] As used herein, the term "biodegradable" or "biodegradable polymer" generally refers to materials that can be degraded by the action of naturally occurring microorganisms such as bacteria, fungi, and algae; environmental heat; moisture; or other environmental factors. The biodegradability of a material can be determined using ASTM test method 5338.92.

[0049] As used herein, "bio-based polymer" refers to polymers produced from sustainable resources such as plant materials and animal materials. In one aspect, bio-based polymers can be produced from biomass. Detailed Description

[0050] Those of ordinary skill in the art should understand that this discussion is only a description of exemplary embodiments and is not intended to limit the broader aspects of the disclosure.

[0051] Generally, the present disclosure relates to a method of forming a nonwoven composite material. The nonwoven composite material includes at least one elastic film layer that is bonded to at least one nonwoven material layer. In the method of manufacturing the nonwoven composite material, the elastic film layer is stretched, perforated, and bonded to the nonwoven material layer. According to the present disclosure, after the holes have been formed and the film has been bonded to the nonwoven material, the film is held under tension for a period of time. It has been found that holding the film in a stretched state after perforation can unexpectedly and significantly improve and control the breathability of the nonwoven composite material. For example, by the method of the present disclosure, the breathability of the nonwoven composite material can be much greater than the breathability that would occur if the elastic film were allowed to contract after hole formation.

[0052] By being able to control the breathability of the elastic nonwoven composite material, unique and novel breathable laminates can be produced. For example, in the past, incorporating low-temperature polymers into one or more nonwoven composite material layers, incorporating ultrafine fibers into the nonwoven web material layer, and / or using nonwoven web materials with increased fiber density have had the tendency to reduce or otherwise interfere with the breathability of the elastic composite material when the elastic composite is perforated. However, by the method of the present disclosure, low-temperature polymers can be incorporated into the elastic film layer or the one or more nonwoven layers while still producing a nonwoven composite material with significant breathability. Similarly, nonwoven composite materials can be produced according to the present disclosure that have a desired level of breathability while still including nonwoven web materials containing fine fibers and / or high-density fibers.

[0053] Reference Figure 1 , shows one embodiment of a method for forming an elastic nonwoven composite material according to the present disclosure. In this embodiment, the elastic film is stretched and bonded to the nonwoven web material on each side. In other embodiments to be explained below, the elastic film can be bonded to a single nonwoven web material on one side. In other embodiments, multiple nonwoven web material layers can be attached and bonded to the elastic film during the method.

[0054] Reference Figure 1 , an elastomeric film 10 is provided and unwound from a first supply roll 12. The elastomeric film 10 can be made in a variety of different ways. For example, the elastomeric film 10 can be produced using blow molding, casting, extrusion, etc. In one aspect, the molten elastomer is extruded, thinned, and cooled to form a film. After the film is cooled, the film can be drawn and its thickness reduced by stretching. The elastomeric film 10 can be uniaxially or biaxially stretched in the longitudinal, transverse, or both directions. In one aspect, the elastic film 10 can be clamped at its lateral edges by chain clamps and conveyed into a tenter frame. In the tenter frame, the film is drawn transversely to a desired draw ratio. When drawn transversely, the elastic film 10 can also utilize, for example Figure 1The S-shaped winding system shown or other devices are used to stretch longitudinally. In Figure 1 In the illustrated embodiment, the elastomeric film 10 is pre-formed and is being unwound from the first supply roll 12.

[0055] The elastomeric film 10 travels away from the first supply roll 12 and toward a first roller assembly 22 that includes a first roller 22A and a second roller 22B. The pair of rollers 22A and 22B are positioned close to each other so as to form a nip 21 and rotate in opposite directions as indicated by the respective arrows. The circumferential speeds (S2) of the first roller assembly 22 and the respective drive rollers 22A, 22B are substantially the same as the speed (S1) of the unwind roll 12; the speeds can be varied slightly as needed to maintain a small degree of tension or slack in the film for ease of handling. The elastomeric polymer film 10 passes through the nip 21 of the first roller assembly 22 and travels in the direction toward the nip 27 of a second roller assembly 26 and enters the nip 27, which second roller assembly 26 includes a pair of drive rollers 26A, 26B.

[0056] The circumferential speeds (S3) of the second roller assembly 26 and the respective drive rollers 26A, 26B are higher than the circumferential speeds (S2) of the first roller assembly 22 and its drive rollers 22A, 22B. Thus, when the elastomeric film 25 travels between the first roller assembly 22 and the second roller assembly 26, it elongates or stretches in the MD. In some embodiments, the circumferential speed (S3) of the downstream roller assembly can be at least 150%, 250%, 300%, or 400% higher than the circumferential speed (S2) of the upstream roller assembly. In additional embodiments, the circumferential speed of the downstream roller assembly (e.g., assembly 26) can be from about 200% to about 1200%, from about 250% to about 1000%, or even from about 300% to about 900% of the circumferential speed of the upstream roller assembly.

[0057] It should be understood that the degree of stretching of the elastic film can be achieved in a single stretching operation or multiple discontinuous stretching operations. For example, in an alternative embodiment, the speed (S1) of the supply roll 12 can optionally be lower than the speed (S2) of the first roller assembly 22, thereby having a first stretching operation of stretching the elastomeric film 10 between the roller assembly 12 and the roller assembly 22 and a second stretching operation of stretching the elastomeric film 25 between the roller assembly 22 and the roller assembly 26. The number and degree of the individual stretching operations can be varied to obtain the desired overall degree of stretching. In this regard, before entering the nip of the bonding and perforating device, the elastic film can be elongated or stretched longitudinally at a draw ratio of from about 1.5 to about 12 (including all increments of 0.1 therebetween). For example, the draw ratio can be greater than about 2, such as greater than about 2.5, such as greater than about 3, such as greater than about 3.5, such as greater than about 4, such as greater than about 4.5. The draw ratio is generally less than about 10, such as less than about 8, such as less than about 7.5, such as less than about 7, such as less than about 6.5.

[0058] In addition to the elastomeric film, at least one support material, such as a fabric, is employed as the facing material laminated to the elastomeric film. In this regard, the fabric may include one or more fiber materials having desired physical properties (such as a pleasant handfeel, softness, improved aesthetics, tensile strength, etc.). The fabric can be made in parallel with the elastomeric polymer film and / or supplied by a supply roll. Refer to Figure 1 , the first fabric 14 can be unwound from the second supply roll 16 and guided towards the nip 27 of the second roll assembly 26. The first fabric 14 overlaps the stretched elastomeric polymer film 25 either before entering the nip 27 or immediately after entering the nip 27. It is often desirable for the laminated material to have outer facings on both sides of the elastic laminate and the resulting composite elastic laminate. Accordingly, the second fabric 18 can be unwound simultaneously from the third supply roll 20 and also guided towards the nip 27 of the second roll assembly 26. However, although the second fabric 18 also overlaps the stretched elastomeric film either before entering the nip 27 or immediately after entering the nip, it is positioned against the bottom layer or the opposite side of the elastomeric film 25 such that the elastomeric film 25 is positioned between the opposing outer fabrics 14, 18. The multiple overlapping layers 14, 25, 18 together form a sheet laminate. Unlike the elastomeric film 10, the nonwoven webs 14, 18 are not significantly stretched as they travel between their respective supply rolls 16, 20 and the bonding and perforating device 30. In this regard, the circumferential speeds (S3) of the supply rolls 16, 20 are substantially similar to the circumferential speed of the second roll assembly 26 as well as the bonding and perforating device 30.

[0059] The sheet laminate is guided to a bonding and perforating device 30 for simultaneously melt - fusing the film 25 to the nonwoven web materials 14 and 18 and forming holes in the film 25 while under the tension of the film 25 being in a stretched state. The bonding and perforating device 30 can include any suitable device capable of melt - fusing the film to the nonwoven web material and forming holes. In Figure 1In an exemplary embodiment, for example, the bonding and perforating device / roller assembly 30 defines a nip 31 formed between two opposing rollers 30A and 30B. In one aspect, lamination is achieved via a patterned bonding technique, where a stack is fed into the nip 31 defined by at least one patterned roller. Hot melt bonding typically utilizes, for example, a nip formed between two rollers (e.g., 30A, 30B), with at least one of the two rollers being patterned (e.g., 30A). The patterned roller can include a plurality of raised bonding elements to simultaneously bond the film to the nonwoven web material and form holes in the film. The size of the bonding elements can be specifically tailored to facilitate hole formation in the film and enhance the melt fusion between the film and the nonwoven web material. For example, the bonding elements can have a relatively large length dimension, such as from about 300 microns to about 5,000 microns. On the other hand, the width dimension of the bonding elements can be from about 20 microns to about 500 microns. In addition to the size of the bonding elements, the overall bonding pattern can also be selectively controlled to achieve the desired hole formation. Alternatively, the bonding and perforating device can include a grooved roller assembly 30 having first and second intermeshing grooved rollers 30A, 30B.

[0060] The circumferential speed (S3) of the roller assembly 30 can be substantially the same as the circumferential speed of the second roller assembly 26 to hold the elastic film in a stretched state as it enters the roller assembly 30. In an alternative embodiment, the roller assembly 30 can operate at a circumferential speed higher than that of the second roller assembly 26 to further longitudinally stretch the elastic film and, in some embodiments, also neck stretch the nonwoven web prior to entering the roller assembly 30.

[0061] In addition to the MD stretch and tension imparted by the upstream components, CD stretch is also imparted to the stacked film and nonwoven web by using the grooved roller assembly 30. It is believed that this multi-dimensional strain causes controlled rupture of the film. For example, the intermeshing grooved rollers 30A, 30B can form an irregular nip 31, and each roller includes a series of alternating ridges and grooves. The rollers 30A, 30B are arranged such that their respective ridges and grooves are offset from and intermesh with each other. In other words, the ridges of the upper grooved roller 30A are positioned to extend into the grooves of the second or lower grooved roller 30B and between the ridges of the second grooved roller 30B. Similarly, the ridges of the second grooved roller 30B are positioned to extend into the grooves of the first grooved roller 30A and between the ridges of the first grooved roller 30A. In certain embodiments, the ridges and grooves run concentrically around the entirety of the rollers 30A, 30B. The grooves or channels of such grooved rollers can be machined into the rollers, can be formed by a series of elements such as discs, or can be any other device providing the indicated functional structure.

[0062] When pulling the laminate 28 through the nip 31, the engagement at the ridges of the opposing grooved rollers 30A, 30B causes the components forming the laminate 28 to be additionally stretched in the width direction or transversely. The biaxial tensile force and heat also act together to cause local controlled rupture of the elastic film. Additionally, in the region on or near the top of the ridges, pressure and heat are applied via the rollers 30A, 30B, which also facilitates the melt fusion between one or more layers within the laminate. Regarding the use of such intermeshing grooved roller assemblies 30, the amount of CD stretch imparted to the unbonded section and the amount of pressure imparted to the bonded section at the top of the ridges are functions of the engagement depth set for the grooved rollers; the deeper the grooved rollers engage, the greater the percentage of elongation in the CD. The opposing grooves and ridges engage or intermesh with each other to a selected depth. Additionally, by arranging the gap distance between the rollers, the nonwoven material can be affected to varying degrees. The engagement depth can be at least about 5 mm and in some embodiments can be about 5 mm to about 20 mm or about 6 mm to about 15 mm. The CD stretch imparted to the material in the grooved roller assembly desirably increases the CD width of the outer nonwoven fabric by at least about 5% and in some embodiments can cause the CD width of the outer nonwoven fabric to increase by about 5% - 20%, about 5% - 15%, about 8% - 15% or even about 6% - 12%.

[0063] The depth of the grooves and / or the height of the ridges can vary widely, as the engagement depth more directly drives the degree of CD stretch. However, the depth and height of the ridges and grooves are selected relative to the laminate height to ensure that the laminate is not significantly squeezed or cut off while being within the grooved roller nip. To effectively bond the sheet laminate 28 while in the nip 31 without cutting the laminate, neither the nip gap distance (top nip gap) between the opposing grooves and ridges nor the nip gap distance (side nip gap) between the sidewalls of adjacent ridges is significantly less than the height of the laminate 28. The height of the laminate or "laminate height" is measured by stacking each sheet of appropriate size on top of each other and according to the method of measuring fabric thickness as described herein. The top nip gap can be slightly less than the laminate height, but desirably is not less than 100% of the laminate height. In some embodiments, the top nip gap and the side nip gap are each at least 100% of the laminate height and in additional embodiments, at least 110%, 120%, 150% or even 200% of the laminate height. In some embodiments, the side nip gap can be greater than the top nip gap. Additionally, the shape of the top of the ridges is desirably circular, including for example having a substantially semi-circular shape.

[0064] Obviously, the number of joining ridges and the frequency of the ridges can vary widely. By way of example only, ridges having a height between about 0.5 cm and about 2 cm will be suitable for many embodiments with relatively low basis weight materials. In certain embodiments, a single roll can have from about 0.25 ridges / cm to about 7 ridges / cm, and in some embodiments, from about 0.5 ridges / cm to about 5 ridges / cm, and in other embodiments, from about 1 ridge / cm to about 4 ridges / cm. Additionally, the distance between the peaks of the ridges can also vary, such as between about 4 cm and about 0.2 cm in certain embodiments, and between about 3 cm and about 0.25 cm in other embodiments, and between about 2 cm and about 0.5 cm in other embodiments. Further, in certain embodiments, the frequency or spacing of the ridges can vary across the CD length of the roll.

[0065] In some embodiments, in order to achieve the melt fusion between the layer and the film and the (simultaneous) rupture of the film, sufficient tensile force and heat are applied to the outer fabric layer and the elastic film. The temperature of the surface layer and the film layer should not be so high that it causes significant melting of the film and / or the fibers together with the pressure applied via the tensile force. In this regard, if the film melts and the fibers are completely embedded in the film, the elasticity of the resulting laminate may be reduced. Additionally, if the fibers significantly melt and are compressed into film-like segments, this may create hard points and / or hard regions that provide a generally rougher feel.

[0066] Heating of the layer can be achieved by any of a variety of methods known in the art. In certain embodiments, the laminate can be heated immediately prior to entering the nip of the roll assembly 30, such as by heating with a heated roll, an IR heater, a convection heater, etc. With respect to Figure 1 the depicted embodiment, one or more of the rolls of the first roll assembly 22 and / or the second roll assembly 26 can be heated. Additionally and / or alternatively, the layer can be heated by heating one or both of the rolls 30A, 30B while in contact with the roll. When using rolls to heat the layer, it should be understood that one or more of these layers can be guided along a portion of the outer circumference of the roll prior to entering the nip in order to increase the length of time the layer is in direct contact with the roll and is heated by the roll.

[0067] In one aspect, one or both of these rollers can be heated to a temperature of about 65°C - 145°C, about 70°C - 120°C, or about 80°C - 98°C. However, it should be understood that the temperature of the one or more rollers will vary depending on various factors, including the speed of the laminate, the softening point of the polymer used, and the force applied to the material. In certain embodiments, at least one or both of the rollers 30 are heated to a temperature that is at least about 5°C, 10°C, 15°C, or even 20°C higher than the Vicat softening temperature of the elastomeric film. In certain embodiments, one or both of the rollers can be about 5°C - 90°C, 10°C - 75°C, or even 10°C - 50°C higher than the Vicat softening temperature of the elastomeric film. Additionally, in certain embodiments, both rollers can be heated, but to a temperature below the melting temperature of the nonwoven fabric. The Vicat softening temperature can be determined according to ASTM D1525 - 09.

[0068] According to the present disclosure, after being bonded together in the bonding and perforating apparatus / roller assembly 30, a cohesive laminate 40 is formed and contacts the tensioning device 32. The tensioning device 32 is used to hold the elastomeric film 25 in a stretched state after holes have been formed in the film. By holding the elastomeric film 25 in a stretched state after the holes are formed, the method allows for better control of the breathability of the resulting nonwoven composite laminate 40.

[0069] As Figure 1 shown, in order to hold the elastomeric film 25 in a stretched state, the laminate 40 enters the tensioning device 32. The tensioning device 32 can be any suitable device capable of holding the elastomeric film 25 in a stretched state without allowing the film to fully contract. In Figure 1 the illustrated embodiment, the tensioning device 32 includes a nip 33 formed between a first guide roller 34A and a second guide roller 34B. The rollers 34A and 34B rotate in opposite directions and rotate at the same circumferential speed (S4) as the rollers 30A and 30B in order to hold the elastomeric film 25 in a stretched state that is substantially the same as when the film was perforated and bonded. Alternatively, the rollers 34A and 34B can be operated at a circumferential speed slightly slower than the rollers 30A and 30B in order to allow the elastomeric film 25 to contract a controlled amount. For example, the tensioning device 32 can be operated such that the elastomeric film contracts longitudinally by no more than about 60%, such as no more than about 50%, such as no more than about 40%, such as no more than about 30%, such as no more than about 20%, such as no more than about 10%. For example, within the nip 33, the elastomeric film 25 can still be at a draw ratio of about 1.5 or greater, such as about 2 or greater, such as about 2.5 or greater, such as about 3 or greater, such as about 3.5 or greater, such as about 4 or greater, such as about 4.5 or greater, such as about 5 or greater, and less than about 11, such as less than about 9, such as less than about 8, such as less than about 7.5.

[0070] Once exiting the tension device 32, the laminate or nonwoven composite material 40 is then allowed to shrink and can be fed directly into a converting line for incorporation into a desired end product, or alternatively, as Figure 1 shown, can be wound onto a winding roll 42 for future use and / or conversion processing. For example, the supply roll 42 can be operated at a circumferential speed (S5) that is less than the circumferential speed (S4) of the tension device 32, once allowing the elastic film 25 to shrink. The laminate material 40 can still be slightly in a stretched state when wound onto the roll 42, or can be completely relaxed. In one aspect, the elastic film can shrink and be wound onto the supply roll 42 such that relative to the amount of stretch contained in the elastic film 25 in the bonding and perforating device 30, the film remains less than about 35% stretched, such as less than about 30% stretched, such as less than about 25% stretched, such as less than about 20% stretched, such as less than about 15% stretched, such as less than about 10% stretched, such as less than about 5% stretched.

[0071] In Figure 1 the illustrated embodiment, the tension device 32 includes a pair of opposing rolls 34A and 34B. Alternatively, the tension device 32 can have an S-shaped winding configuration similar to rolls 22A and 22B for maintaining the elastic film 25 under tension after it exits the bonding and perforating device 30.

[0072] The amount of time that the elastic film 25 remains in a stretched state after being perforated can vary depending on different factors, including the process configuration and the materials used to form the different layers. In one aspect, the elastic film 25 only needs to remain in a stretched state for a very short time in order to provide proper control over the breathability of the resulting nonwoven composite. For example, the tension device 32 can be spaced apart from the bonding and perforating device 30 such that the elastic film 25 is maintained under tension for less than about 10 seconds, such as less than about 8 seconds, such as less than about 6 seconds, such as less than about 4 seconds, such as less than about 2 seconds. In one aspect, the time that the elastic film 25 is maintained in a stretched state after the holes have been formed is less than about 1 second, such as less than about 0.8 second, such as less than about 0.6 second, such as less than about 0.4 second, and generally greater than about 0.1 second, such as greater than about 0.2 second.

[0073] It has been found that post-bonding causes an unexpected and significant increase in the breathability of the elastic composite by holding the elastic laminate 40, and in particular the elastic film 25, in a stretched state for a relatively short period of time after the holes have been formed, which otherwise would not occur. Although unknown, it is believed that holding the laminate in a stretched state allows the elastic film 25 to cool to prevent hole closure and / or also affects the point bonding to the nonwoven material of the elastic film. For example, it is believed that holding the laminate 40 in a stretched state can prevent the fibers in the nonwoven web material from interfering with the breathability of the nonwoven composite, even when the nonwoven web material contains very fine or high-density fibers.

[0074] As will be described in more detail below, the ability to better control the breathability of the elastic nonwoven composite allows the use of low-temperature polymers while still being able to produce a composite with improved and desired breathability. For example, in the past, the low-temperature polymer materials contained in the elastic film and / or nonwoven web material caused blockage or closure of the holes formed in the elastic film. However, due to the method of the present disclosure, these low-temperature polymer materials can be incorporated into the nonwoven composite while still producing a laminate with the desired breathability.

[0075] Reference Figure 2 , an alternative embodiment of a method for producing a nonwoven composite manufactured in accordance with the present disclosure is shown. In this embodiment, the elastomeric polymer is fed from a hopper (not shown), melted, and directed to an extrusion device 110, such as a film die. The extruded polymer 112 is directed onto a cooling roll 114 to form a single-layer elastic film 116. If a multi-layer film is to be produced, multiple layers can be co-extruded together and directed onto the cooling roll. Generally, the cooling roll 114 is maintained at a temperature sufficient to cure and quench the extruded polymer and form a film thereon. In certain embodiments, the cooling roll can be maintained at a temperature between about 20°C and 60°C.

[0076] To obtain the desired elasticity of the film, various parameters of the film formation and stretching operations are selectively controlled. For example, the circumferential speed of the cooling roll can be higher than the extrusion speed of the molten polymer exiting the film die. This difference in rate causes the film to be stretched and / or oriented to some extent in the MD. After the film is formed on the cooling roll, the film can be drawn or stretched in the MD, as generally described above. In some embodiments, for example, the formed film is cumulatively stretched in the longitudinal direction at a draw ratio of about 3 to about 12, in some embodiments about 3 to about 9, and in some embodiments about 4 to about 7. The draw ratio can be determined by dividing the linear speed of the film exiting the stretching operation by the linear speed of the film entering the stretching operation.

[0077] Reference Figure 2In the illustrated embodiment, the elastic film 116 is longitudinally stretched by passing through a series of rollers, where the downstream rollers travel at a relatively higher circumferential speed than the preceding upstream rollers. In this regard, the elastic film 116 is guided from the cooling roller 114 and the cooperating guide roller 115 to an S-shaped winding roller assembly 118 including at least a stacked first roller and second rollers 118A, 118B. The rollers 118A, 118B of the S-shaped winding assembly operate at a circumferential speed (S2) faster than the circumferential speed (S1) of the cooling roller 114. This speed difference serves to stretch the elastic film 116 longitudinally. Optionally, the stretched elastic film 116 may then be guided to another downstream drive roller assembly 119, which includes a stacked first roller and second rollers 119A, 119B and operates at a circumferential speed (S3) greater than the circumferential speed (S2) of the upstream or first roller assembly 118. This operation imparts a further incremental stretch and elongation to the elastic film 117. Although two sets of roller assemblies are illustrated as Figure 2 part of the system depicted, it should be understood that the number of assemblies can vary as needed, depending on the desired overall stretch level and the degree of stretch between each assembly.

[0078] The stretched film 120 exits the S-shaped winding rollers 119A, 119B and is then guided to another downstream bonding and perforating device, in this case, a grooved roller assembly 130 having intermeshing grooved rollers 130A, 130B. The outer facing materials 122, 128 are guided to overlap the elastic film 120 to form a fabric / membrane / fabric laminate before entering the nip 131 of the grooved roller assembly 130. In this regard, the outer fabric may optionally be manufactured online with the elastic film and / or supplied by supply rollers. Referring Figure 2 , the first nonwoven fabric 122 is unwound from the first supply roller 124 and the second nonwoven web 128 may be unwound from the second supply roller 126. The nonwoven webs 122, 128 may then be guided to overlap opposite surfaces of the elastic film 120 just before entering the nip 131 of the grooved roller assembly 130.

[0079] The circumferential speed (S3) of the upstream roller assembly 119 is lower than the circumferential speed (S4) of the grooved rollers 130A, 130B. Thus, due to the speed difference, when the film 120 enters the nip 131 of the roller assembly 130 together with the nonwoven fabrics 122, 128, the film 120 is further elongated longitudinally and is in a stretched state. As discussed above, due to heating and engagement with the grooved rollers, the laminate is stretched in the CD and cohesively bonded together.

[0080] The laminate 140 is fed from the roller assembly 130 to the tension device 32. In this embodiment, the tension device 32 includes a nip 133 formed between the rollers 134A and 134B. The rollers 134A and 134B engage the laminate 140 and rotate at a speed that inhibits the elastic film 120 from shrinking by more than 60%. More specifically, the tension device 132 is operated such that the film 120 does not shrink by more than about 50%, such as not more than about 40%, such as not more than about 30%, such as not more than about 20%, such as not more than about 10%. In this way, after holes are formed in the film by the rollers 130A and 130B, the elastic film 120 is held in a stretched state. By holding the elastic film in a stretched state, the breathability of the laminate 140 can be significantly and unexpectedly improved.

[0081] In the embodiment of the invention shown in the reference Figure 2 the composite elastic laminate 140 is then wound around the winding roller 142 while under significantly reduced MD tension. In this regard, the composite laminate 140 is held at a sufficient tension for processing, but by employing a circumferential speed of the take-up roller 142 (S5) that is slower than the speed of the upstream rollers 134A, 134B, significant shrinkage of the composite laminate 140 is allowed. In this regard, the elastic composite can be allowed to shrink by at least about 60%, such as at least about 70%, such as at least about 80%, such as at least about 90%, or can shrink 100%. For example, relaxing the laminate 140 can cause the elastic film 120 to have its original pre-stretched longitudinal length. Shrinkage of the elastic film 120 can cause the bonded nonwoven web to form pleats in the composite. The resulting elastic laminate is thus longitudinally extensible to at least such an extent that the pleats or bends in the web can become flat after being pulled back, thereby allowing the elastic film to elongate.

[0082] Reference Figure 3 shows yet another embodiment of a method for forming a nonwoven composite according to the present disclosure. In this embodiment, only a single nonwoven web material is bonded to the elastic film layer.

[0083] As Figure 3 shown, an elastic film 210 is provided and unwound from a first supply roller 212. The film 210 travels away from the first supply roller 212 and toward a first roller assembly 222 that includes a first roller 222A and a second roller 222B. The pair of rollers 222A and 222B are positioned close to each other to form a nip 221. The circumferential speed of the first roller assembly 222 can be the same as the speed of the unwind roller 212.

[0084] The elastic polymer film 210 passes through the nip 221 and travels in the direction of the nip 227 towards the second roller assembly 226, which includes a pair of drive rollers 226A and 226B. The circumferential speed of the second roller assembly 226 can be controlled to stretch the elastic film 225 longitudinally. As described above, the elastic film 225 can be stretched from about 150% to about 1,200%, including all increments of 1% therebetween.

[0085] As Figure 3 shown, the fabric 214 can be unwound from the second supply roller 216 and guided towards the nip 227 of the second roller assembly 226. When the elastic film 225 is in a stretched state, the fabric 214 overlaps the film and is fed into the bonding and perforating device 230, which may include a pair of rollers 30A and 30B. The rollers 30A and 30B can perforate the film and form discrete bonding points between the elastic film 225 and the fabric 214.

[0086] According to the present disclosure, the bonded and perforated laminate 40 is held in a stretched state by the tension device 232. The tension device 232 can include a pair of spaced rollers 234A and 234B that form a nip 233. The rollers 234A and 234B can rotate at a speed to hold the elastic film 225 in a stretched state such that the film shrinks by no more than about 60%, such as no more than about 50%, such as no more than about 40%, such as no more than about 30%, such as no more than about 20%, such as no more than about 10%. As described above, it has been found that holding the elastic film 225 in a stretched state after hole formation can significantly improve and increase the breathability of the laminate 240.

[0087] Once it leaves the tension device 232, the laminate 40 is allowed to contract and wind onto the supply roller 242.

[0088] In Figure 3 the illustrated embodiment, in one aspect, the elastic film 225 fed by the method can be a multilayer film. For example, as Figure 4As shown, the elastic membrane 225 may include a main membrane layer 260 adjacent to the surface layer 262. The surface layer 262 may be positioned on the side of the main membrane layer 260 opposite the fabric 214. In other words, the main membrane layer 260 may be positioned between the surface layer 262 and the fabric layer 214. The surface layer 262 may be formed of a polymer that is less sticky than the main membrane layer 260 and may thus prevent the material from sticking to itself during winding. The surface layer 262 may be made of a non-elastomeric polymer or may be made of a mixture of a non-elastomeric polymer and an elastomeric polymer. Advantageously, the surface layer 262 may be made of a low-temperature polymer that in the past would have interfered with the breathability of the elastic nonwoven material. However, by the method of the present disclosure, a surface layer 262 containing a low-temperature polymer may be used without adversely interfering with the pores formed in the membrane. In one aspect, for example, the surface layer 262 may be made of a polyethylene polymer or may include a polyethylene polymer, such as a linear low-density polyethylene polymer, which may have a melting temperature of less than about 150 °C, such as less than about 140 °C, such as less than about 130 °C, such as less than about 120 °C, such as less than about 110 °C.

[0089] The elastic laminates manufactured according to the present disclosure may have a variety of different properties. In certain embodiments, when fully shrunk and in an unstretched state, the elastic laminate may have a basis weight of at least about 15 g / m 2 and in certain embodiments may have a basis weight of at least about 25, 30, 35 or 40 g / m 2 and less than about 120, 90, 75, 65 or 60 g / m 2 of the basis weight. In certain embodiments, in the relaxed and unstretched state, the elastic membrane may account for at least 10 wt% of the laminate, such as at least 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt% or 45 wt% of the laminate. Additionally, in the relaxed and unstretched state, the elastic membrane may account for at least about 10 wt% of the laminate, such as at least about 10 wt%, 15 wt%, 20 wt% and 25 wt% of the laminate. Additionally, in the relaxed and unstretched state, the elastic membrane may account for less than about 45 wt%, 40 wt%, 35 wt% or even 30 wt% of the laminate. The outer fabric may account for about 55 wt% - 90 wt% of the laminate, such as at least about 55 wt%, 60 wt%, 65 wt% or 70 wt% of the laminate, and / or less than about 90 wt%, 85 wt%, 80 wt% or 75 wt% of the elastic laminate.

[0090] As described above, the methods of the present disclosure are designed to control and increase the breathability of elastic laminates or nonwoven composites. Generally, an elastic laminate can have a breathability of from about 10 CFM to about 1,500 CFM, including all increments of 1 CFM therebetween. For example, an elastic laminate can have a breathability greater than about 20 CFM, such as greater than about 25 CFM, such as greater than about 30 CFM, such as greater than about 40 CFM, such as greater than about 50 CFM, such as greater than about 60 CFM, such as greater than about 70 CFM, such as greater than about 80 CFM, such as greater than about 90 CFM, such as greater than about 100 CFM, such as greater than about 110 CFM, such as greater than about 120 CFM, such as greater than about 130 CFM, such as greater than about 140 CFM, such as greater than about 150 CFM, such as greater than about 160 CFM, such as greater than about 170 CFM, such as greater than about 180 CFM, such as greater than about 190 CFM, such as greater than about 200 CFM. The breathability is generally less than about 1,000 CFM, such as less than about 700 CFM, such as less than about 500 CFM, such as less than about 300 CFM, such as less than about 200 CFM, such as less than about 150 CFM. Advantageously, the elastic laminates of the present disclosure can contain a low temperature polymer in the nonwoven web material or in the top layer on the elastic film and still have a breathability greater than about 10 CFM, such as greater than about 20 CFM, such as greater than about 25 CFM, such as greater than about 30 CFM, such as greater than about 40 CFM, such as greater than about 50 CFM. In the past, low temperature polymers have interfered with pore formation and / or pore retention. Thus, incorporating low temperature polymers into elastic laminates and maintaining a desired and improved breathability has been problematic. However, the methods of the present disclosure unexpectedly and significantly overcome the problems experienced in the past.

[0091] In addition, despite the relatively low basis weight and excellent breathability, the elastic laminate provides desirable elasticity. In this regard, the elastic laminate can provide and have a percent elongation greater than about 75%, 80%, 85%, 90%, 95% or even 100% at 2000 g-f. Additionally and / or alternatively, the elastic laminate can provide or have a percent elongation less than about 260%, 255%, 250%, 245%, 340% or even 235% at 2000 g-f.

[0092] A variety of elastic membranes are believed to be suitable for use in combination with the present disclosure. In this regard, the elastic membrane can include a single-layer membrane or a multi-layer membrane. Additionally, a variety of different elastomeric polymers and their blends are believed to be suitable for use in the present invention. In certain embodiments, the elastomeric membrane and the corresponding polymer mainly include a thermoplastic polymer having a softening point lower than that of the fabric forming the outer layer. Generally, the polymer portion of the elastic membrane will desirably contain greater than 85%, 90%, 92%, 95% or 98% of an elastomeric polymer. The specific type and amount of the selected elastomer will vary with the desired properties, particularly including elasticity such as % elongation and resilience. Any of a variety of thermoplastic elastomers can generally be used as the elastic membrane of the elastic composite laminate of the present invention. Such polymers include elastomeric polyesters, elastomeric polyurethanes, elastomeric polyamides, elastomeric styrene polymers, elastomeric polyolefins, and the like.

[0093] In certain embodiments, the polymer portion of the membrane elastic membrane can mainly or completely comprise an olefin elastomer, such as comprising greater than 55%, 75%, 85%, 90%, 95% or 97% of an elastomeric olefin polymer. In one aspect, the elastic membrane can comprise a semi-crystalline polyolefin polymer. The semi-crystalline polyolefin has or can exhibit a substantially regular structure. For example, the semi-crystalline polyolefin can be substantially amorphous in its undeformed state, but forms crystalline domains and / or increased polymer chain alignment upon stretching. The crystallinity of the olefin polymer can be from about 3% to about 30%, in some embodiments from about 5% to about 25% and in some embodiments from about 5% to about 15%. The semi-crystalline polyolefin can have a melting temperature of about 40°C to about 120°C, in some embodiments about 45°C to about 90°C, and in some embodiments about 50°C to about 80°C.

[0094] Particularly suitable polyethylene copolymers are those that are "linear" or "substantially linear". The term "substantially linear" means that, in addition to short chain branches attributable to the incorporation of comonomers, the ethylene polymer also contains long chain branches in the polymer backbone. A "long chain branch" is a chain length of at least 6 carbons. Each long chain branch can have the same comonomer distribution as the polymer backbone and be as long as the polymer backbone to which it is attached. Preferred substantially linear polymers are substituted with from 0.01 long chain branches per 1000 carbons to 1 long chain branch per 1000 carbons, and in some embodiments from 0.05 long chain branches per 1000 carbons to 1 long chain branch per 1000 carbons. In contrast to the term "substantially linear", the term "linear" means that the polymer lacks measurable or obvious long chain branches. That is, the polymer is on average substituted with less than 0.01 long chain branches per 1000 carbons.

[0095] Exemplary semi-crystalline polyolefins include polyethylene, polypropylene, blends and copolymers thereof. In one particular embodiment, an ethylene polymer is employed which is a copolymer of ethylene and an α-olefin such as a C3-C 20 α-olefin or a C3-C 12 α-olefin. Suitable α-olefins can be linear or branched (e.g., having one or more C1-C3 alkyl branches, or aryl groups). Specific examples include 1-butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene having one or more methyl, ethyl or propyl substituents; 1-hexene having one or more methyl, ethyl or propyl substituents; 1-heptene having one or more methyl, ethyl or propyl substituents; 1-octene having one or more methyl, ethyl or propyl substituents; 1-nonene having one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl substituted 1-decene; 1-dodecene and styrene. Particularly desirable α-olefin comonomers are 1-butene, 1-hexene and 1-octene. The ethylene or propylene content of such copolymers can be from about 60 mole % to about 99 mole %, in some embodiments from about 80 mole % to about 98.5 mole % and in some embodiments from about 87 mole % to about 97.5 mole %. The α-olefin content can likewise be in the range from about 1 mole % to about 40 mole %, in some embodiments from about 1.5 mole % to about 15 mole % and in some embodiments from about 2.5 mole % to about 13 mole %. The ethylene polymer elastomer can have a density of from about 0.85 g / cm 3 to about 0.90 g / cm 3 and, in certain embodiments, between about 0.86 and about 0.89 g / cm 3 .

[0096] Any of a variety of known techniques can generally be used to form the elastomeric polyolefin. For example, the olefin polymer can be formed using free radical or coordination catalysts (e.g., Ziegler-Natta). Preferably, the olefin polymer is formed from a single-site coordination catalyst such as a metallocene catalyst. Such catalyst systems produce ethylene copolymers in which the comonomer is randomly distributed within the molecular chain and uniformly distributed among fractions of different molecular weights. Olefin elastomers and methods for their manufacture are described, for example, in U.S. Patent Nos. 5,272,236 to Lai et al., 5,278,272 to Lai et al., 5,472,775 to Obijeski et al., 5,539,056 to Yang et al., 7,582,716 to Liang et al., the contents of which are incorporated herein by reference to the extent consistent with the present disclosure.

[0097] Exemplary commercially available polyolefin - based thermoplastic elastomers suitable for the elastomeric film include VISTAMAXX TM (propylene - based elastomer, available from ExxonMobil Chemical, Houston, Tex.), INFUSE TM (olefin block copolymer, available from Dow Chemical Company, Midland, Mich.), VERSIFY TM (propylene - ethylene copolymer, available from Dow Chemical Company, Midland, Mich.), ENGAGE TM (ethylene - octene copolymer, available from Dow Chemical, Houston, Tex.), and NOTIO 0040 and NOTIO 3560 (available from Mitsui Chemical(USA), New York, New York). In one particularly suitable embodiment, the polyolefin - based thermoplastic elastomer is VISTAMAXX TM 6102FL.

[0098] In addition, elastomers containing block copolymers are also considered suitable, such as those containing blocks of mono - vinyl aromatic hydrocarbons and saturated conjugated dienes. The mono - vinyl aromatic hydrocarbon blocks can include styrene and its analogs and homologs, such as o - methylstyrene, p - methylstyrene, p - tert - butylstyrene, 1,3 - dimethylstyrene, p - methylstyrene, etc., and other mono - vinyl polycyclic aromatic compounds, such as vinylnaphthalene, vinylanthracene, etc. Preferred mono - vinyl aromatic hydrocarbons are styrene and p - methylstyrene. The conjugated diene blocks can include: homopolymers of conjugated diene monomers, copolymers of two or more conjugated dienes, and copolymers of one or more dienes with another monomer, where the blocks are predominantly conjugated diene units. Preferably, the conjugated diene contains from 4 to 8 carbon atoms, such as 1,3 - butadiene (butadiene), 2 - methyl - 1,3 - butadiene, isoprene, 2,3 - dimethyl - 1,3 - butadiene, 1,3 - pentadiene (piperylene), 1,3 - hexadiene, etc. The amount of the mono - vinyl aromatic hydrocarbon (e.g., polystyrene) block can vary, but typically accounts for about 8 wt% to about 55 wt% of the copolymer, about 10 wt% to about 35 wt% of the copolymer in some embodiments, and about 15 wt% to about 25 wt% of the copolymer in some embodiments. This type of thermoplastic elastomer copolymer is available under the trade name Kraton TM from Kraton Polymers LLC, Houston, Tex. Kraton TMThe polymers include styrene-diene block copolymers such as styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, styrene-isoprene-styrene, and styrene-isoprene / butadiene-styrene. Kraton TM The polymers also include styrene-olefin block copolymers formed by selective hydrogenation of styrene-diene block copolymers. Examples of such styrene-olefin block copolymers include styrene-(ethylene-butene), styrene-(ethylene-propylene), styrene-(ethylene-butene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(ethylene-butene)-styrene-(ethylene-butene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene), and styrene-ethylene-(ethylene-propylene)-styrene. Polymers composed of A-B-A-B tetrablock copolymers are also suitable, such as styrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene) (“S-EP-S-EP”) block copolymers. Various suitable styrene block copolymers are described in, but not limited to, U.S. Patent No. 4,663,220 to Wisneski et al., U.S. Patent No. 5,093,422 to Himes, U.S. Patent No. 5,332,613 to Taylor et al., U.S. Patent No. 8,604,129 to Thomas, and U.S. Patent No. 8,980,994 to Wright et al.

[0099] In certain embodiments, the film extrudate and the corresponding elastic film can comprise a mixture of one or more different elastic polymers. By way of example, blends comprising a mixture of a styrenic block copolymer and a polyolefin elastomer are well-suited for use in combination with the present disclosure. Blends comprising 55%-95% polyolefin elastomer and 5%-45% styrene block copolymer provide a good combination of shrink force and cost. Alternatively, blends comprising 5%-45% polyolefin elastomer and 55%-95% styrene block copolymer provide excellent tensile and recovery properties. Further still, in certain embodiments, the film extrudate and the corresponding elastic film can comprise a mixture of one or more elastic polymers and a minor portion of a non-elastic polymer. By way of example, the elastomeric polymer composition can include a mixture of semi-crystalline ethylene and propylene polymers. For example, in certain embodiments, an elastomeric polymer such as an ethylene polymer comprises from about 80% to about 99% or from about 85% to about 95% of the polymer portion of the extrudate and the film, and a non-elastomeric polymer such as a propylene polymer comprises from about 1% to about 20% or from about 5% to about 15% of the polymer portion of the extrudate and the film.

[0100] The film may also include other components as needed to achieve or enhance various properties. For example, in addition to the elastomeric polymer, the film may optionally include fillers, colorants, plasticizers, tackifiers, antioxidants, and / or other known additives. In certain embodiments, the film may include an opaque filler or colorant such as TiO2 in an amount of about 0.1 to about 5 wt% or about 0.5 to about 3 wt% of the film extrudate and / or the elastomeric film. In additional embodiments, a heat and / or UV stabilizer package such as Eastman Regalrez 1049 or 1126 may be used in an amount between about 2 wt% - 10 wt% of the film extrudate and / or the elastomeric film.

[0101] As described above, in one embodiment, the elastomeric film may include a skin layer. For example, the skin layer is particularly suitable for applications where the laminate material contains only one or more nonwoven web materials bonded to one side of the film. The skin layer can provide anti-blocking characteristics and can provide various other advantages. According to the present disclosure, the elastomeric film may include a skin layer containing a low-temperature polymer. For example, the melting point of the low-temperature polymer may be lower than about 150 °C, such as lower than about 140 °C, such as lower than about 130 °C, such as lower than about 120 °C, such as lower than about 110 °C, such as lower than about 100 °C, such as lower than about 90 °C, such as lower than about 80 °C, and generally higher than about 50 °C, such as higher than about 70 °C, such as higher than about 80 °C. The Vicat softening temperature of the low-temperature polymer may also be lower than about 125 °C, such as lower than about 120 °C, such as lower than about 110 °C, such as lower than about 100 °C, such as lower than about 90 °C, such as lower than about 80 °C, such as lower than about 70 °C, such as lower than about 60 °C, such as lower than about 55 °C, and higher than about 40 °C. Optionally, the Shore A hardness of the low-temperature polymer may be lower than about 125, such as lower than about 110, such as lower than about 100, such as lower than about 95, such as lower than about 90, and higher than about 50, which is higher than about 65.

[0102] The low-temperature polymer can be incorporated into the skin layer without adversely affecting the breathability of the laminate. For example, the skin layer may contain one or more low-temperature polymers in an amount greater than about 30 wt%, such as an amount greater than about 50 wt%, such as an amount greater than about 70 wt%, such as an amount greater than about 90 wt%. In one application, the skin layer may be made entirely of one or more low-temperature polymers. In one embodiment, the low-temperature polymer may be a polyolefin polymer, such as a polyethylene homopolymer or copolymer. In one aspect, for example, the skin layer may contain a linear low-density polyethylene polymer.

[0103] At least one support material, such as fabric, is used as the outer layer of a multi-layer composite material. The fabric used in conjunction with the present disclosure is inherently porous, providing many direct or tortuous channels therein. In this regard, the fabric may include one or more fiber materials having desired physical properties (such as a pleasant handfeel, softness, tensile strength, and / or other desired properties). Importantly, the fabric provides CD strength characteristics for the elastic laminate required for the relevant processing, conversion processing, and manufacturing of the final product and / or enables sufficient durability in use. In this regard, the fabric may have a tensile strength of at least about 50 g-f, including, for example, having a tensile strength greater than about 100 g-f, 150 g-f, 200 g-f, 250 g-f, or even 300 g-f, and in certain embodiments, less than about 5000 g-f, 3000 g-f, 2500 g-f, 2000 g-f, or even 1500 g-f. Additionally, the fabric desirably provides a pleasant handfeel. The fabric may also be selected to be highly drapable and / or have a low flexural modulus.

[0104] Fabrics suitable for use in the present invention include, but are not limited to, woven or knitted fabrics and nonwoven fabrics, such as those made by meltblowing, spunbonding, air-laying, carding, and / or hydroentangling processes. Examples of suitable fabrics and their manufacturing methods include, but are not limited to, those described in U.S. Patent No. 4,548,856 to Ali Kahn et al., U.S. Patent No. 5,492,751 to Butt et al., U.S. Patent No. 6,224,977 to Kobylivker et al., U.S. Patent No. 8,603,281 to Welch et al., WO99 / 32699 to Stokes et al., and WO16 / 080960 to Kupelian et al. Generally, in many embodiments, it is advantageous to utilize fabrics with a relatively low basis weight to limit the negative impact on shrinkage forces. In this regard, the fabric desirably has a basis weight of less than about 30 g / m 2 of basis weight. In certain embodiments, the fabric may have a basis weight of less than about 25 g / m 2 , 20 g / m 2 , 18 g / m 2 or even 16 g / m 2 , and in addition, in certain embodiments, may have a basis weight of more than about 5 g / m 2 , 7 g / m 2 or even 8 g / m 2basis weight. Polymers suitable for use in nonwovens are believed to be without particular limitation and include polyolefins, polyesters, polyamides, and the like. In certain embodiments, the polymeric portion of the fibers can comprise at least 50%, 60%, 70%, 80%, or 100% of a propylene polymer or an ethylene polymer. Additionally, as is known in the art, the fibers can include continuous fibers or staple fibers and can also include multicomponent fibers or multi-component fibers.

[0105] In addition, to obtain greater drapeability, it is desirable to treat the fabric in one or more additional aspects, such as by using internal softeners, external softeners, and / or mechanical softening treatments. For example, mechanical treatment of the web can be carried out by many different methods, such as micro-creping, cold embossing, breaker bar treatment, necking, and combinations thereof. However, other methods known in the art can also be used. Examples of various methods for mechanically treating a fabric to impart improved drapeability or softness include, but are not limited to, those described in U.S. Patent No. 5,413,811 to Fitting et al., U.S. Patent No. 5,770,531 to Sudduth et al., U.S. Patent No. 5,810,954 to Jacobs et al., U.S. Patent No. 6,197,404 to Varona et al., U.S. Patent No. 6,372,172 to Sudduth et al., and US2004005457 to DeLucia et al. Examples of softeners include, but are not limited to, the following: olefin waxes, such as polyethylene wax; fatty acids, such as erucic acid, oleic acid, stearic acid; fatty acid amides, such as stearamide or oleylamine; sulfated oils, such as castor, olive, and soybean; sulfated fatty alcohols or fatty acid esters; diols and their derivatives, such as glycerol, glycerol monostearate, glyceryl trioleate; polyethylene glycol esters of fatty acids, such as long-chain amides of palmitic acid and stearic acid; sugar alcohols and their derivatives, such as sorbitol and sorbitan stearate; imidazolines; and the like. Examples of additives for improving the drapeability and / or handle of nonwoven webs include, but are not limited to, those described in U.S. Patent No. 5,770,531 to Sudduth et al., U.S. Patent No. 6,197,404 to Varona, US2004005457 to DeLucia et al., and WO2014 / 044235 to Klaska et al. Improved drapeability and softness of the nonwoven web can be achieved by incorporating less than about 5 wt% of one or more softeners into the final composition of the extruded or otherwise formed fibers or nonwoven.

[0106] The nonwoven web material incorporated into the elastic laminates of the present disclosure can contain a variety of different polymers. In the past, polymers that do not substantially soften during melt fusion were selected so that the web would not interfere with the formation of pores in the elastic film.

[0107] Exemplary high softening point polymers for forming nonwoven web materials can include, for example: polyolefins such as polyethylene, polypropylene, polybutene, etc.; polytetrafluoroethylene; polyesters such as polyethylene terephthalate, etc.; polyvinyl acetate; polyvinyl chloride-vinyl acetate; polyvinyl butyral; acrylic resins such as polyacrylates, polymethyl acrylate, polymethyl methacrylate, etc.; polyamides such as nylon; polyvinyl chloride; polyvinylidene chloride; polystyrene; polyvinyl alcohol; polyurethane; polylactic acid; their copolymers and the like. If desired, biodegradable polymers such as those described above can also be employed. Synthetic or natural cellulose polymers can also be used, including but not limited to cellulose esters, cellulose ethers, nitrocellulose, cellulose acetate, cellulose acetate butyrate, ethyl cellulose, regenerated cellulose such as viscose, rayon, and the like. It should be noted that the polymers can also contain other additives such as processing aids or treatment compositions that impart desired properties to the fibers, residual amounts of solvents, pigments or colorants, etc.

[0108] Single-component and / or multi-component fibers can be used to form nonwoven web materials. Single-component fibers are typically formed from one polymer or a blend of polymers extruded from a single extruder. Multi-component fibers are typically formed from two or more polymers extruded from separate extruders (e.g., bicomponent fibers). The polymers can be arranged in different zones with a substantially constant setting throughout the cross-section of the fiber. The components can be arranged in any desired configuration, such as core-sheath type, side-by-side type, sandwich type, sea-island type, three-island type, bull's-eye type, or various other arrangements, etc.

[0109] As described above, the method of the present disclosure allows for the use of low-temperature polymers to produce nonwoven web materials while still providing a method capable of producing a laminate having a desired level of breathability. In this regard, the nonwoven web material incorporated into the elastic laminate can contain one or more low-temperature polymers. The melting point of the low-temperature polymer can be below about 150 °C, such as below about 140 °C, such as below about 130 °C, such as below about 120 °C, such as below about 110 °C, such as below about 100 °C, such as below about 90 °C, such as below about 80 °C, and generally above about 60 °C, such as above about 70 °C, such as above about 80 °C, such as above about 90 °C. The Vicat softening temperature of the low-temperature polymer can be below about 125 °C, such as below about 120 °C, such as below about 110 °C, such as below about 100 °C, such as below about 90 °C, such as below about 80 °C, such as below about 70 °C, such as below about 60 °C, such as below about 55 °C, and above about 40 °C. Optionally, the Shore A hardness of the low-temperature polymer can be below about 125, such as below about 110, such as below about 100, such as below about 95, such as below about 90, and above about 50, as well as above about 65.

[0110] The low-temperature polymer can generally be present in the nonwoven web material in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight, such as in an amount greater than about 80% by weight, such as in an amount greater than about 90% by weight. One or more low-temperature polymers can generally be present in the nonwoven web material in an amount less than about 100% by weight, such as in an amount less than about 80% by weight, such as in an amount less than about 60% by weight, such as in an amount less than about 40% by weight, such as in an amount less than about 30% by weight, such as in an amount less than about 20% by weight, such as in an amount less than about 15% by weight, such as in an amount less than about 10% by weight. For example, the low-temperature polymer can be included in a surface layer on the fibers contained within the nonwoven web material and can be present in a relatively low amount.

[0111] In one embodiment, the low-temperature polymer can be a non-elastomeric polymer. For example, the non-elastomeric polymer can be a polyolefin polymer, such as an ethylene polymer. The ethylene polymer can be an ethylene homopolymer or an ethylene copolymer. In one embodiment, the low-temperature polymer can be low-density polyethylene, such as linear low-density polyethylene.

[0112] Alternatively, the low-temperature polymer can be an elastomeric polymer or have elasticity. In one aspect, an extensible or elastic nonwoven web material can be made from multicomponent fibers containing a low-temperature polymer. For example, the multicomponent fibers can be spunbond fibers made from thermoplastic materials having different glass transition temperatures or melting temperatures, where the temperature at which the first component (e.g., the skin) melts is lower than that of the second component (e.g., the core). The softening or melting of the first polymer component of the multicomponent fibers causes the multicomponent fibers to form a viscous skeletal structure that stabilizes the fiber structure upon cooling. For example, the multicomponent fibers can have a low-melting polymer in an amount of about 20% to about 80% by weight, and in some embodiments about 40% to about 60% by weight. Additionally, the multicomponent fibers can have a high-melting polymer in an amount of about 80% to about 20% by weight, and in some embodiments about 60% to about 40% by weight. In some embodiments, the core of the skin-core bicomponent fiber contains a polypropylene homopolymer or copolymer based on a Ziegler-Natta catalyst or a single-site catalyst, and / or the skin of the skin-core bicomponent fiber contains a homopolymer, copolymer, or mixture thereof derived from ethylene, propylene, or styrene polymers.

[0113] The bicomponent fiber can contain a polyethylene skin and a polypropylene-based elastomeric core, where the core (rather than the skin) can contain a secondary amide non-stick additive, and the non-stick additive can further improve the clothing-like feel of the surface layer.

[0114] For example, in one aspect, the secondary amide additive is erucamide, oleamide, oleyl palmitamide, ethylene bisoleamide, stearyl erucamide, or a combination thereof. Of course, it should be understood that in one aspect, the secondary amide can be a non-fatty acid amide.

[0115] Regardless of the secondary amide selected, in one aspect, based on the weight of the core, the secondary amide is present in the core in an amount of from about 0.1 wt% to about 10 wt%, such as from about 0.25 wt% to about 5 wt%, such as from about 0.5% to about 2.5 wt%, such as from about 0.6% to about 1.5 wt%, such as from about 0.7% to about 1%, or any range or value therebetween. Specifically, the present disclosure has found that, surprisingly, the secondary amide in the core provides improved spinnability and non-stickiness characteristics to the bicomponent fiber even when used in small amounts in the core.

[0116] In addition, in one aspect, the (one or more) sheath is formed of one or more ethylene or propylene polymers, such as one or more substantially non-elastomeric ethylene or propylene polymers. Thus, in one aspect, the non-elastomeric polyolefin can include typically non-elastomeric polymers such as conventional polyolefins (e.g., polyethylene, low density polyethylene (LDPE), Ziegler-Natta catalyzed linear low density polyethylene (LLDPE), etc., ultra low density polyethylene (ULDPE), polypropylene, polybutene, etc.), polytetrafluoroethylene, polyesters (e.g., polyethylene terephthalate (PET), etc.), polyvinyl acetate, polyvinyl chloride-vinyl acetate, polyvinyl butyral, acrylic resins (e.g., polyacrylate, methyl acrylate, polymethyl methacrylate, etc.), polyamides (e.g., nylon), polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl alcohol, polyurethane, polylactic acid, copolymers and mixtures thereof, and the like. For example, the sheath can include LLDPE available from Dow Chemical Co., Midland, Mich., such as DOWLEX TM 2517 or DOWLEX TM 2047 or a combination thereof, or Westlake Chemical Corp., Houston, Tex. In addition, in one aspect, the non-stick polyolefin material can be other suitable ethylene polymers, such as those that can be named ASPUN TM (LLDPE) and ATTANE TM obtained from Dow Chemical Company. Available from Dow ChemicalCompany under the name DOWLEX TM (LLDPE), ASPUNTM (LLDPE) and ATTANE TM (ULDPE).

[0117] In addition, in one aspect, the core is formed of an acrylene polymer and / or copolymer. Thus, in one aspect, the core is formed of a propylene-based copolymer plastomer, such as those sold under the name VISTAMAXX TM (e.g., 2330, 6202, and 6102) propylene-based copolymers (propylene-ethylene copolymer-based plastomers) commercially available from ExxonMobil Chemical Co. of Houston, Texas, sold under the name FINA TM (e.g., 8573) commercially available from Atofina Chemicals of Feluy, Belgium, sold under the name TAFMER TM commercially available from Mitsui Petrochemical Industries, and those sold under the name VERSIFY TM commercially available from Dow Chemical Co. of Midland, Michigan. In addition to the above, the core may also contain an inelastic olefin polymer, such as a metallocene-catalyzed (single-site catalyzed) polypropylene polymer, in an amount of about 1 wt% to about 40 wt% of the core, such as about 2 wt% to about 5 wt% of the core.

[0118] Regardless of the elastomeric and inelastic polyolefins selected, in one aspect, the core is present in an amount of about 50 wt% to about 97.5 wt% of the total weight of the elastomeric composition, such as about 60 wt% to about 95 wt% of the total weight of the elastomeric composition, such as about 70 wt% to about 92.5 wt%, such as about 80 wt% to about 90 wt%, such as about 82.5 wt% to about 87.5 wt%, or any range or value therebetween.

[0119] As is known in the art, the elastic laminates of the present disclosure can be readily incorporated into end products. Those skilled in the art will appreciate that the elastic laminates of the present disclosure can be used in absorbent personal care products, including, for example, diapers, adult incontinence garments, incontinence pads / liners, sanitary napkins, pantiliners, and the like. In this regard, absorbent personal care products generally include a liquid-impermeable outer cover, a liquid-permeable topsheet positioned in facing relation to the outer cover, and an absorbent core between the outer cover and the topsheet. In addition, absorbent personal care products also generally include one or more fit-related components, such as fastening tapes or tabs, waistbands, elastic waist panels, elastic side panels, elastomeric leg cuffs, and the like. The unique elastic laminates fabricated and provided herein are well suited for use as a component or as components of absorbent personal care products having one or more elastomeric components. By way of example only, various personal care absorbent articles including elastomeric components and methods of making the same are described in U.S. Patent No. 4,685,916 to Enloe, U.S. Patent No. 4,816,094 to Pomplum et al., U.S. Patent No. 4,857,067 to Wood et al., U.S. Patent No. 6,336,922 to VanGompel et al., U.S. Patent No. 6,953,452 to Popp et al., U.S. Patent No. 7,018,369 to VanGompel et al., U.S. Patent No. 7,150,731 to Cazzato et al., the contents of which are incorporated herein by reference to the extent consistent with the present disclosure.

[0120] As previously noted, absorbent personal care products generally include a liquid-permeable topsheet facing the wearer and a liquid-impermeable backsheet or outer cover. Positioned between the topsheet and the outer cover is an absorbent core. In this regard, the topsheet and the outer cover are generally joined and / or sealed to enclose the absorbent core. Although certain aspects of the present invention are described in the context of specific personal care absorbent articles, it should be readily understood that similar uses and / or additional combinations or modifications of the specific configurations discussed below can be made by those skilled in the art without departing from the spirit and scope of the present invention.

[0121] In a particular embodiment, and with reference to Figure 5, the diaper 150 may include a liquid-impermeable outer cover 154, a liquid-permeable topsheet 152 positioned in a facing relationship with the outer cover 154, and an absorbent core (not shown) between the outer cover 154 and the topsheet 152. The diaper 150 may have various shapes, such as an overall rectangular shape, a T-shape, an hourglass shape, etc. The topsheet generally coextends with the outer cover, but may optionally cover an area larger or smaller than the area of the outer cover as needed. Although not shown, it should be understood that portions of the diaper (such as the edge sections of the outer cover) may extend past and around the end edges of the product and form part of the body-facing layer.

[0122] The topsheet or body-side liner 152 desirably presents a compliant, soft-to-touch, and non-irritating body-facing surface to the wearer's skin. The topsheet 152 desirably serves to help separate the wearer's skin from the liquid retained in the absorbent core. Topsheets are well known in the art and may comprise a wide variety of materials, such as porous foams, reticulated foams, open-cell plastic films, natural fibers (wool, cotton fibers, etc.), synthetic fibers (polyester, polypropylene, polyethylene, etc.), combinations of natural and synthetic fibers, and the like. The topsheet may include a single layer or multiple layers, the layers comprising a combination of one or more different materials. Perforated membranes, nonwoven fabrics, and their laminates are commonly used to form the topsheet.

[0123] Suitable topsheet materials include, but are not limited to, those described in U.S. Patent No. 5,382,400 to Pike et al., U.S. Patent No. 5,415,640 to Kirby et al., U.S. Patent No. 5,527,300 to Sauer et al., U.S. Patent No. 5,994,615 to Dodge et al., U.S. Patent No. 6,383,960 to Everett et al., U.S. Patent No. 6,410,823 to Daley et al., and US2014 / 0121623 to Biggs et al.

[0124] The backsheet or outer cover 154 comprises a liquid-impermeable material. Desirably, the outer cover comprises a material that prevents water passage but allows air and water vapor to pass through. The outer cover may comprise a single layer of material or multiple layers comprising one or more different materials. In a particular embodiment, the outer cover may comprise a film fixedly attached or bonded to one or more nonwoven webs. The particular structure and composition of the outer cover may be selected from various combinations of films and / or fabrics. In this regard, the outermost layer is typically selected to provide the desired strength, abrasion resistance, tactile properties, and / or aesthetics. Suitable outer covers include, but are not limited to, those described in U.S. Patent No. 4,041,203 to Brock et al., U.S. Patent No. 6,075,179 to McCormack et al., U.S. Patent No. 6,111,163 to McCormack et al., and US2015 / 099086 to Cho et al., the contents of which are incorporated herein to the extent consistent with the present disclosure.

[0125] In this embodiment, the diaper 150 may include an elastic waistband 156 disposed around the waist opening 155. The elastic composite material providing elasticity to the waistband may be located on the skin-contacting side of the topsheet, exposed on the outer side of the backsheet, and / or located between the topsheet and the backsheet. When located on the skin-contacting surface of the topsheet, the waistband may also provide a dual function of serving as a containment pocket known in the prior art. Additionally, in some embodiments, the diaper may be provided with separate front and rear waistbands 156A, 156B, respectively. Alternatively, for some pant-type garments, a continuous elastic waistband may be employed.

[0126] In some embodiments, the diaper 150 may further include elastic side panels 157. The elastic laminate material providing elasticity to the side panels may form all or a part of each side panel. For example, optionally, a non-elastic sheet 158 may be positioned between the fastener 160 and the elastic laminate material forming a part of the side panel 156. As is known in the art, the elastic side panels may be integrally formed with the backsheet and / or the topsheet, or alternatively, include separate components attached to the central diaper base, such as attached to one or both of the backsheet and / or the topsheet.

[0127] The diaper 150 may further include elastic leg cuffs 162 disposed around the leg openings 161. The leg cuffs may be curved around the leg openings, or multiple leg elastics extending towards the side panels and the front and rear waist openings near the leg openings may be used.

[0128] Personal care products may optionally contain one or more additional elements or components. In this regard, many additional features and various configurations are known in the art. Those skilled in the art will understand that the application and use of the elastic composite material of the present invention can be used as or in one or more components to provide the desired elasticity and feel. Additionally, those skilled in the art will understand that the elastic laminate can similarly be used to provide elasticity and / or fit-enhancing properties for other garments or articles, including, for example, protective clothing. In this regard, the elastic composite material can be employed to form elastic sheets, waistbands, cuffs, fastening joints, etc. By way of example only, the elastic composite material can be used in garments, as described in U.S. Patent No. 5,594,955 to Sommers, U.S. Patent No. 6,799,331 to Griesbach et al., and US 2005 / 097659 to Aroch et al., the contents of which are incorporated herein by reference to the extent consistent with the present disclosure. In a similar manner, the elastic composite material can also be used in other articles, such as sweat pads, bandages, wraps, and protective articles.

[0129] In another aspect, the elastic composite laminate of the present invention can be used as a wipe suitable for personal use or for use on hard surfaces. The selection of the individual layers will of course vary depending on the intended end use. For example, for use as a personal care wipe, the materials typically selected will place greater emphasis on softness and feel, while those intended for hard surface cleaning may place greater emphasis on strength and durability. The laminate of the present invention can be used to form wipes, wipe stacks, and other products, including but not limited to those described in U.S. Patent No. 3,401,927 to Frick et al., U.S. Patent No. 4,171,047 to Doyle et al., U.S. Patent No. 4,502,675 to Clark et al., U.S. Patent No. 4,353,480 to McFadyen, U.S. Patent No. 4,651,895 to Niske et al., U.S. Patent No. 4,741,944 to Jackson et al., U.S. Patent No. 4,778,048 to Kaspar et al., U.S. Patent No. 5,264,265 to Kaufmann, U.S. Patent No. 5,310,398 to Yoneyama, U.S. Patent No. 5,964,351 to Zander, U.S. Patent No. 6,158,614 to Haines et al., U.S. Patent No. 6,592,004 to Huang et al., and U.S. Patent No. 6,612,462 to Sosalla et al.

[0130] Testing method

[0131] Tensile Strength: As used herein, "tensile strength" or "strip tensile" is the peak load value, i.e., the maximum force generated by the sample when pulled to rupture. Samples for tensile strength testing are prepared by die-cutting the specimen to a width of 25 mm and a length of approximately 152 mm. The instruments used to measure tensile strength are MTS Criterian 42 and MTS TestWorks TM for Windows version 4 (MTS Systems Corp., Research Triangle Park, North Carolina). Depending on the strength of the sample being tested, a load cell is selected such that the peak load value falls between 10% and 90% of the full-scale value of the load cell. The gauge length is 76 mm and the jaw length is 76 mm. The crosshead speed is 305 mm / min and the break sensitivity is set at 70%, with slope preset points at 70 and 157 g. The sample is placed in the jaws of the instrument and centered with the longer dimension parallel to the load application direction. The test is then started and ended when the sample breaks. For the purposes of this article, the peak load is determined based on the CD tensile strength. Six (6) representative samples are tested and the arithmetic mean of all the individual samples tested is the tensile strength of the product.

[0132] Elongation at 2000 gf: This value is the percentage elongation of the elastic laminate in the longitudinal direction when a tensile force of 2000 gf is applied. Samples for tensile strength testing are prepared by die-cutting the specimen to a CD length of 25 mm and an MD length of approximately 152 mm. The instruments used to measure tensile strength are MTS Criterian 42 and MTS TestWorks TM for Windows version 4 (MTS Systems Corp., Research Triangle Park, North Carolina). Depending on the strength of the sample being tested, a load cell is selected such that the peak load value falls between 10% and 90% of the full-scale value of the load cell. The gauge length is 50 mm and the rubber-faced grips are 25×102 mm. The crosshead speed is 500 mm / min. The sample is placed in the jaws of the instrument and centered with the longer dimension parallel to the load application direction. The test is then started and the sample is initially elongated until stopped, the sample is returned to the initial gauge length, and then the sample is pulled to rupture. The stress / strain data indicates the force required to elongate the sample. The load output during elongation characterizes the force at a specified point of sample elongation. The higher the force value, the more difficult it is to elongate the sample. The load at the desired elongation rate is measured from the second cycle. Six (6) representative samples are tested and the arithmetic mean of all the individual samples tested is the tensile strength of the product.

[0133] As used herein, "basis weight" is determined using the average dry weight of twelve (12) 150 mm×150 mm samples.

[0134] As used herein, the "caliper (or thickness)" of a sheet is determined using a micrometer with an acrylic platen having a foot area of 45.6 cm 2 (3-inch diameter), providing a load of 0.345 kPa (0.5 psi), and taking a reading after a dwell time of 3 seconds. Measurements are made using samples cut to a size of 90 × 102 mm (3.5 × 4 inches).

[0135] As used herein, air permeability is measured on dry samples and determined using a TEXTEST FX3300 air permeability tester from Textest AG at a test pressure of 125 Pa and a test head area of 38 cm 2 .

[0136] Example 1

[0137] A variety of different elastic laminates were produced, which contained an elastic film positioned between two nonwoven web materials. The method used to produce the laminates was similar to Figure 1 the method illustrated. Three different elastic laminates were produced. For each elastic laminate, the nip speed of the tension device (e.g., 32) downstream of the perforating and bonding device (e.g., 26) was varied such that the elastic laminate could shrink different amounts during each trial.

[0138] The elastic film of each elastic laminate was the same. The elastic film of each sample consisted of 100% semi-crystalline olefin elastomeric copolymer.

[0139] The elastic laminates were manufactured using a cast film-based method described in US7803244B2 and US8361913B2, where the outer facing layers were simultaneously unwound from a winding roll and guided into the nip of a laminating roll so as to be laid adjacent to opposite sides of the elastic film, forming a nonwoven / fabric / nonwoven laminate. The nonwoven facing layers were unwound and guided into the nip of the laminating roll at substantially the same speed as the laminating roll. Due to the nip of the laminating roll assembly (the patterned roll opposite the anvil roll), the elastic film was stretched longitudinally and melt-bonded to the nonwoven layers to form a cohesive laminate. After the laminating roll assembly, the laminate was fed into the nip of the tension device. After the tension device, the laminate was allowed to shrink and wound onto a winding roll.

[0140] The outer nonwoven layers used during the trials were as follows:

[0141] Sample No. 1: Both layers were 15 gsm polypropylene spunbond facing layers.

[0142] Sample 2: One layer is a 15 gsm polypropylene spunbond layer, and one layer is a 17 gsm bicomponent spunbond layer, composed of at least one low-temperature polymer (such as polyethylene) and a semi-crystalline polypropylene elastomer.

[0143] Sample 3: Both layers are 17 gsm bicomponent spunbond, composed of polyethylene and a semi-crystalline polypropylene elastomer (containing a low-temperature polymer).

[0144] After the elastic laminate is formed, the air permeability of the laminate is tested on the same day the laminate is formed, and then the air permeability is tested again three weeks after the laminate is formed. The following results are obtained:

[0145]

[0146]

[0147] As shown above, the air permeability of the laminate is a function of the amount by which the laminate can shrink after leaving the laminating roll. Maintaining a greater tension on the laminate increases the air permeability.

[0148] Example 2

[0149] Additional elastic laminates were produced, which contained an elastic film and at least one layer of nonwoven web material. Sample 4 and Sample 5 were produced on a pilot production line, while Sample 6 was produced on a commercial production line.

[0150] The elastic film of each sample is composed of 100% semi-crystalline olefin elastomeric copolymer. The elastic laminate is manufactured using the cast film-based method described in US7803244B2 and US8361913B2. The outer surface layer is simultaneously unwound from a winding roll and guided into the nip of the laminating roll so as to be laid adjacent to opposite sides of the elastic film to form a nonwoven / film / nonwoven laminate. The nonwoven surface layer is unwound and guided into the nip of the laminating roll at substantially the same speed as the laminating roll. Due to passing through the nip of the laminating roll assembly, the elastic film is stretched longitudinally and melt-bonded to the nonwoven layer to form a cohesive laminate. After the laminating roll assembly, the laminate is fed into the nip of a tension device. After the tension device, the laminate is allowed to shrink and is wound onto a winding roll.

[0151] The outer nonwoven layers used during the tests are as follows. Both samples contain a low-temperature polymer.

[0152] Sample 4: Both layers are 17 gsm bicomponent spunbond, composed of polyethylene and a semi-crystalline polypropylene elastomer.

[0153] Sample 5: One layer is an 11 gsm polypropylene spunbond surface layer, and one layer is a 17 gsm bicomponent spunbond surface layer, composed of polyethylene and a semi-crystalline polypropylene elastomer.

[0154] After the elastic laminate is formed, the breathability of the laminate is tested on the same day as the laminate is formed and then again approximately one week after the laminate is formed. The following results are obtained:

[0155]

[0156]

[0157] In the following experiments, elastic laminates are manufactured using the cast film-based method described in US7803244B2 and US8361913B2. A single 12 gsm polypropylene spunbond outer layer is unwound from a wound roll and guided simultaneously into the nip of a laminating roll so as to be laid adjacent to the elastic film to form a nonwoven / film laminate. Additionally, a film skin layer coextruded with the elastic film is coextruded on the opposite side of the nonwoven layer. The total weight of the film consists of 5 wt% skin layer. The skin layer containing the low-temperature polymer consists of 50% LLDP and 50% polyethylene-based plastomer, while the elastic film of each sample consists of 100% semicrystalline olefin elastomeric copolymer.

[0158] The coextruded film and the nonwoven surface layer are unwound and guided into the nip of the laminating roll at substantially the same speed as the laminating roll. Due to passing through the nip of the laminating roll assembly, the elastic film is stretched longitudinally and melt-bonded to the nonwoven layer to form a cohesive laminate, and the laminating roll assembly is heated to at least 150 °C on the nonwoven side and at least 101 °C on the film side. After the laminating roll assembly, the laminate is fed into the nip of a tension device. After the tension device, the laminate is allowed to shrink and is wound onto a wound roll.

[0159]

[0160]

[0161] These and other modifications and variations of the invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention more particularly described in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, in whole or in part. Further, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention as further described in such appended claims.

Claims

1. A method of forming a nonwoven composite material, the method comprising: simultaneously melt - fusing an elastic film onto a nonwoven web material and perforating the film, and forming holes in the film while the film is under a tension in the longitudinal direction at a draw ratio of about 1.5 or greater; and holding the film under tension such that after the holes have been formed and the film has been melt - fused to the nonwoven web material, the film shrinks no more than about 55% in the longitudinal direction.

2. The method according to claim 1, wherein the nonwoven composite material is thereafter shrunk such that less than 20% of the draw in the longitudinal direction is retained in the film before or during winding onto a roll.

3. The method according to claim 1, wherein the film is held under tension such that after the holes have been formed and the film has been melt - fused to the nonwoven web material, the film shrinks no more than about 50%, such as no more than about 40%, such as no more than about 30% in the longitudinal direction.

4. The method according to claim 1, wherein the length of at least one of the holes is from about 200 microns to about 5000 microns.

5. The method according to claim 1, wherein the air permeability of the nonwoven composite material is greater than about 10 cfm, such as greater than about 25 cfm, such as greater than about 30 cfm, such as greater than about 50 cfm, such as greater than about 80 cfm.

6. The method according to claim 1, wherein after the holes have been formed and the film has been melt - fused to the nonwoven web material, the film is held under tension for at least about 0.1 second and less than about 10 seconds.

7. The method according to claim 1, wherein after the holes have been formed and the film has been melt - fused to the nonwoven web material, the film is held under tension by a downstream tension device.

8. The method according to claim 7, wherein the tension device comprises a nip formed between two rolls or an s - shaped winding configuration including guide rolls.

9. The method according to claim 1, wherein the nonwoven web material and the elastic film are melt - fused at a plurality of discrete bond points separated by unbonded regions.

10. The method according to claim 1, wherein the elastic film comprises an elastomeric block copolymer or an elastomeric semi - crystalline polyolefin, and wherein the semi - crystalline polyolefin is an ethylene / α - olefin copolymer, a propylene / α - olefin copolymer, or a combination thereof.

11. The method according to claim 1, wherein the elastic film is open - celled and is melt - fused under a tension with a draw ratio of about 2.5 to about 7.

0.

12. The method according to claim 1, wherein the nonwoven web material contains fibers, the fibers including spunbond fibers, meltblown fibers, staple fibers, or a combination thereof, and wherein the fibers comprise a low - temperature polymer.

13. The method according to claim 12, wherein the low-temperature polymer comprises a polyethylene polymer, poly(lactic acid), a polyhydroxyalkanoate polymer, a poly(ethylene adipate) polymer, a poly(ethylene oxide) (PEG) polymer, an elastomer, a plastomer, a random copolymer, or a polymer blend containing a plasticizer.

14. The method according to claim 12, wherein the low-temperature polymer has a melting point below about 150 °C, such as below about 140 °C, such as below about 130 °C, such as below about 120 °C.

15. The method according to claim 12, wherein the Vicat softening temperature of the low-temperature polymer is below about 125 °C, such as below about 110 °C, such as below about 100 °C, such as below about 90 °C, and above about 40 °C.

16. The method according to claim 12, wherein the Shore A hardness of the low-temperature polymer is below about 110, such as below about 100, such as below about 90, and above about 65.

17. The method according to claim 1, wherein the elastic film is fed through a nip formed between two rolls while being melt-bonded to the nonwoven web material and perforated, and wherein at least one of the rolls is heated to a surface temperature of about 50 °C to about 160 °C.

18. The method according to claim 1, wherein the nonwoven web material is pore-free after being melt-bonded to the film.

19. The method according to claim 1, wherein an additional nonwoven web material is melt-bonded to the elastic film such that the elastic film is positioned between the nonwoven web materials.

20. The method according to claim 1, wherein the elastic film comprises a surface layer and wherein the surface layer is positioned on the elastic film and opposite the nonwoven web material, and the surface layer contains a low-temperature polymer.

21. A nonwoven composite material, the nonwoven composite material comprising: an elastic film containing an elastomeric polymer; and a nonwoven web material containing fibers, and wherein the fibers contain a low-temperature polymer, wherein the film is positioned adjacent to the nonwoven web material and melt-bonded to the nonwoven web material such that the elastic film adheres to the nonwoven web material at a plurality of discrete bond points, the elastic film defining a plurality of holes, and corresponding discrete bond points are generally located around the perimeter of the holes, wherein the length of at least one of the holes is from about 200 microns to about 5000 microns, wherein the nonwoven web material is pore-free in the region adjacent to the holes in the film and is not bonded to the film except at the corresponding discrete bond points, and the air permeability of the nonwoven composite material is greater than about 10 cfm.

22. The nonwoven composite material according to claim 21, wherein the air permeability of the nonwoven composite material is greater than about 25 cfm, such as greater than about 40 cfm, such as greater than about 45 cfm, such as greater than about 50 cfm, such as greater than about 70 cfm, such as greater than about 90 cfm.

23. The nonwoven composite material according to claim 21, wherein the nonwoven web material contains fibers, and the fibers include spunbond fibers, meltblown fibers, staple fibers, or a combination thereof.

24. The nonwoven composite material according to claim 21, wherein the low-temperature polymer includes a polyethylene polymer, poly(lactic acid), polyhydroxyalkanoate polymer, poly(ethylene adipate) polymer, poly(ethylene oxide) (PEG) polymer, elastomer, plastomer, random copolymer, or a polymer blend containing a plasticizer.

25. The nonwoven composite material according to claim 21, wherein the low-temperature polymer includes an elastomer.

26. The nonwoven composite material according to claim 21, wherein the melting point of the low-temperature polymer is lower than about 150 °C, such as lower than about 140 °C, such as lower than about 130 °C, such as lower than about 120 °C, and higher than about 80 °C.

27. The nonwoven composite material according to claim 21, wherein the Vicat softening temperature of the low-temperature polymer is lower than about 125 °C, such as lower than about 110 °C, such as lower than about 100 °C, such as lower than about 90 °C, and higher than about 40 °C.

28. The nonwoven composite material according to claim 21, wherein the Shore A hardness of the low-temperature polymer is lower than about 110, such as lower than about 100, such as lower than about 90, and higher than about 65.

29. A nonwoven composite material, the nonwoven composite material comprising: an elastic film containing an elastomeric polymer and at least one surface layer, the surface layer comprising a low-temperature polymer; and a nonwoven web material containing fibers, wherein the film is positioned adjacent to the nonwoven web material along a surface opposite to the surface layer and is melt-bonded to the nonwoven web material such that the elastic film adheres to the nonwoven web material at a plurality of discrete bonding points, the elastic film defining a plurality of holes, and the corresponding discrete bonding points are generally located around the perimeter of the holes, wherein the length of at least one of the holes is from about 200 microns to about 5000 microns, and the nonwoven web material is pore-free in the region adjacent to the holes in the film and is not bonded to the film except at the corresponding discrete bonding points, and the air permeability of the nonwoven composite material is greater than about 25 cfm, such as less than about 40 cfm.

30. The nonwoven composite material according to claim 29, wherein the air permeability of the nonwoven composite material is greater than about 45 cfm, such as greater than about 50 cfm, such as greater than about 70 cfm, such as greater than about 90 cfm.

31. The nonwoven composite material according to claim 29, wherein the nonwoven web material contains fibers, and the fibers include spunbond fibers, meltblown fibers, staple fibers, or a combination thereof.

32. The nonwoven composite material according to claim 29, wherein the low-temperature polymer comprises a polyethylene polymer, poly(lactic acid), a polyhydroxyalkanoate polymer, a poly(ethylene adipate) polymer, a poly(ethylene oxide) (PEG) polymer, an elastomer, a plastomer, a random copolymer, or a polymer blend containing a plasticizer.

33. The nonwoven composite material according to claim 29, wherein the low-temperature polymer comprises an elastomer.

34. The nonwoven composite material according to claim 29, wherein the melting point of the low-temperature polymer is lower than about 150 °C, such as lower than about 140 °C, such as lower than about 130 °C, such as lower than about 120 °C, and higher than about 80 °C.

35. The nonwoven composite material according to claim 29, wherein the Vicat softening temperature of the low-temperature polymer is lower than about 125 °C, such as lower than about 110 °C, such as lower than about 100 °C, such as lower than about 90 °C, and higher than about 40 °C.

36. The nonwoven composite material according to claim 29, wherein the Shore A hardness of the low-temperature polymer is lower than about 110, such as lower than about 100, such as lower than about 90, and higher than about 65.

37. An absorbent article, the absorbent article comprising an outer cover, a body-side liner joined to the outer cover, and an absorbent core positioned between the outer cover and the body-side liner, wherein the absorbent article comprises the nonwoven composite material according to any one of claims 21 to 36.

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