Stretchable composite material having ribs

Abstract

The stretchable composite material (10) includes a first layer (20) and a second layer (40). The first layer has a first surface (22) of the first layer and a second surface (24) of the first layer facing the first surface of the first layer. The first layer is constructed of a non-woven material. The second layer has a first surface (42) of the second layer facing the first surface of the first layer and a second surface (44) of the second layer facing the first surface of the second layer. The second layer is constructed of an elastomeric material and includes a plurality of ribs (50) extending from at least the first surface of the second layer. At least a portion of the first surface of the first layer is attached to the first surface of the second layer at a plurality of attachment positions (26). The first layer and the second layer are configured to define a space between the first surface of the first layer and the first surface of the second layer between adjacent attachment positions of the plurality of attachment positions.

Description

Technical Field

[0001] The present disclosure relates to the field of hygiene and / or disposable clothing. In particular, the present disclosure relates to stretchable composites configured for use in hygiene and / or disposable clothing.

Background Art

[0002] Typical hygiene and / or disposable clothing such as diapers can be a type of underwear configured to be worn on the central part of a user to collect, absorb, and / or contain the user's waste and prevent soiling of the user's outer clothing and / or the user's surrounding environment. Hygiene clothing can be worn by users including infants and young children who have not yet received toilet training, adults experiencing medical conditions such as incontinence, and adults working in extreme conditions such as astronauts. For this purpose, it is essential that the hygiene clothing is comfortable and promotes ease of use.

[0003] At least a part of the hygiene clothing may include a stretchable component configured to enable the hygiene clothing to be fastened around the central part of the user and / or to slide the hygiene clothing up to the central part of the user in order to provide a secure and adjustable fit around the central part of the user. The stretchable component of the hygiene clothing can be a composite material including at least a nonwoven layer configured to be gripped by the user and / or to contact the user's skin and an elastic film configured to expand and contract.

[0004] Currently available stretchable components, and thus hygiene clothing, typically include a flat nonwoven layer, resulting in a reduction in the cushioning, texture, and absorbency of the stretchable component and thus the hygiene clothing. Furthermore, currently available stretchable components, and thus hygiene clothing, typically include a flat elastic film, resulting not only in a low structural integrity of the stretchable component but also in a reduced visual indication to the user of the expansion and contraction of the stretchable component.

[0005] In order to provide a stretchable component and thus ensure the comfort and ease of use of sanitary clothing, it is desirable to provide a stretchable component configured to be used on sanitary clothing that enhances the adjustability, cushioning, texture, and absorbency of sanitary clothing, while also providing a visual indication of the elongation of the stretchable component. SUMMARY OF THE INVENTION

[0006] According to an aspect of the present disclosure, a stretchable composite and / or a stretchable laminate is provided, particularly a stretchable composite and / or a stretchable laminate configured to be used in sanitary clothing and the like. The stretchable composite includes a first layer having a first surface of the first layer and a second surface of the first layer facing the first surface of the first layer, the first layer including a non-woven material, and a second layer having a first surface of the second layer facing the first surface of the first layer and a second surface of the second layer facing the first surface of the second layer, the second layer including an elastomeric material. The second layer includes a plurality of ribs extending at least from the first surface of the second layer, at least a part of the first surface of the first layer is attached to the first surface of the second layer at a plurality of attachment positions, and the first layer and the second layer are configured to define a space between the first surface of the first layer and the first surface of the second layer between adjacent attachment positions of the plurality of attachment positions.

[0007] According to an aspect of the present disclosure, the first layer and the second layer may be configured to stretch and contract between a relaxed state and a stretched state.

[0008] According to an aspect of the present disclosure, the first layer may include a first average distance between adjacent ribs of the plurality of ribs in a relaxed state, the first layer may include a second average distance between adjacent ribs of the plurality of ribs in a stretched state, and the second average distance between adjacent ribs of the plurality of ribs may be greater than the first average distance between adjacent ribs of the plurality of ribs.

[0009] According to an aspect of the present disclosure, the gap may extend between adjacent ribs of the plurality of ribs of the second layer.

[0010] According to an aspect of the present disclosure, the second layer may have a first thickness within each gap of the second layer and a second thickness along each rib of the plurality of ribs of the second layer, and the second thickness along each rib of the plurality of ribs of the second layer may be greater than the first thickness within each gap of the second layer.

[0011] According to an aspect of the present disclosure, the first thickness of the second layer within each gap of the second layer may be in the range of 10% to 50%, more specifically, in the range of 20% to 45% of the second thickness of the second layer along each rib of the plurality of ribs of the second layer, particularly in the relaxed state. The thickness of the second layer is typically observed from a photograph obtained, for example, at a magnification of 200 times under reference "VHX6000" using a digital microscope manufactured by Keyence Corporation, and the measured value is obtained using digital microscope image analysis software.

[0012] According to an aspect of the present disclosure, the second layer may include an inner sublayer encapsulated by two outer sublayers, and each of the two outer sublayers forms a skin layer for protecting the inner sublayer. The plurality of ribs may be formed by one or both of the outer sublayers and / or by the inner sublayer. According to another aspect of the present disclosure, the second layer may not include a skin layer for protecting the inner sublayer and may be a layer of an elastic film.

[0013]

[0014] According to an aspect of the present disclosure, one or more of the plurality of attachment positions may be located between adjacent ribs of the plurality of ribs of the second layer.

[0015] According to an aspect of the present disclosure, one or more of the plurality of attachment positions may be located along at least a part of one or more ribs of the plurality of ribs of the second layer.

[0016] According to an aspect of the present disclosure, one or more attachment positions among a plurality of attachment positions may be located between adjacent ribs of the plurality of ribs of the second layer, and one or more attachment positions among the plurality of attachment positions may be located along at least a part of one or more ribs of the plurality of ribs of the second layer.

[0017] According to an aspect of the present disclosure, at least 1% to ١٠% of the plurality of attachment positions between the first layer and the second layer may be located along at least a part of the ribs among the plurality of ribs of the second layer.

[0018] According to an aspect of the present disclosure, at least 5% to 40% of the plurality of attachment positions between the first layer and the second layer may be located between adjacent ribs of the plurality of ribs of the second layer.

[0019] According to an aspect of the present disclosure, in a cross-section in a plane perpendicular to the machine direction or the machine transverse direction, at least 1% of the plurality of attachment positions between the first layer and the second layer may be located along at least a part of the ribs among the plurality of ribs of the second layer, and up to 99% of the plurality of attachment positions may be located between adjacent ribs of the plurality of ribs of the second layer.

[0020] According to an aspect of the present disclosure, in a cross-section in a plane perpendicular to the machine direction or the machine transverse direction, up to 20% of the plurality of attachment positions between the first layer and the second layer may be located along at least a part of the ribs among the plurality of ribs of the second layer, and at least 80% of the plurality of attachment positions may be located between adjacent ribs of the plurality of ribs of the second layer.

[0021] According to an aspect of the present disclosure, the second layer may include a first end of the second layer and a second end of the second layer, and the plurality of ribs of the second layer extend continuously, particularly in a linear pattern, more particularly in a straight line pattern, across the entire second layer between the first end of the second layer and the second end of the second layer, particularly in the machine direction or the machine transverse direction.

[0022] According to aspects of the present disclosure, the first layer may be oriented farther from the second layer between adjacent attachment positions of the plurality of attachment positions than at each attachment position of the plurality of attachment positions between the first layer and the second layer.

[0023] According to aspects of the present disclosure, the first layer may include a waveform that crosses the second layer in the machine direction and / or the machine transverse direction.

[0024] According to aspects of the present disclosure, an extensible composite according to any aspect presented herein may include a second first layer, the second first layer may have a first surface of the second first layer and a second surface of the second first layer that faces the first surface of the second first layer, the second first layer may include a non-woven material, and the second first layer may be attached to the second surface of the second layer.

[0025] According to aspects of the present disclosure, a plurality of ribs may extend from a first surface of the second layer and a second surface of the second layer.

[0026] According to aspects of the present disclosure, at least 50% of the plurality of ribs extending from the first surface of the second layer and at least 50% of the plurality of ribs extending from the second surface of the second layer may be aligned or offset from each other.

[0027] According to aspects of the present disclosure, an adhesive may be included at each attachment position of the plurality of attachment positions between the first layer and the second layer.

[0028] According to aspects of the present disclosure, an extensible composite according to any aspect presented herein may include fastening elements configured to secure the extensible composite to at least a portion of a sanitary garment.

[0029] According to an aspect of the present disclosure, the first surface of the second layer including a plurality of ribs may have a density in the range of 0.20 to 15 ribs / cm when viewed in the machine direction or the machine transverse direction, or a density in the range of 0.75 to 10 ribs / cm when viewed in the machine direction or the machine transverse direction, or a density in the range of 1.0 to 7 ribs / cm when viewed in the machine direction or the machine transverse direction.

[0030] According to an aspect of the present disclosure, the stretchable composite material according to any aspect presented herein may at least include a region without a plurality of ribs, and this region is disposed at one or more of the first end of the second layer and the second end of the second layer.

[0031] According to an aspect of the present disclosure, each rib of the plurality of ribs may have an aspect ratio (thickness / width in one or more of the machine direction views and the machine transverse direction view) in the range of 0.1 to 0.6, or an aspect ratio in the range of 0.15 to 0.5.

[0032] According to an aspect of the present disclosure, the stretchable composite material according to any aspect presented herein is not inconsistent with another aspect of the present disclosure. In particular, when the second surface of the second layer may include a plurality of ribs, the second first layer may be the same as or different from the first layer.

[0033] The stretchable composite material according to any aspect presented herein may include those in which the first layer and the second first layer are made of, respectively or conversely, a card nonwoven fabric (e.g., a heat-bonded card nonwoven fabric) and a spunlace nonwoven fabric, a card nonwoven fabric (e.g., a heat-bonded card nonwoven fabric) and a spunmelt nonwoven fabric (e.g., a spunbond nonwoven fabric), a spunlace nonwoven fabric and a spunlace nonwoven fabric, a spunmelt nonwoven fabric (e.g., a spunbond nonwoven fabric) and a spunlace nonwoven fabric, a spunmelt nonwoven fabric (e.g., a spunbond nonwoven fabric) and a spunmelt nonwoven fabric (e.g., a spunbond nonwoven fabric), or a card nonwoven fabric (e.g., a heat-bonded card nonwoven fabric) and a card nonwoven fabric (e.g., a heat-bonded card nonwoven fabric).

[0034] Each of these combinations of the first layer and the nonwoven fabric of the second first layer may, more precisely, extend to other nonwoven fabrics described in the present application, particularly another nonwoven fabric of the same type.

[0035] According to an aspect of the present disclosure, a roll is provided that includes an extensible composite material in an unwinding direction and according to any aspect presented herein, and a plurality of ribs extend in the unwinding direction. With such a plurality of ribs, the extensible composite material is less likely to undergo undesirable deformation during winding, unwinding, and / or on manufacturing equipment for sanitary clothing. Further, with such a plurality of ribs, the extensible composite material disposed as a roll has a reduced tendency to slip.

[0036] According to an aspect of the present disclosure, the extensible composite material may include a third layer having a first surface of the third layer facing a second surface of the second layer and a second surface of the third layer facing the first surface of the third layer, and the third layer may include a nonwoven material.

[0037] According to an aspect of the present disclosure, a method of manufacturing an extensible composite material is provided, particularly a method of manufacturing an extensible composite material configured for use in sanitary clothing and the like. The method includes providing a first layer having a first surface of the first layer and a second surface of the first layer facing the first surface of the first layer and constructed from a nonwoven material, and a first surface of a second layer facing the first surface of the first layer and a second surface of the second layer facing the first surface of the second layer, and including a plurality of ribs extending from at least the first surface of the second layer, and providing a second layer constructed from an elastomeric material; and attaching the first surface of the first layer to the first surface of the second layer at a plurality of attachment positions such that the first layer and the second layer are configured to define a space between the first surface of the first layer and the first surface of the second layer between adjacent attachment positions of the plurality of attachment positions.

[0038] According to an aspect of the present disclosure, the method may include attaching a second first layer to the second surface of the second layer.

[0039] According to the methods described herein and the embodiments shown herein, stretchable composite materials and methods of manufacturing stretchable composite materials can enhance the adjustability, cushioning, texture, and absorbency of sanitary clothing, and thus ensure the comfort and ease of use of stretchable composite materials and sanitary clothing, while also providing a visual indication of the elongation of the stretchable composite material.

[0040] Aspects of the embodiments are described with reference to the drawings, and like reference numerals reflect like elements.

Brief Description of the Drawings

[0041]

Figure 1A

[0042]

Figure 1B

[0043]

Figure 2

[0044]

Figure 3

[0045]

Figure 4A

[0046]

Figure 4B

[0047]

Figure 5A

[0048]

Figure 5B

[0049]

Figure 6A

[0050]

Figure 6B

[0051] [[ID=2OA]]Here, with reference to FIGS. 1A to 6B, embodiments of an extensible composite material and a method of manufacturing the extensible composite material according to aspects of the present disclosure will be described. Like reference numerals represent like parts, and the extensible composite material is generally referred to by reference numeral 10. Although the extensible composite material 10 is described with reference to specific examples, it should be understood that modifications and changes can be made to these examples without exceeding the general scope defined by the claims. In particular, the individual features of the various embodiments shown and / or referred to herein may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than a limiting sense. The drawings are not necessarily to scale and are shown in an illustrative manner and are not intended to limit the scope of the present disclosure. The illustrated exemplary embodiments are intended only as examples.

[0052] The term "exemplary" is used in the sense of "example" rather than "ideal". Aspects of the present disclosure are suitable for various modifications and alternative forms, and the details are shown in the drawings by way of example and are described in detail. However, it should be understood that the aspects of the present disclosure are not intended to be limited to the specific embodiments described. On the contrary, the intention of the present disclosure is to cover all modifications, equivalents, and alternative forms that fall within the scope of the present disclosure.

[0053] A variety of materials, methods of construction, and methods of fastening are considered in the context of the disclosed embodiments. Those skilled in the art will recognize known alternatives for materials, methods of construction, and methods of fastening, and all of these are intended to be compatible with the disclosed embodiments and are intended to be encompassed by the appended claims.

[0054] As used in this disclosure and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. As used in this disclosure and the appended claims, the term "or" is generally used in the sense of "and / or" unless the context clearly dictates otherwise.

[0055] Throughout the description including the claims, unless otherwise specified, the terms "comprising a," "including a," and "having a" should be understood to be synonymous with "comprising one or more," "including one or more," and "having one or more." Additionally, any range recited in the specification including the claims should be understood to include its end values unless otherwise specified. Specific values of recited elements should be understood to be within the acceptable manufacturing or industrial tolerances known to those skilled in the art, and the use of the terms "substantially," "approximately," and "about" should be understood to mean within such acceptable tolerances.

[0056] When an element or feature is referred to in this specification as being "on," "engaged with," "connected to," or "coupled to" another element or feature, it may be directly on, engaged with, connected to, or coupled to the other element or feature, or intervening elements or features may be present. In contrast, when an element or feature is referred to as being "directly on," "directly engaged with," "directly connected to," or "directly coupled to" another element or feature, intervening elements or features may not be present. Other words used to describe relationships between elements or features should be interpreted in a like manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0057] Spatially relative terms such as "top," "bottom," "middle," "inner," "outer," "beneath," "below," "lower," "above," "upper," etc. may be used herein to facilitate description of the relationship of one element or feature to another element or feature as shown in the drawings. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the drawings. For example, if the device in the drawing is turned over, an element described as "below" or "beneath" another element or feature will be oriented "above" the other element or feature. Accordingly, the exemplary term "below" can encompass both an orientation above and below. The device may be oriented in other directions (rotated 90 degrees or other orientations), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0058] Terms such as "first", "second", "third", etc. may be used herein to describe various elements, components, regions, layers, parts, and / or parameters, but these elements, components, regions, layers, parts, and / or parameters should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or part from another region, layer, or part. Thus, a first element, component, region, layer, or part discussed herein could be termed a second element, component, region, layer, or part without departing from the teachings of this disclosure.

[0059] As shown in FIG. 1A, the extensible composite material 10 may be configured to use a sanitary garment (also referred to herein as a "disposable garment") 100. In particular, the sanitary garment 100 may be a diaper or the like configured to be worn as underwear around the central part of a user to collect, absorb, and / or contain the user's waste and prevent soiling of the user's outer clothing and / or the user's surrounding environment. For this purpose, the sanitary garment 100 includes a front portion 120, a rear portion 140 opposite the front portion 120, an intermediate portion 160 connecting the front portion 120 and the rear portion 140, and a waistband and / or waist flap portion 180 extending around the upper regions of the front portion 120 and the rear portion 140 to support the sanitary garment 100 around the central part of the user. The terms "front" and "rear" are intended to be understood in relation to components, surfaces, positions, regions, directions, etc. corresponding to the front and rear of the human anatomical structure. Further, the terms "upper" and "lower" are intended to be understood in relation to components, surfaces, positions, regions, directions, etc. corresponding to the upper and lower regions of the human anatomical structure.

[0060] Referring to FIG. 1A, in an example, the stretch composite material 10 may be located on or adjacent to the waistband and / or waist flap portion 180 of the sanitary garment 100. Additionally or alternatively, the stretch composite material 10 may extend from one or more of the front portion 120 of the sanitary garment 100 and / or the rear portion 140 of the sanitary garment 100 such that the front portion 120 of the sanitary garment 100 can be fastened to the rear portion 140 of the sanitary garment 100. For this purpose, the stretch composite material 10 may include fastening elements 15 configured to engage one or more of the front portion 120 of the sanitary garment 100 and the rear portion 140 of the sanitary garment 100, and / or complementary fastening elements 115 included in one or more of the front portion 120 of the sanitary garment 100 and / or the rear portion 140 of the sanitary garment 100. The fastening elements 15 of the stretch composite material 10 are contemplated to include any type of fastening mechanism that can be compatible with the stretch composite material 10, such as, for example, a hook and loop fastening mechanism (see FIG. 1A), an adhesive fastening mechanism (see FIG. 1B), etc. In particular, the fastening elements 15 may include hooks, and the complementary fastening elements 115 may include loops. Alternatively, the stretch composite material 10 may include fastening elements 15 configured to directly engage at least the front portion 120 of the sanitary garment 100, which form complementary fastening elements 115, such as, for example, loops. Additionally or alternatively, the stretch composite material 10 may be a part of the waistband and / or waist flap portion 180 of the sanitary garment 100, thereby extending continuously across the entire front portion 120 and the entire rear portion 140 of the sanitary garment 100. In this way, the stretch composite material 10 is configured to enable fastening the sanitary garment 100 around the central portion of the user and / or sliding the sanitary garment 100 towards the central portion of the user, thereby providing a secure and adjustable fit of the stretch composite material 10, and thus the sanitary garment 100, around the central portion of the user. Additionally or alternatively, the fastening elements 15 may be laminated directly onto the first layer 20 and / or the second first layer 20 without an adhesive as a hook layer.

[0061] As shown in FIGS. 5A to 5B, the extensible composite material 10 is configured to extend and contract between a relaxed state (see FIG. 5A) and an extended state (the extended state of the extensible composite material 10 is contemplated to correspond to 100% elongation of the extensible composite material). For example, if the extensible composite material 10 has a dimension L0 in the relaxed state, 100% elongation of the extensible composite material corresponds to 100% of the dimension L0 + L0 of the extensible composite material 10 = 2*L0) (see FIG. 5B). In particular, the extensible composite material 10 is configured to extend from the relaxed state toward the extended state and contract from the extended state toward the relaxed state. For this purpose, referring to FIGS. 1B to 4B, the extensible composite material 10 includes at least two layers 20, 40 that can extend and contract together. In the example, the extensible composite material 10 includes a first layer 20 and a second layer 40. In particular, the extensible composite material 10 may include one or more of the first layer 20 and one or more of the second layer 40. In the example, the extensible composite material 10 may include the first layer 20, the first layer of the second (also referred to herein as the "third layer") 20, and one second layer 40. However, since the structure and / or relationship corresponding to the first layer 20 and the first layer 20 of the second are the same or substantially the same, the first layer 20 and the first layer 20 of the second are collectively referred to herein as the "first layer 20" unless the consideration of the first layer 20 of the second is particularly necessary.

[0062] For example, the second layer 40 may be a material that, at room temperature (i.e., 23°C), retains less than 30%, or less than 20%, or less than 15%, or less than 10%, or less than 5% residual deformation or residual magnetization (residual deformation may also be referred to herein as "permanent strain" and / or "SET") after elongation and release when the extensible composite material 10 is elongated to 100% of its initial dimension. SET can be measured as shown in European Patent Application Publication No. 1783257, the content of which is incorporated herein by reference, particularly in paragraphs

[0056] to

[0062] of European Patent Application Publication No. 1783257, which detail an example of SET measurement.

[0063] Referring to FIGS. 1B to 4B, the first layer 20 of the stretchable composite material 10 includes a first surface 22 of the first layer and a second surface 24 of the first layer facing the first surface 22 of the first layer. Thus, it should be understood that the second first layer 20 includes a first surface 22 of the second first layer and a second surface 24 of the second first layer facing the first surface 22 of the second first layer. In the example, the first layer 20 is constructed from a nonwoven material. As used herein, the term "nonwoven fabric" is intended to be understood as a sheet-like material including fibers and / or filaments that are not woven or knitted together and are bonded and / or intertwined with each other chemically, mechanically, thermally, etc. For example, the nonwoven material of the first layer 20 or the second first layer 20 may be any nonwoven material compatible with the stretchable composite material 10 such as a meltblown nonwoven material, a point-bonded nonwoven material, a carded nonwoven material, a spunlace nonwoven material, a spunbond nonwoven material, a spunmelt nonwoven material (i.e., SMS type nonwoven fabric (see below)), SM, SMS, SSMMS, SMSMS, SMMMS, SMMS, SSMMSS, SSMMMSS, SSMMMSSS, and / or any other combination of "S" layer and "M" layer ("S" represents a spunbond type layer and "M" represents a meltblown type layer). Additionally or alternatively, the nonwoven material may include bonded fibers such as crimped carded fibers or crimped spunbond fibers of the same material, or two different materials of the same type of material, or two different materials of different types of materials (i.e., a two-component material). The fibers of the nonwoven material may be any material compatible with the stretchable composite material 10 such as polyester (i.e., PET), polyolefin (i.e., PP), polyethylene (i.e., PE), polyamide (i.e., PA), acrylonitrile butadiene styrene (i.e., ABS), acrylic, polystyrene (i.e., PS), cellulose-based, fluorocarbon, polylactic acid (i.e., PLA), blends thereof, etc. In the example, the nonwoven material of the first layer 20 has a basis weight in the range of 1 g / m 2 ~50 g / m 2 and may be. In particular, the nonwoven material of the first layer 20 is 4 g / m2 ~35 g / m 2 It may have a basis weight in the range of. The nonwoven material of the first layer 20 may be stretchable in the machine cross direction. For this purpose, the nonwoven material of the first layer 20 and / or the second first layer 20 may have a machine cross direction stretch at a peak load of at least 100%. The nonwoven material of the first layer 20 is contemplated to be stretchable in the machine direction. For this purpose, the nonwoven fabric material of the first layer 20 may have a machine cross direction / machine direction elongation ratio in the range of at least 1:1, at least 2:1, at least 3:1, in the range of 3 to 6:1, or in the range of 4 to 5:1. In this way, the first layer 20 is inelastic but highly stretchable, thereby enabling the stretching and contraction of the stretchable composite 10 between the relaxed state and the stretched state. The nonwoven material of the first layer 20 and / or the second first layer 20 may be the same as or different from any combination described herein.

[0064] Referring to FIGS. 1B - 4B, the second layer 40 of the extensible composite 10 includes a first surface 42 of the second layer and a second surface 44 of the second layer that faces the first surface 42 of the second layer. Further, the second layer 40 extends between a first end 46 of the second layer and a second end 48 of the second layer. It is contemplated that the first end 46 and the second end 48 of the second layer may define and / or correspond to the machine direction or the machine cross - direction. In an example, the second layer 40 is constructed from an elastomeric material. As used herein, the term "elastomer" is contemplated to be understood as any polymeric material having elasticity. For example, the elastomeric material of the second layer 40 may be any elastomeric material compatible with the extensible composite 10, such as a styrenic block copolymer that may include, as a main component, styrene - isoprene - styrene (i.e., SIS) block copolymer, styrene - butadiene - styrene (i.e., SBS) block copolymer, styrene - ethylene - butylene - styrene (i.e., SEBS) and styrene - ethylene - propylene - styrene (i.e., SEPS), and / or combinations thereof. Further, the elastomeric material of the second layer 40 may include additional materials such as polyethylene (i.e., PE), polypropylene (i.e., PP), polystyrene (i.e., PS), and / or combinations thereof as minor components. In an example, the elastomeric material of the second layer 40 may have a basis weight of 30 g / m 2 ~ 100 g / m 2 . In particular, the elastomeric material of the second layer 40 may have a basis weight of 35 g / m 2 ~ 65 g / m 2 . Further, the elastomeric material of the second layer 40 may have at least 100% elongation in the machine cross - direction. In this way, the second layer 40 is elastic and highly extensible, thereby enabling the extensible composite 10 to stretch and contract between a relaxed state and a stretched state. As shown in FIG. 1B, the extensible composite 10 of FIG. 1A is obtained by a cut along the cut line Lc. Alternatively, depending on the application, for example, in the case of adult incontinence, the extensible composite 10 may include one or more second layers 40 including an elastic film, as shown in FIG. 1B.

[0065] As shown in FIGS. 1B to 4B, the second layer 40 includes a plurality of ribs 50 extending from at least the first surface 42 of the second layer. The plurality of ribs 50 are contemplated to be able to extend from the first surface 42 and the second surface 44 of the second layer. The plurality of ribs 50 extending from the second surface 44 of the second layer are contemplated to be aligned with and / or offset from the plurality of ribs 50 extending from the first surface 42 of the second layer. The plurality of ribs 50 may be integrally formed with the second layer 40 such that the plurality of ribs 50 extend continuously and integrally from the second layer 40. Thus, during the manufacture of the second layer 40, it is contemplated that the plurality of ribs 50 can be extruded together with the second layer 40 through a die (not shown) such that the plurality of ribs 50 are integrally formed on the second layer 40. The plurality of ribs 50 are contemplated to include any shape that can be compatible with the stretchable composite material 10 such as a cylindrical column, a trapezoidal column, a triangular column, etc. In an example, the plurality of ribs 50 extend in a machine direction that can be parallel or substantially parallel to the first end 46 and the second end 48 of the second layer. Further, the plurality of ribs 50 extend continuously throughout the second layer 40 between the first end 46 and the second end 48 of the second layer.

[0066] Referring to FIGS. 1B to 4B, the gap 52 extends between each rib 50 of the plurality of ribs 50 and an adjacent rib 50 of the plurality of ribs 50. In the example, the adjacent ribs 50 of the plurality of ribs 50 are spaced apart from each other such that the average distance (width) between the adjacent ribs 50 of the plurality of ribs 50, within which each gap 52 is in the range of 0.1 mm to 20 mm. In particular, the adjacent ribs 50 of the plurality of ribs 50 may be spaced apart from each other such that, particularly after 100% elongation of the stretchable composite material 10, the average distance (width) between the adjacent ribs 50 of the plurality of ribs 50, within which each gap 52 is in the range of 0.2 mm to 15 mm. The spacing between adjacent ribs 50 of the plurality of ribs 50 (i.e., the width of the gap 52) is contemplated to be stepwise such that the spacing between adjacent ribs 50 of the plurality of ribs 50 increases respectively towards the first end 46 of the second layer 40 and the second end 48 of the second layer from the center of the second layer 40. In particular, the spacing between adjacent ribs 50 of the plurality of ribs 50 may increase respectively in the range of 25% to 100% towards the first end 46 of the second layer 40 and the second end 48 of the second layer from the center of the second layer 40. Thereby, the visibility of the plurality of ribs 50 increases towards the center of the second layer 40, for example, in the stretched state of 100% or 200%.

[0067] In the example, the second layer 40 has a first thickness within each gap 52 between adjacent ribs 50 of the plurality of ribs 50, and a second thickness along each rib 50 of the plurality of ribs 50 when the stretchable composite 10 is in a relaxed state (whether initial or not) and / or a stretched state where the elongation of the stretchable composite 10 is 100% in the machine direction and / or the transverse machine direction. Further, the second thickness of the second layer 40 along each rib 50 of the plurality of ribs 50 is greater than the first thickness of the second layer 40 between adjacent ribs 50 of the plurality of ribs 50 when the stretchable composite 10 is in a relaxed state (whether initial or not) and / or a stretched state where 100% elongation of the stretchable composite 10 is in the machine direction and / or the transverse machine direction. In the example, the first thickness of the second layer 40 is in the range of 0.025 mm to 0.075 mm when the stretchable composite 10 is in a relaxed state (whether initial or not) and / or a stretched state where 100% elongation of the stretchable composite 10 is in the machine direction and / or the transverse machine direction. In the example, the second thickness of the second layer 40 is in the range of 0.125 mm to 0.2 mm when the stretchable composite 10 is in a relaxed state (whether initial or not) and / or a stretched state where 100% elongation of the stretchable composite is in the machine direction and / or the transverse machine direction. In particular, the second thickness of the second layer 40 along each rib 50 of the plurality of ribs 50 can be greater than the first thickness of the second layer 40 between adjacent ribs 50 of the plurality of ribs 50 when the stretchable composite 10 is in a relaxed state. In the example, the first thickness of the second layer 40 between adjacent ribs 50 of the plurality of ribs 50 is in the range of 10% to 50% of the second thickness of the second layer 40 along each rib 50 of the plurality of ribs 50, particularly when the stretchable composite 10 is in a relaxed state. In particular, the first thickness of the second layer 40 between adjacent ribs 50 of the plurality of ribs 50 can be in the range of 20% to 45% of the second thickness of the second layer 40 along each rib 50 of the plurality of ribs 50 when the stretchable composite 10 is in a relaxed state. In this way, due to the first (reduced) thickness of the second layer 40 within each gap 52 of the second layer 40, the second layer 40, and thus the stretchable composite 10, has regions of different stretchability and locally increased stretchability.Furthermore, due to the second (increased) thickness of the second layer 40 along each rib 50 of the plurality of ribs 50, the plurality of ribs 50 increase the visibility through the first layer 20 and the second layer 40, and thus, the stretchable composite 10 increases the structural integrity and, in particular, increases the resistance to forces applied in the same direction as the main direction of the plurality of ribs 50. The initial relaxed state of the stretchable composite 10 is intended to correspond to the stretchable composite 10 that is not stretched at all when first produced and / or recovered from the manufacturing equipment of the stretchable composite 10 and / or from a roll and / or from the sanitary article 100, i.e., when first used or tested.

[0068] As shown in FIGS. 5A to 5B, the stretchable composite material 10 is configured to stretch and contract between a relaxed state and a stretched state. In the example, the first average distance (width) between adjacent ribs 50 of the plurality of ribs 50 in the relaxed state of the stretchable composite material 10 (i.e., the first average distance of the gap 52 of the second layer 40) is smaller than the second average distance between adjacent ribs 50 of the plurality of ribs 50 in the stretched state of the stretchable composite material 10 (i.e., the second average distance of the gap 52 of the second layer 40). In particular, the first average distance between adjacent ribs 50 of the plurality of ribs 50 is in the range of 0.5 mm to 30 mm in the relaxed state of the stretchable composite material 10. Further, the second average distance between adjacent ribs 50 of the plurality of ribs 50 in the stretched state where the elongation of the stretchable composite material 10 is 100% is in the range of 100% to 200% of the first average distance between adjacent ribs 50 of the plurality of ribs 50, in particular, in the range of 105% to 170% of the first average distance between adjacent ribs 50 of the plurality of ribs 50, and more specifically, in the range of 105% to 150% of the first average distance between adjacent ribs 50 of the plurality of ribs 50. In this way, the user can visualize the change and / or increase in the interval between adjacent ribs 50 of the plurality of ribs 50, thereby obtaining a clear visual indication of the elongation rate and / or elongation amount of the stretchable composite material 10. Therefore, the user can more accurately adjust the size of the stretchable composite material 10, and thus the sanitary clothing 100, and / or reduce the risk that the stretchable composite material 10 stretches beyond a predetermined elongation range, preventing damage to the stretchable composite material 10, and thus the sanitary clothing 100. Additionally or alternatively, the second layer 40 may include a plurality of stripes (not shown) similar to the arrangement of the plurality of ribs 50 in addition to or instead of the plurality of ribs 50, thereby enabling the user to visualize the change and / or increase in the interval between adjacent stripes of the plurality of stripes, and thereby also enabling a clear visual indication of the elongation rate and / or elongation amount of the stretchable composite material 10 to be obtained.

[0069] As shown in FIGS. 1B to 6B, the first layer 20 is arranged to face the second layer 40. In particular, the first surface 22 of the first layer is arranged to face the first surface 42 of the second layer. In the example, at least a part of the first surface 22 of the first layer is attached to the first surface 42 of the second layer. For this purpose, the first surface 22 of the first layer is attached to the first surface 42 of the second layer at a plurality of attachment positions 26. Additionally or alternatively, the second first layer 20 may be arranged to face the second layer 40. In particular, the second first layer 20 may be arranged to face the second surface 44 of the second layer. In the example, at least a part of the second first layer 20 may be attached to the second surface 44 of the second layer in the same manner as the first layer 20 is attached to the first surface 42 of the second layer. In this way, the first layer 20, the second first layer 20, and the second layer 40 are arranged in a sandwiched state with the second layer 40 disposed between the first layer 20 and the second first layer 20.

[0070] In the example, each attachment position 26 of the plurality of attachment positions 26 may be spaced from an adjacent attachment position 26 of the plurality of attachment positions 26 by an average distance (width) within the range of 0.5 mm to 5.0 mm. In particular, each attachment position 26 of the plurality of attachment positions 26 may be spaced from an adjacent attachment position 26 of the plurality of attachment positions 26 by an average distance (width) within the range of 1.5 mm to 4.5 mm, and more particularly within the range of 2.5 mm to 4.0 mm. At each attachment position 26, the first surface 22 of the first layer may be adhesively bonded to the first surface 42 of the second layer. For this purpose, a bead of adhesive may bond the first surface 22 of the first layer to the first surface 42 of the second layer at each attachment position 26. As shown in FIG. 1B, one or more beads of adhesive may be included as part of the adhesive layer 30. However, the first surface 22 of the first layer is contemplated to be attached to the first surface 42 of the second layer at each attachment position 26 of the plurality of attachment positions 26 by any alternative attachment method that may be suitable for the stretchable composite material 10, such as direct lamination, thermal bonding, ultrasonic bonding, and / or infrared bonding.

[0071] As shown in FIGS. 1B to 6B, a space 28 is defined between each attachment position 26 of the plurality of attachment positions 26 and an adjacent attachment position 26 of the plurality of attachment positions 26, between the first surface 22 of the first layer and the first surface 42 of the second layer. Thus, the first layer 20 is oriented farther from the second layer 40 between adjacent attachment positions 26 than when the first layer 20 is at each attachment position 26. The first layer 20 includes a waveform and / or corrugation that traverses the second layer 40 between the first end 46 of the second layer and the second end 48 of the second layer when the first layer 20 is oriented farther from the second layer 40 between adjacent attachment positions 26 than when the first layer 20 is at each attachment position 26. In particular, the first layer 20 includes a waveform and / or corrugation that traverses the second layer 40 when the stretchable composite 10 is in a relaxed state after being stretched 50% to 200% of the stretchable composite 10, and more particularly when the stretchable composite 10 is in a relaxed state after being stretched 100%. In this way, the space 28 defined between the first layer 20 forming the waveform of the first layer 20 and the second layer 40 enables an increase in the compressibility of the first layer 20, thereby increasing the visual perception of softness due to changes in the thickness and / or texture of the stretchable composite 10, and / or the potential sensation of cushioning and / or softness of the first layer 20, enhancing the comfort of the stretchable composite 10 and thus the sanitary garment 100. Further, the plurality of ribs 50 can accentuate the waveform of the first layer 20, thereby further enhancing the cushioning and / or softness of the first layer 20 and it is contemplated that the comfort of the stretchable composite 10 and thus the sanitary garment 100 can be enhanced.

[0072] Referring to FIGS. 1B to 6B, one or more of the plurality of attachment positions 26 may be located between adjacent ribs 50 of the plurality of ribs 50 (i.e., within at least a portion of the gap 52 of the second layer 40). Attaching the first layer 20 to the second layer 40 at one or more of the plurality of attachment positions 26 located between adjacent ribs 50 of the plurality of ribs 50 enables an increase in the volume of the first layer 20 and / or enhancement of the formation of the waveform of the first layer 20, enables an increase in the compressibility of the first layer 20, thereby increasing the cushioning property and / or flexibility of the first layer 20 and enhancing the comfort of the stretchable composite material 10. However, attaching the first layer 20 to the second layer 40 at one or more of the plurality of attachment positions 26 located between adjacent ribs 50 of the plurality of ribs 50 may reduce the elasticity of the second layer 40 because the attachment of the first layer 20 to the second layer 40 may increase the rigidity at one or more attachment positions 26 that would be more elastic (i.e., the regions corresponding to the gaps 52 of the second layer 40) as opposed to the regions where the thickness of the second layer 40 is increased (i.e., the regions corresponding to the ribs 50 of the plurality of ribs 50), thereby reducing the stretchability of the stretchable composite material 10.

[0073] Additionally or alternatively, one or more of the attachment locations 26 of the plurality of attachment locations 26 may be located along at least a portion of one or more of the ribs 50 of the plurality of ribs 50. Attaching the first layer 20 to the second layer 40 at one or more of the attachment locations 26 that are located along one or more of the ribs 50 of the plurality of ribs 50 allows for an increase in the elasticity of the second layer 40 because one or more of the attachment locations 26 do not increase the rigidity in the region of increased elasticity (i.e., the region corresponding to the gap 52 of the second layer 40). However, attaching the first layer 20 to the second layer 40 at one or more of the attachment locations 26 that are located along one or more of the ribs 50 of the plurality of ribs 50 increases the tension of the first layer 20, reduces the volume of the first layer 20 and / or the formation of the waveform of the first layer 20 (i.e., flattens the first layer 20), reduces the compressibility of the first layer 20, thereby reducing the cushioning and / or flexibility of the first layer 20 and potentially reducing the comfort of the stretch composite 10.

[0074] In an example, one or more of the plurality of attachment locations 26 are located between adjacent ribs 50 of the plurality of ribs 50, and one or more of the plurality of attachment locations 26 are located along one or more of the ribs 50 of the plurality of ribs 50. Additionally or alternatively, more than one of the plurality of attachment locations 26 are located between adjacent ribs 50 of the plurality of ribs 50, and more than one of the plurality of attachment locations 26 are located along one or more of the ribs 50 of the plurality of ribs 50. In an example, at least 5% to 40% of the plurality of attachment locations 26 may be located between adjacent ribs 50 of the plurality of ribs 50. In particular, at least 5% to 15% of the plurality of attachment locations 26 may be located between adjacent ribs 50 of the plurality of ribs 50. Additionally or alternatively, at least 1% to 10% of the plurality of attachment locations 26 may be located along the ribs 50 of the plurality of ribs 50. In particular, at least 1% to 5% of the plurality of attachment locations 26 may be located along the ribs 50 of the plurality of ribs 50. In this way, by including the hybrid attachment locations 26 located between adjacent ribs 50 of the plurality of ribs 50 and along one or more of the ribs 50 of the plurality of ribs 50, more volume of the first layer 20 and more elasticity between adjacent ribs 50 of the plurality of ribs 50 are maintained, thereby enabling enhancement of the stretchability and comfort of the stretchable composite 10, and thus the sanitary garment 100. Referring to FIGS. 6A - 6B, each attachment location 26 of the plurality of attachment locations 26 can be obtained by using an adhesive, ultrasonic, calendaring, and / or a combination thereof. The attachment location 26 extends in the machine direction in the central region of the second layer 40 (preferably continuously extends in the machine direction) and continuously extends in the machine cross - direction both outside the region of the second layer 40 and at the boundary of the second layer 40, and may vary according to the region of the stretchable composite 10 (see FIG. 1B) having beads.

[0075] Additionally or alternatively, the extensible composite material 10 may be configured to be activated. Activation may be, for example, an incremental stretching of the extensible composite material 10 by a ring roller, for example, see U.S. Patent Application Publication No. 2014 / 0378924 and / or International Application Publication No. 2019 / 086344, the contents of each of which are incorporated by reference. The amount of activation measured as applied strain (see U.S. Patent Application Publication No. 2014 / 0378924 and / or International Publication No. 2019 / 086344) can be in the range of 10% to 250%, particularly in the range of 50% to 190%. As shown in FIGS. 1A-1B, the two extensible composite materials 10 are activated in activation regions 60 having a width smaller than the respective width of the second layer 40.

[0076] Additionally or alternatively, the first layer 20 and / or the second first layer 20 of the extensible composite material 10 may be activated before being laminated with the second layer 40. Activation may be, for example, an incremental stretching of the extensible composite material 10 by a ring roller, for example, see U.S. Patent Application Publication No. 2014 / 0378924 and / or International Application Publication No. 2019 / 086344, the contents of each of which are incorporated by reference. The amount of activation measured as applied strain (see U.S. Patent Application Publication No. 2014 / 0378924 and / or International Publication No. 2019 / 086344) can be in the range of 1% to 200%, particularly in the range of 5% to 120%, more particularly in the range of 10% to 100%.

[0077] Additionally or alternatively, the first layer 20 and / or the second first layer 20 of the extensible composite material 10 may be shaped before being laminated with the second layer 40, for example, wavy in the machine direction and / or the cross-machine direction to form a waveform.

[0078] Although the present disclosure herein has been described with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure.

[0079] This specification and the examples are intended to be considered as illustrative only, and the true scope of the disclosure is indicated by the following claims.

[0080] Furthermore, all of the disclosed features of the equipment may be transposed into a method, either alone or in combination, and vice versa.

Claims

**Claim 1** An extensible composite material (10), a first layer 20 including a first surface (22) of the first layer and a second surface (24) of the first layer facing the first surface (22) of the first layer, the first layer (20) including a non-woven material, a second layer 40 including a first surface (42) of the second layer facing the first surface (22) of the first layer and a second surface (44) of the second layer facing the first surface (42) of the second layer, the second layer (40) including an elastomeric material, wherein the second layer (40) includes a plurality of ribs (50) extending at least from the first surface (42) of the second layer, at least a part of the first surface (22) of the first layer is attached to the first surface (42) of the second layer at a plurality of attachment positions (26), and the first layer (20) and the second layer (40) are configured to define a space between the first surface (22) of the first layer and the first surface (42) of the second layer between adjacent attachment positions of the plurality of attachment positions (26). An extensible composite material (10). **Claim 2** The extensible composite material (10) according to claim 1, wherein the first layer (20) and the second layer (40) are configured to stretch and contract between a relaxed state and a stretched state. **Claim 3** The first layer (20) includes a first average distance between adjacent ribs (50) of the plurality of ribs (50) in the relaxed state, the first layer (20) includes a second average distance between adjacent ribs (50) of the plurality of ribs in the stretched state, and the second average distance between adjacent ribs (50) of the plurality of ribs (50) is greater than the first average distance between adjacent ribs (50) of the plurality of ribs (50). The extensible composite material (10) according to claim 1 or 2. **Claim 4** The extensible composite material (10) according to any one of claims 1 to 3, wherein a gap extends between adjacent ribs (50) of the plurality of ribs (50) of the second layer. **Claim 5** The second layer (40) has a first thickness within each gap of the second layer (40) and a second thickness along each rib (50) of the plurality of ribs (50) of the second layer (40), and the second thickness along each rib (50) of the plurality of ribs (50) of the second layer (40) is greater than the first thickness within each gap of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 4.

6. The first thickness of the second layer (40) within each gap of the second layer (40) is in the range of 10% to 50% of the second thickness of the second layer (40) along each rib (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 5.

7. One or more of the plurality of attachment positions (26) are located between adjacent ribs (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 6.

8. One or more of the plurality of attachment positions (26) are located along at least a part of one or more ribs (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 7.

9. One or more of the plurality of attachment positions (26) are located between adjacent ribs (50) of the plurality of ribs (50) of the second layer (40), and one or more of the plurality of attachment positions (26) are located along at least a part of one or more ribs (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 8.

10. At least 1% to 10% of the plurality of attachment positions (26) are located along at least a part of the ribs (50) among the plurality of ribs of the second layer (40). The stretchable composite material (10) according to claim 8 or 9.

11. At least 5% to 40% of the plurality of attachment positions (26) are located between adjacent ribs (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to claim 7 or claim 9.

12. In a cross-section in a plane perpendicular to the machine direction or the machine transverse direction, at least 1% of the plurality of attachment positions (26) are located along at least a part of the ribs (50) among the plurality of ribs (50) of the second layer, and at most 99% of the plurality of attachment positions are located between adjacent ribs (50) of the plurality of ribs (50) of the second layer. The stretchable composite material (10) according to any one of claims 1 to 11.

13. In a cross-section in a plane perpendicular to the machine direction or the machine transverse direction, at most 20% of the plurality of attachment positions (26) are located along at least a part of the ribs (50) among the plurality of ribs (50) of the second layer, and at least 80% of the plurality of attachment positions (26) are located between adjacent ribs (50) of the plurality of ribs (50) of the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 12.

14. The second layer includes a first end (46) of the second layer and a second end (48) of the second layer, and the plurality of ribs (50) of the second layer (40) extend continuously throughout the second layer between the first end (46) of the second layer and the second end (48) of the second layer. The stretchable composite material (10) according to any one of claims 1 to 13.

15. The first layer is oriented farther from the second layer (40) between adjacent attachment positions of the plurality of attachment positions (26) than when the first layer (20) is at each attachment position (26) of the plurality of attachment positions (26). The stretchable composite material (10) according to any one of claims 1 to 14.

16. The first layer (20) includes a waveform crossing the second layer (40). The stretchable composite material (10) according to any one of claims 1 to 15.

17. Including a second first layer (20), and the second first layer (20) is attached to the second surface (44) of the second layer. The stretchable composite material (10) according to any one of claims 1 to 16.

18. The plurality of ribs (50) extend from the first surface (42) of the second layer and the second surface (44) of the second layer. The stretchable composite material (10) according to any one of claims 1 to 17.

19. At least 50% of the plurality of ribs (50) extending from the first surface (42) of the second layer and at least 50% of the plurality of ribs (50) extending from the second surface (44) of the second layer are aligned or offset from each other, the stretchable composite material (10) according to claim 18.

20. The stretchable composite material (10) according to any one of claims 1 to 19, wherein each of the plurality of attachment positions (26) includes an adhesive.

21. The stretchable composite material (10) according to any one of claims 1 to 20, comprising a fastening element (115) configured to fix the stretchable composite material (10) to at least a part of sanitary clothing.

22. The first surface (42) of the second layer including the plurality of ribs (50) has a density in the range of 0.20 to 15 ribs / cm in the machine direction or the machine cross direction, or a density in the range of 0.75 to 10 ribs / cm in the machine direction or the machine cross direction, or a density in the range of 1.0 to 7 ribs / cm in the machine direction or the machine cross direction, the stretchable composite material (10) according to any one of claims 1 to 21.

23. The stretchable composite material (10) according to any one of claims 1 to 22, including at least a region without the plurality of ribs (50), the region being disposed at one or more of the first end (46) of the second layer and the second end (48) of the second layer.

24. Each of the plurality of ribs (50) has an aspect ratio in the range of 0.1 to 0.6, or an aspect ratio in the range of 0.15 to 0.5, the stretchable composite material (10) according to any one of claims 1 to 23.

25. A roll including an unwinding direction and the stretchable composite material (10) according to any one of claims 1 to 24, wherein the plurality of ribs (50) extend in the unwinding direction.

26. A method of manufacturing a stretchable composite material (10), comprising providing a first layer (20) constructed of a nonwoven material and including a first surface (22) of the first layer and a second surface (24) of the first layer facing the first surface (22) of the first layer. including a first surface (42) of a second layer facing a first surface (22) of the first layer and a second surface (44) of the second layer facing the first surface (42) of the second layer, and providing a second layer (40) constructed of an elastomeric material including a plurality of ribs (50) extending at least from the first surface (42) of the second layer attaching the first surface (22) of the first layer to the first surface (42) of the second layer at the plurality of attachment locations (26) such that the first layer (20) and the second layer (40) are configured to define a space between adjacent attachment locations (26) of the plurality of attachment locations (26) between the first surface (22) of the first layer and the first surface (42) of the second layer, the method comprising **Claim 27** The method according to claim 26, including attaching a second first layer (20) to the second surface (44) of the second layer

Images