Elastic laminate with reinforced elastomer material layer

Abstract

The invention relates to an elastic laminate (3; 3'), extending widthwise in a first direction, in particular CD, and lengthwise in a second direction, in particular MD, the elasticity of the laminate being greatest in at least one stretch direction (F), for example the CD direction, the elastic laminate comprising: - at least one nonwoven layer (2; 2', 7'); and - at least one elastomer material layer (1; 1') fixed by an upper face, respectively a lower face, to a lower face, respectively an upper face, of the at least one nonwoven layer; characterized in that, - in the unstretched state of the laminate in the at least one stretch direction, at least one raised portion (5; 5') is formed on the upper face of the at least one elastomer material layer (1; 1'), the raised portion being delimited by a peripheral edge of the raised portion and having a greatest raised portion length along a raised portion length direction and, measured along the direction perpendicular to the raised portion length direction, a greatest raised portion width; - the ratio of the greatest raised portion length to the greatest raised portion width, or aspect ratio, being strictly greater than 1, in particular being at least equal to 1.2, preferably greater than 2, even more preferably greater than 5; and the raised portion length direction is not perpendicular to the at least one stretch direction (F), in particular forming an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, thereto.

Description

Description Title of the invention: Elastic laminate with a reinforced elastomer layer

[0001] The present invention relates to an elastic laminate intended for use in the medical and / or hygiene fields, and in particular for adult incontinence diapers or diapers, or in the field of feminine hygiene, in particular for sanitary napkins, the laminate extending along a given length, for example a large length corresponding to the direction of unwinding of the machine during the continuous manufacture of the laminate, called the MD direction (Machine Direction), and a given width, in particular corresponding to the CD direction (Cross Direction or Transverse Direction), perpendicular to the MD direction, and comprising a stack of at least one layer of non-woven material and at least one layer of elastomeric material, in particular two lower and upper non-woven layers sandwiching the at least one layer of elastomeric material.These laminates are intended in particular for use in the manufacture of at least one part of a diaper waistband, for example elastic ears intended to carry hooks and to be attached to the edges of the central rear part of the diaper waistband to cooperate with loop elements from the front part of the waistband to make a removable elastically adaptable closure of the diaper.

[0002] We know, for example, from document US2024 / 0024168 A1 in the name of the plaintiff, a stratification of this kind.

[0003] Although this prior art elastic laminate has considerable advantages over what existed previously, it would still be desirable to improve it, and in particular to increase its effective service life, prior art laminates tending to deteriorate and / or deform after being stretched and then released a number of times.

[0004] The present invention thus relates, according to one aspect, to an elastic laminate, in particular disposable, as defined in claim 1, of the modes favorable realizations and improvements being defined in subclaims 2 to 9.

[0005] Preferably, when at least one layer of elastomeric material comprises at least one base part and reliefs formed on a lower and / or upper face of at least one base part, the base part is preferably formed directly on a lower and / or upper face of at least one non-woven layer, possibly with the interposition of an adhesive.

[0006] According to another aspect of the invention, the elastic laminate, in particular disposable, extending in width in a first direction, in particular CD, and in length in a second direction, in particular MD, the elasticity of the laminate being greatest in at least one direction of stretching, for example the direction CD, comprising: - at least one layer of non-woven fabric; and - at least one layer of elastomeric material fixed by an upper, or respectively lower, face to an upper, or respectively lower, face of at least one layer of non-woven fabric; characterized in that, - in the unstretched state of the laminate in said at least one stretching direction, at least one relief is formed on the upper face of the at least one layer of elastomeric material, the relief being delimited by a peripheral relief edge, having a greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, a greatest relief width; - the ratio of the greatest relief length, particularly in the first direction, particularly CD, to the greatest relief width, particularly in the second direction, particularly MD, or aspect ratio, being strictly greater than or equal to 1, in particular being at least equal to 1.2, preferably greater than or equal to 2, and even more preferably greater than or equal to 5; and - the longitudinal direction of relief is not perpendicular to at least one stretching direction (or in other words, makes an angle other than 90° or 270° with the stretching direction), in particular makes an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

[0007] Preferably, at least one relief can have the shape of a rib and / or a hollow.

[0008] According to one example, the longest relief extends in a direction parallel to at least one direction of stretching.

[0009] According to an example, for each relief, the ratio of the greatest relief length, in particular in the first direction, in particular CD, to the greatest relief width, in particular in the second direction, in particular MD, or aspect ratio, is strictly greater than 1, in particular is at least equal to 1, 2, preferably greater than or equal to 2, even more preferably greater than or equal to 5.

[0010] According to one example, the elastic laminate comprising a first pair of edges opposite each other, each of the edges of the first pair of opposite edges extending mainly in the first direction, the layer of elastomeric material, in particular each of the reliefs, being arranged at a distance from at least one of the edges of the first pair of opposite edges, in particular being arranged at a distance from both edges of the first pair of opposite edges.

[0011] According to one example, the elastic laminate comprising a second pair of edges opposite each other, each of the edges of the second pair of opposite edges extending mainly in the second direction, the layer of elastomeric material, in particular each of the reliefs, being arranged at a distance from at least one of the edges of the second pair of opposite edges, in particular being arranged at a distance from both edges of the second pair of opposite edges.

[0012] As an example, the laminate may include, per face of the elastomeric material layer, a number of reliefs greater than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and / or a number of reliefs less than or equal to 100, 90, 80, 60, 50, for example for an area of ​​the elastomeric layer with a surface area of ​​less than 2500mm 2 (for example, a square surface of 50mm x 50mm).

[0013] For example, the laminate may include, per face of the elastomeric layer, a number of relief types greater than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and / or a number of reliefs less than or equal to 100, 90, 80, 60, 50, for example, for an area of ​​the elastomeric layer with a surface area of ​​less than 2500 mm². 2 (for example, a square surface of 50mm x 50mm).

[0014] According to a preferred embodiment, at least one layer of nonwoven material comprises fibers and / or filaments oriented predominantly in a direction perpendicular to at least one direction of stretching.

[0015] According to a favorable embodiment, in the rest state (for example in the initial state or after stretching), or in the stretched state, for example at 50% elongation, at least one layer of nonwoven fabric has undulations which, in cross-section along the first direction, in particular in cross-section CD, in particular along a direction parallel to at least one stretching direction, form curved sections in the shape of an inverted U and / or inverted V and / or Q and / or inverted V, the two feet of which are constricted.

[0016] Preferably, the attachment of at least one elastomeric layer to at least one non-woven layer is carried out along a plurality of lines, including continuous lines, extending along the second direction and / or in a direction perpendicular to at least one stretching direction.

[0017] Preferably, some of the plurality of fixing lines are fixed to one or more reliefs.

[0018] Preferably, some of the plurality of fixing lines are not fixed to one or more reliefs, in particular the majority of the plurality of fixing lines are not fixed to one or more reliefs.

[0019] Preferably, the attachment of at least one non-woven layer to at least one elastomeric layer is carried out by ultrasound, and / or hot lamination and / or by interposition of a layer of adhesive, in particular glue and / or by encapsulation, in particular at least partial, by at least one layer of elastomeric material (namely either the base or the reliefs) of one or more fibers / filaments, thus achieving an anchor.

[0020] Preferably, the fixing of at least one layer of non-woven material to at least one layer of elastomeric material comprises a plurality of fixings attached only to the reliefs.

[0021] According to a particularly favorable embodiment, in an area comprising at least one layer of elastomeric material and delimited by two parallel straight lines extending in a direction perpendicular to the direction of stretching, the two parallel straight lines each bordering the opposite edges of the at least one layer of elastomeric material, less than 90% of the surface of the at least one non-woven layer of said area is overlapped by the at least one layer of elastomeric material, in particular less than 80%, in particular less than 70% and / or more than 20% of the surface of the at least one non-woven layer is overlapped by the at least one layer of elastomeric material.

[0022] Thus, breathability is improved, the amount of material is reduced, and the neckdown effect is reduced.

[0023] According to a particularly favorable embodiment, the elastic laminate comprises, on one of its lower and upper faces or on each of the two faces, at least two layers of elastomeric material, the two layers being spaced apart from each other in a direction perpendicular to the direction of stretching.

[0024] According to a particularly favorable embodiment, it is possible to trace on the upper and / or lower face of at least one layer of elastomeric material at least one straight line not passing over any relief, in particular at least one straight line parallel to the direction of stretching not passing over any relief and / or at least one straight line perpendicular to the direction of stretching not passing over any relief.

[0025] In a particularly favorable embodiment, it is possible to trace on the upper and / or lower face of the non-layer woven a straight line not passing over any relief (and / or not passing over any elastomer layer), in particular at least one straight line parallel to the direction of stretching not passing over any relief (and / or not passing over any elastomer layer) and / or at least one straight line perpendicular to the direction of stretching not passing over any relief (and / or not passing over any elastomer layer).

[0026] Preferably, the ratio of the spacing along the direction perpendicular to the stretch direction between two adjacent reliefs of the elastomeric layer and the width of either of the reliefs of the elastomeric layer, in particular each relief of the elastomeric layer, is greater than or equal to 0.2, in particular greater than or equal to 0.6, in particular greater than or equal to 0.8 and / or less than or equal to 3.0, in particular less than or equal to 2.0, in particular less than or equal to 1.5.

[0027] Preferably, the at least one elastomeric layer, in particular each elastomeric layer, has an aspect ratio corresponding to the dimension of the elastomeric layer measured in a plane perpendicular to the direction of stretching and parallel to the upper face of the at least one nonwoven layer, and the thickness, measured in a plane perpendicular to the direction of stretching and perpendicular to the upper face of the at least one nonwoven layer, may be greater than or equal to 1.0, in particular greater than or equal to 1.5, in particular greater than or equal to 3.0 and / or less than or equal to 30, in particular less than or equal to 15, in particular less than or equal to 10.

[0028] Preferably, the relief, in particular the majority of the reliefs, in particular each relief of the at least one layer of elastomeric material, has an aspect ratio corresponding to the dimension of the relief of the elastomeric material measured in a plane perpendicular to the direction of stretching and parallel to the upper face of the at least one layer of nonwoven material, and the thickness, measured in a plane perpendicular to the direction of stretching and perpendicular to the upper face of the at least one layer of nonwoven material, may be greater than or equal to 5, in particular greater than or equal to 10, in particular greater than or equal to 15 and / or less than or equal to 250, in particular less than or equal to 200, in particular less than or equal to 180.

[0029] For example, at least one layer of elastomeric material, in particular each layer of elastomeric material, in particular each raised feature, has a substantially rectangular shape, in particular a substantially rectangular shape extending along a principal direction parallel, or substantially parallel, to the direction of stretching. For example, at least one layer of elastomeric material, in particular each layer of elastomeric material, in particular each raised feature, has a shape of varying dimensions with a variable pitch / spacing. For example, the shape could be an arc, a sinusoid, a chevron, or a sawtooth shape. With such shapes, the elongation of the elastic laminate is influenced by the material used as well as by the shape of the elastomeric material layer and / or the raised features.

[0030] By providing oblong-shaped reliefs that are no longer, as in the prior art, oriented parallel to the direction perpendicular to the direction of stretching (in particular CD), it is possible to concentrate the efforts on the reliefs forming overthicknesses which limit the slippage of the laminate while fighting against a phenomenon called "neckdown" or shrinkage of the elastic which appears quickly after an elongation of the laminate, for example in the case of a diaper, for example from a first elongation of the laminate and / or as the diaper is used, for example by being opened, then closed repeatedly, especially when too much stretching is carried out.

[0031] In addition, for example in the case of a diaper, the reduction of the "neckdown" leads to a reduction of the sagging of the diaper positioned on the wearer's body, particularly at the temperature at which the laminate is used.

[0032] Preferably, at least one layer of non-woven material comprises continuous filaments.

[0033] Preferably, at least one layer of non-woven material includes curled filaments, for example a Carded non-woven material or a Spunbond non-woven material.

[0034] Preferably, at least one layer of non-woven material comprises a Spunbond non-woven material.

[0035] Preferably, at least one layer of nonwoven fabric comprises a meltblown nonwoven fabric, in particular a Spunbond (S) layer, in particular a Spunbond based on crimped filaments (according to the English designation, usual in the field) or a Meltblown (M) layer, or a combination of several of these layers (for example SM, SMS, SMMS, SSMMS, SSSMMS, SSSMMSS).

[0036] According to one example, at least one layer of nonwoven fabric includes a carded nonwoven fabric, for example a hydro-entanglement bonded carded nonwoven fabric, commonly referred to as a Spunlace nonwoven fabric.

[0037] According to one example, at least one layer of non-woven material has a basis weight between 10 and 50 g / m² 2 , in particular between 5 and 40 g / m 2

[0038] As an example, at least one layer of non-woven material has a thickness under a pressure of 0.05 N / cm². 2, between 0.30mm and 0.85mm, in particular between 0.35mm and 0.75mm.

[0039] According to one example, at least one layer of non-woven material includes a weight-to-thickness ratio greater than or equal to 12 kg / m3, in particular greater than or equal to 20 kg / m3 and / or less than or equal to 167 kg / m3, in particular less than or equal to 133 kg / m3.

[0040] According to one example, at least one nonwoven layer includes an elongation at maximum force (Fmax) in a direction perpendicular to the manufacturing direction of the nonwoven layer, i.e. the CD direction of the nonwoven layer, measured according to the NWSP 110.4 method, between 100% and 250%, in particular between 140% and 190%.

[0041] As an example, at least one layer of non-woven material has a thickness of 0.05 N / cm² under a pressure of 2 , between 0.05mm and 0.35mm, in particular between 0.1mm and 0.25mm.

[0042] For example, at least one layer of non-woven material has a basis weight to thickness ratio that may be greater than or equal to 29 kg / m³, in particular greater than or equal to 40 kg / m³, in particular greater than or equal to 55 kg / m3 and / or less than or equal to 1000 kg / m3, in particular less than or equal to 800 kg / m3, in particular less than or equal to 400 kg / m3.

[0043] Preferably, two layers of non-woven material are provided, respectively upper and lower, on either side of at least one layer of elastomeric material.

[0044] According to one example, the second layer of non-woven fabric is of the same type as the first layer of non-woven fabric, for example both layers of non-woven fabric are Carded non-woven fabrics or Spunbond non-woven fabrics.

[0045] According to another example, the second layer of non-woven fabric is of a different type than the first layer of non-woven fabric, for example one is a Spunbond non-woven fabric, and the other is a Carded non-woven fabric.

[0046] The various characteristics described in this application for the first nonwoven layer apply respectively to the second nonwoven layer, either as an alternative to or in combination with those of the first nonwoven layer. For example, the first and second nonwoven layers may have, respectively or conversely, - a carded nonwoven (for example a thermally bonded carded nonwoven) and a spunlace nonwoven, - a carded nonwoven (for example a thermally bonded carded nonwoven) and a spunmelt nonwoven (for example a spunbond nonwoven), - a Spunlace non-woven fabric and a Spunlace non-woven fabric, - a spunmelt nonwoven (for example, a spunbond nonwoven) and a spunlace nonwoven, - a spunmelt nonwoven (for example, a spunbond nonwoven) and a spunmelt nonwoven (for example, a spunbond nonwoven), or - a carded non-woven (for example a thermally bonded carded non-woven) and a carded non-woven (for example a thermally bonded carded non-woven).

[0047] The term "non-woven" refers to a material made from continuous (long) and / or discontinuous (short) filaments (fibers) by processes such as spinning, melt blowing, carding, etc. Non-wovens do not include woven or knitted fabrics.

[0048] Preferably, the fibers and / or filaments are based on polypropylene or polyethylene or a polypropylene-polyethylene blend or polylactic acid or bi-component fibers of one or more of these materials or a blend of bi-component fibers of one or more of these materials.

[0049] Preferably, reliefs are present on each face respectively upper and lower of at least one layer of elastomeric material.

[0050] Preferably, reliefs are present on each face respectively upper and lower of at least one layer of non-woven material.

[0051] The present invention also relates to an elastomeric layer intended to form part of an elastic laminate comprising the elastomeric layer fixed to at least one non-woven layer, the elastomeric layer extending widthwise in a first direction, in particular CD, and lengthwise in a second direction, in particular MD, at least one relief, in the unstretched state of the elastomeric layer, being formed on an upper face of the elastomeric layer, the relief being delimited by a peripheral relief edge, having a greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, a greatest relief width, the ratio of the greatest relief length, in particular in the first direction, in particular CD, to the greatest relief width, in particular in the second direction, in particular MD,or aspect ratio being strictly greater than 1, in particular being at least equal to 1.2, preferably greater than or equal to 2, even more preferably greater than or equal to 5, and the longitudinal relief direction not being perpendicular to the first direction (or in other words, making an angle other than 90° or 270° with the first direction), in particular making an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

[0052] The present invention also relates to a layer (1; T) of elastomeric material intended to form part of an elastic laminate comprising the elastomeric material layer fixed to at least one non-woven layer, the elastomeric material layer extending in width in a first direction, in particular CD, and in length in a second direction, in particular MD, comprising a plurality of reliefs, in the unstretched state of the layer, each relief being delimited by a peripheral relief edge, having a greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, a greatest relief width, the ratio of the greatest relief length, in particular in the first direction, in particular CD, to the greatest relief width, in particular in the second direction, in particular MD, or aspect ratio being strictly greater than 1,in particular being at least equal to 1.2, preferably greater than or equal to 2, even more preferably greater than or equal to 5, and the longitudinal direction of relief not being perpendicular to the first direction, in particular making an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

[0053] The present invention also relates to a method for manufacturing a layer of elastomeric material according to the invention.

[0054] According to the invention, the process comprises the steps in which - a layer of elastomeric material, preferably without raised features, in a softened state, is extruded from an extrusion nozzle; and - the elastomeric material layer is passed in a softened state over a roller or an endless conveyor belt having cavities and / or protrusions to form reliefs of complementary or substantially complementary shape to the cavities and / or protrusions, in particular to a surface of the elastomeric material layer.

[0055] According to a favorable embodiment, the extrusion step is carried out continuously in the MD direction.

[0056] According to a favorable embodiment, the extruded elastomer layer, preferably without reliefs, in a softened state is sent, directly or indirectly, onto a conveyor belt having notches on its surface which open in the rounded areas of its path and the extruded layer being deposited on the conveyor belt in one of these rounded areas, to form reliefs on a surface of the elastomer layer.

[0057] As an example, the shape of the reliefs can be of different forms, for example having rounded, chamfered, softened or other edges and / or having a general shape of rectangle, square, triangle, trapezoid, arc, arc of circle or even in a form resulting from the combination of one or more of these different forms.

[0058] According to another favorable embodiment, the layer of extruded elastomer material, preferably without reliefs, in the softened state is sent, directly or indirectly, onto a forming roller having cavities, the layer exiting the roller having ribs of complementary or substantially complementary shape to the cavities.

[0059] Preferably, a vacuum system can be provided to draw material from the extruded elastomer layer, preferably without reliefs, especially in the softened state, into the cavities.

[0060] Preferably, hot air heating can also be provided on the outer surface of the extruded elastomer layer, preferably without reliefs, to soften it and / or to keep it in a softened state during its passage over the forming roller.

[0061] According to yet another favorable embodiment, the elastomer material layer in the softened state, preferably without reliefs, is sent, directly or indirectly, between two rollers respectively of support and engraving, the engraving roller having calendering ribs, the elastomer material layer exiting the roller having hollows of complementary or substantially complementary shape to the calendering ribs.

[0062] The layer of extruded elastomer material, preferably without reliefs, in a softened state is sent, directly or indirectly, onto an engraving roller, the engraving roller having calendering ribs, the layer exiting the roller having hollows of complementary shape to the calendering ribs.

[0063] According to one embodiment, the steps of extruding the elastomer material layer by an extrusion nozzle, and of passing the elastomer material layer in a softened state over a roller or a conveyor belt are carried out on the same production line.

[0064] According to another embodiment, the steps of extruding the elastomeric material layer by an extrusion nozzle and of passing the elastomeric material layer in a softened state over a roller or a conveyor belt are separated by a winding and unwinding step of the elastomeric material layer, for example to carry out the two steps on different production lines.

[0065] According to another embodiment, the elastomeric material layer includes a skin layer (or “skin layer” according to the English designation, which is common in the field).

[0066] The present invention also relates to a method of manufacturing a laminate according to the invention, consisting of obtaining a layer of elastomeric material according to the invention by the above process and fixing the layer of elastomeric material obtained on a layer of non-woven material, in particular by lamination and / or by welding, in particular by ultrasound and / or by encapsulation, in particular at least partially, by at least one layer of elastomeric material (namely either the base or the reliefs) of one or more fibers / filaments.

[0067] According to a favorable embodiment, the step of fixing the elastomeric material layer with the non-woven layer is carried out continuously in the MD direction, for example the elastomeric material layer comprising a base part.

[0068] According to a favorable embodiment, the step of fixing the elastomeric material layer with the non-woven layer is carried out discontinuously or intermittently in the MD direction, for example the elastomeric material layer comprising reliefs spaced apart and distinct from each other.

[0069] According to one embodiment, before fixing the non-woven layer to the elastomeric layer, a strip of adhesive, in particular glue, is placed on the elastomeric layer and / or on the non-woven layer, then the non-woven layer is laminated onto the elastomeric layer, in particular on the base of the elastomeric layer and / or on the relief(s) forming the elastomeric layer.

[0070] According to another embodiment, the layer of extruded elastomer material is kept hot after the reliefs have been formed and is sent into a gap between two rollers between which also passes at least one layer of non-woven material to create the bond between the layers.

[0071] According to another aspect, the present invention also relates to a method of manufacturing a laminate according to the invention, consisting of depositing at least one layer of elastomeric material made up of a plurality of elastomeric material strips to form at least one plurality of reliefs on at least one layer of non-woven material and fixing the at least one strip on the at least one layer of non-woven material, in particular by lamination and / or by welding, in particular by ultrasound, and / or by encapsulation, in particular at least partial, by the elastomeric material reliefs of one or more fibers / filaments.

[0072] According to one embodiment, the strips are laid and fixed onto at least one layer of nonwoven material over a width less than that of the at least one layer of nonwoven material. In particular, the ratio of the length of a strip, particularly in the first direction, particularly CD, to the width of the nonwoven material, particularly in the first direction, particularly CD, is greater than or equal to 60%, particularly greater than or equal to 70% and / or less than or equal to 100%, particularly less than or equal to 95%.

[0073] The present invention also relates to an absorbent article, for example a baby diaper or an adult incontinence diaper comprising at least one laminate according to the invention, in particular to form the hook legs from laterally from the back waistband of the diaper or incontinence diaper, so that the hooks cooperate with loops from the front face of the waistband of the diaper, to achieve the closure of the diaper or incontinence diaper, in particular to form part of an elastic waistband, for example a front and / or back part of an elastic waistband of an absorbent article.

[0074] The present invention also relates to an absorbent article, for example, of the diaper type (open or closed "pants") for babies or an incontinence diaper (open or closed "pants") for adults, which includes, - an upper sheet, a lower sheet and an absorbent core, arranged between the two upper and lower sheets, - at least one elastic laminate as defined previously.

[0075] The present invention also relates to an elastic hook laminate, comprising a laminate according to the invention and at least one hook web fixed to the laminate, in particular on the upper non-woven layer, preferably in an area without inverted U and / or inverted V and / or Q.

[0076] In one example, the laminate is in the form of a roll, the longitudinal dimension of the laminate extending in a circumferential direction around said roll.

[0077] The present invention also relates to a roll which includes a laminate according to the invention, which laminate having a length of at least 1 meter and being wound around an axis perpendicular to the MD axis, which laminate comprising a single layer of elastomeric material, for example extending over a width (here perpendicular to the MD axis) only of the elastic laminate or over the entire width of the elastic laminate, or at least two adjacent layers of elastomeric material.

[0078] In particular, the laminate according to the invention has a greater length, especially in the second direction, particularly MD, than width, particularly in the first direction, particularly CD, particularly in a ratio greater than 1.25, particularly greater than 2, particularly greater than 50, more particularly greater than 100 and, preferably, less than 10,000, 5,000, 2,000 or 1,000. In particular, the laminate is rolled and / or unrolled, particularly in its length direction.

[0079] In particular, the laminate according to the invention has a greater length, in particular in the first direction, in particular CD, than width, in particular in the second direction, in particular MD, in particular in a ratio greater than 1.25, in particular greater than 2, in particular greater than 50, more particularly greater than 100 and, preferably, less than 10,000, 5,000, 2,000 or 1,000. In particular, the laminate is rolled and / or unrolled, in particular in the direction of its length.

[0080] The term "disposable" refers to items, for example disposable laminates, which are not generally intended to be washed or restored or reused as a laminate, i.e., they are intended to be discarded after fewer than 5 uses, preferably fewer than 3 uses after being fitted to the specified application, for example, and preferably to be recycled, composted or otherwise disposed of in a manner compatible with the environment and regulations.

[0081] The terms "elastic", "elastomer" or "elastomer" refer to materials exhibiting elastic properties, in particular any material which, under the effect of a force exerted on its initial relaxed length, can stretch or elongate to a length more than 15% greater than its initial length and return substantially to its initial length upon release of the force exerted, particularly at room temperature (laboratory conditions).

[0082] The elastic laminate and / or the non-woven fabric(s) and / or the elastomeric material layer can be perforated.

[0083] The elastomeric material layer can be perforated, in particular and mainly outside of the reliefs, for example in the base of the elastomeric material layer.

[0084] The non-woven material(s) of the laminate can form folds and / or waves in the unstretched state, for example via an overfeeding of CD in the non-woven material.

[0085] For example, the developed width of the nonwoven layer(s) of the laminate may be greater (e.g., 10% greater, 20% greater, 30% greater, 40% greater, 50% greater) than the developed width of the elastomeric layer, particularly in the area directly above the elastomeric layer. In the present invention, the developed width of the nonwoven layer(s) of the laminate and / or the elastomeric layer refers to the largest dimension of the neutral fiber of the element under consideration, measured in a plane perpendicular to the first and / or second face of the nonwoven layer and / or the elastomeric layer.

[0086] The elastomeric material layer, in particular the base part, may have a thickness (ef), extending perpendicularly to the upper face of the layer, greater than or equal to 10 micrometers, in particular greater than or equal to 15 micrometers, preferably greater than or equal to 20 micrometers and / or less than or equal to 70 micrometers, in particular less than or equal to 60 micrometers, preferably less than or equal to 50 micrometers.

[0087] The relief, in particular each relief, may have a thickness (er1 and / or er2), extending perpendicularly to the upper face of the elastomeric material layer, greater than or equal to 20 micrometers, in particular greater than or equal to 30 micrometers, preferably greater than or equal to 40 micrometers and / or less than or equal to 400 micrometers, in particular less than or equal to 140 micrometers, in particular less than or equal to 120 micrometers, preferably less than or equal to 100 micrometers.

[0088] For example, the ratio (er1 / ef) or (er2 / ef) or (er1 +er2 / ef) of the thickness of the relief to the thickness of the elastomeric layer (excluding the relief or the base part of the elastomeric layer) is greater than or equal to 0.5, in particular greater than or equal to 0.7, preferably greater than or equal to 1.0, more preferably greater than or equal to 1.5 and / or less than or equal to 10, in particular less than or equal to 3.

[0089] The thickness of the elastomer layer, particularly of the base and / or reliefs, is typically observed from a photo obtained with a Keyence Corporation digital microscope under the reference "VHX 6000", for example at a magnification of X500 or equivalent, and the measurements are obtained with digital microscope image analysis software.

[0090] As one example, the elastomeric layer may comprise an inner sublayer encapsulated by two outer sublayers, each forming a skin layer to protect the inner sublayer. The plurality of ribs may be formed by the inner sublayer itself such that the two outer sublayers have equivalent thicknesses that are significantly less (at least 2, 3, 4, 5, or 10 times less) than the thickness of the inner layer. As another example, the elastomeric layer may comprise a single skin sublayer arranged on one face of the inner layer. The skin layer is typically made of a non-adhesive or tacky material that is not elastomeric. As yet another example, the elastomeric layer may lack a skin layer.

[0091] The projected area (or projected surface) of the relief(s) on the base of the elastomeric material layer and / or on the non-woven layer may represent an area greater than or equal to 5% of the total area of ​​the elastomeric material layer, in particular greater than or equal to 10% and / or less than or equal to 50% of the total area of ​​the base of the elastomeric material layer and / or the non-woven layer, in particular less than or equal to 30% of the area of ​​the base of the elastomeric material layer and / or the non-woven layer.

[0092] The projected area (or projected surface) of the relief(s) on the base of the elastomeric material layer and / or on the non-woven layer may represent an area greater than or equal to 10% (in particular 20%) of the total surface area of ​​the non-woven layer arranged directly above the elastomeric layer, in particular greater than or equal to 30% (in particular 50%) and / or less than or equal to 90% (in particular) of the total surface area of ​​the non-woven layer arranged directly above the elastomeric layer, in particular less than or equal to 60% of the total surface area of ​​the non-woven layer arranged directly above the elastomeric layer.

[0093] For example, the elastomeric layer and the raised feature(s) may be contiguous and / or made of the same material. In its resting state or when stretched, for example at 50% elongation, the raised feature(s) may have a thickness that varies according to the direction of stretching and / or the CD direction.

[0094] According to an example, the projected surface of the reliefs on the non-woven layer may represent an area greater than or equal to 10% (in particular 20%) of the total surface of the non-woven layer, in particular greater than or equal to 30% (in particular 45%) and / or less than or equal to 90% (in particular) of the total surface of the non-woven layer, in particular less than or equal to 65% of the total surface of the non-woven layer.

[0095] In its resting or stretched state, for example at 50% elongation, the relief(s) may exhibit a thickness that varies according to the direction of stretching and / or the CD direction. For example, the thickness may have a decreasing portion and / or an increasing portion along a straight line extending parallel to the CD direction and / or in the direction of elongation. As an example, the decreasing portion may decrease in the same direction as the stretching direction and / or exhibit one or more optimal thicknesses, or even exhibit a thickness that varies according to a general sinusoidal shape.

[0096] According to an example, the relief(s) is / are exclusively formed on the upper face of at least one layer (1; T) of elastomeric material.

[0097] According to an example, the relief(s) is / are formed on the upper face of the at least one layer (1; T) and on the lower face of the at least one layer (1; T).

[0098] For example, given that the relief(s) are formed on the upper surface of at least one layer (1; T) of elastomeric material and on the lower surface of at least one layer (1; T) of elastomeric material, the projection onto the upper surface of the relief(s) formed on the upper surface of the at least one layer of elastomeric material and the projection onto the upper surface of the relief(s) formed on the lower surface of the at least one layer overlap by more than 10%, in particular by more than 50%, preferably by more than 70%, and more preferably by more than 90%. Thus, the elastic laminate exhibits a symmetry that facilitates its manufacture.

[0099] The relief(s) being formed on the upper face of at least one layer (1; T) of elastomeric material and on the lower face of at least one layer (1; T) of elastomeric material, the projection onto the upper face of the relief(s) formed on the upper face of the at least one layer of elastomeric material and the projection onto the upper face of the relief(s) formed on the lower face of the at least one layer of elastomeric material overlap by less than 50%, in particular by less than 30%, preferably by less than 10%, and more preferably by less than 5%. Thus, the elastic laminate exhibits improved winding capacity.

[0100] According to an example, in the rest state, the projection on the upper face of the relief(s) formed on the upper face of the at least one layer of elastomeric material represents at least 5% of the upper face of the at least one layer of elastomeric material, in particular at least 10%, preferably at least 20%, even more preferably at least 25%, and / or less than 90% of the upper face, in particular less than 70%, preferably less than 60%, even more preferably less than 50%.

[0101] In one example, the invention relates to an elastic laminate for use in an absorbent article and / or a hygiene article. In another example, the invention relates to an elastomeric layer intended to form part of an elastic laminate for use in an absorbent article and / or a hygiene article. The absorbent article may, for example, be of the type open or closed diaper (for example of the "Pant" type according to the English designation) or even hybrid, for an adult or for a child.

[0102] According to yet another aspect of the invention, independent of the preceding aspects, an elastic laminate, extending in width in a first direction, in particular CD, and in length in a second direction, in particular MD, the elasticity of the laminate being greatest in at least one direction (F) of stretching, for example the direction CD, characterized in that it comprises: - at least one layer of non-woven fabric; and - at least a plurality of reliefs, for example in the form of strips, made of elastomeric material, fixed directly, possibly with interposition of an adhesive layer, for example a layer of glue, to at least one layer of non-woven material, and, in the unstretched state of the laminate, the reliefs being spaced apart from each other in the second direction, in particular MD, for example in a regular manner.

[0103] Preferably, a majority of reliefs, preferably each relief, being delimited by a peripheral relief edge, having the greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, the greatest relief width, the ratio of the greatest relief length, in particular in the first direction, in particular CD, to the greatest relief width, in particular in the second direction, in particular MD, or aspect ratio being strictly greater than 1, in particular being at least equal to 1.2, preferably greater than or equal to 2, still more preferably greater than or equal to 5.

[0104] Preferably, the longitudinal relief direction is not perpendicular to at least one (F) stretching direction, in particular makes an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

[0105] Preferably, the reliefs can have the same shape.

[0106] Preferably, the landforms can be at the same distance from each other.

[0107] According to an advantageous embodiment, the distance in the second direction, in particular MD, between two reliefs is greater than the dimension of each of the two reliefs in this same second direction, in particular MD.

[0108] According to another advantageous embodiment, the distance in the second direction, in particular MD, between two reliefs is less than the dimension of each of the two reliefs in this same second direction, in particular MD, but however without two reliefs being in contact with each other, in particular without the facing edges of the two reliefs being in contact with each other.

[0109] By way of example, several embodiments of the invention are now described with reference to the drawings, in which:

[0110] Figure 1 is a top view of an embodiment of an elastomeric material layer according to the invention.

[0111] Figure 2 is a top view of a laminate according to the invention comprising the elastomeric material layer of Figure 1 and a non-woven layer.

[0112] Figure 3 is a cross-sectional view along line AA of Figure 2.

[0113] Figure 4 is a top view of another embodiment of an elastomeric material layer according to the invention.

[0114] Figure 5 is a cross-sectional view of a laminate according to the invention comprising the elastomeric material layer of Figure 4 and a non-woven layer.

[0115] Figure 6 is a cross-sectional view along line AA of Figure 5.

[0116] Figure 7 is a schematic representation of a method for manufacturing an elastomeric material layer according to the invention and a laminate according to the invention.

[0117] Figure 8 is a schematic representation of a method for manufacturing an elastomeric material layer according to the invention and a laminate according to the invention.

[0118] Figure 9 is a schematic representation of a method for manufacturing an elastomeric material layer and a laminate according to the invention.

[0119] Figure 10 is a top view of another laminate according to the invention comprising the elastomeric material layer of Figure 1 and a non-woven layer, the elastomeric material layer extending over the entire CD direction of the laminate, the rectangular ribs also extending in the CD direction over the entire width of the elastomeric material layer as well as the laminate.

[0120] Figure 11 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending over the entire CD direction of the laminate, the ribs, all identical in rectangular shape, also extending in the CD direction, but over a lesser width of the elastomeric layer than of the laminate, only one rib being present in the CD direction.

[0121] Figure 12 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending over the entire CD direction of the laminate, the ribs, all identical in rectangular shape, also extending in the CD direction, but over a lesser width of the elastomeric layer than of the laminate, the ribs being arranged along CD lines and MD columns, each line comprising several ribs and the ribs being aligned along the lines and columns.

[0122] Figure 13 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending along the entire CD direction of the laminate, the rectangular ribs also extending in the CD direction, but over a narrower width of the elastomeric layer than the laminate and discontinuously in the CD direction, arranged along CD lines and MD columns, each lines having several ribs and the ribs being aligned along the lines but offset along the columns.

[0123] Figure 14 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending over the entire CD direction of the laminate, the rectangular ribs also extending in the CD direction, but over a lesser width of the elastomeric layer as of the laminate and discontinuously in the CD direction, the ribs being of two types respectively of long length and short length being arranged along CD lines and MD columns, each line comprising alternately long and short ribs and each column also comprising alternately long and short ribs.

[0124] Figure 15 is a top view of another laminate according to the invention comprising an elastomeric material layer and a non-woven material layer, the elastomeric material layer extending over the entire CD direction of the laminate, the rectangular ribs also extending in the CD direction from one lateral edge of the laminate having a thickness which decreases towards the other lateral edge until ending at a distance from the other lateral edge.

[0125] Figure 16 is a cross-sectional view of Figure 15 at the level of a rib.

[0126] Figure 17 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending in the CD direction of the laminate over a width less than that of the laminate, the ribs, all identical in corrugated shape, also extending in the CD direction, over the entire width of the elastomeric layer but over a lesser width of the laminate.

[0127] Figure 18 is a top view of another laminate according to the invention comprising an elastomeric layer and a layer of non-woven, the elastomeric layer extending over the entire CD direction of the laminate, the ribs, all identical in rectangular shape, extending inclined relative to the CD direction from one lateral edge to the other of the laminate and the elastomeric layer.

[0128] Figure 19 is a top view of another laminate according to the invention comprising an elastomeric layer and a non-woven layer, the elastomeric layer extending in the CD direction over a width less than that of the laminate, the arc-shaped ribs also extending in the CD direction, but over a width less than that of the elastomeric layer than the laminate and discontinuously in the CD direction, the ribs being of two types, respectively with their concavity facing upwards and downwards, being arranged along lines CD and columns MD, each line comprising in succession alternately arc-shaped ribs with concavity upwards and downwards and each column also comprising in succession alternately arc-shaped ribs with concavity upwards and downwards.

[0129] Figure 20 is a cross-sectional view of an example of an elastomeric material layer according to the invention, with ribs formed only on the upper face of the layer.

[0130] Figure 21 is a cross-sectional view of an example of an elastomeric material layer according to the invention, ribs being formed on both the upper and lower face of the layer, the lower ribs being offset from the upper ribs in the vertical direction (the direction in which thicknesses are measured) and / or in the stretching direction.

[0131] Figure 22 is a cross-sectional view of an example of an elastomeric material layer according to the invention, ribs being formed on both the upper and lower faces of the elastomeric material layer, the lower ribs being arranged in correspondence with the upper ribs in the vertical direction (direction in which thicknesses are measured) and / or in the stretching direction.

[0132] Figure 23 is a top view of another laminate according to the invention comprising strips of elastomeric material and a non-woven layer, the elastomeric material strips extending in the CD direction of the laminate over a width less than that of the laminate.

[0133] Figure 24 is a cross-sectional view along line AA of Figure 23 representing only the elastomeric material layer.

[0134] Figure 25 is a cross-sectional view along line BB of Figure 23 representing only the elastomeric material layer.

[0135] In figures 2, 5, 10 to 19 and 23, the elastomeric material layer is represented by dotted lines.

[0136] Figure 1 shows a first embodiment of a layer 1 made of elastomeric material according to the invention.

[0137] The elastomeric layer 1 comprises a rectangular base portion 4, which is longer than it is wide. Specifically, the length corresponds to the MD direction of extension of the extruded profile during the manufacturing of the elastomeric layer.

[0138] Oblong or elongated ribs 5 protrude from an upper face 6 of the base part 4 of layer 1.

[0139] The ribs, forming reliefs here, for example according to a view perpendicular to the upper surface, have a length greater than their width, in particular in a ratio of at least 1.2, in particular at least 2, in particular at least 5, the length extending in the direction CD perpendicular to the direction MD.

[0140] The ribs 5 are regularly spaced from each other along the MD direction of the elastomeric layer 1. However, they may not be regularly spaced and / or may have a different number of columns.

[0141] The ribs 5 extend from one lateral edge of the base part 4 to the other lateral edge. However, they could also be located at a distance from one or both lateral edges. Furthermore, the ribs are all They are identical. However, they may have different shapes and / or dimensions.

[0142] Figure 2 shows a top view of a laminate 3 comprising a non-woven layer 2 and the elastomeric material layer of Figure 1, the elastomeric material layer being shown in dotted lines.

[0143] Laminate 3 has the greatest elasticity in its width direction. This direction is called the principal stretch direction F. The principal stretch direction F corresponds to the main stretch direction of the elastic laminate after it has been mounted in the specified application. In the case of an absorbent product such as a diaper, the principal stretch direction typically corresponds to the manufacturing direction CD of the laminate. Indeed, since diaper manufacturing line speeds range from 700 diapers per minute to over 1000 diapers per minute, there are significant technical constraints to using the laminate in another direction while still achieving suitable elasticity. It can, for example, correspond to the CD direction, as shown, which is perpendicular to the manufacturing direction MD.However, the laminate could also have its primary stretch direction along its width, which may or may not correspond to the MD manufacturing direction.

[0144] Figure 3 shows a cross-sectional view along line AA of Figure 2. The non-woven layer 2 and the elastomeric layer 1 were bonded together by hot lamination. An adhesive layer, such as glue, or ultrasonic welding or a similar method could have been used instead, for example, by encapsulating at least one or more fibers / filaments, at least partially.

[0145] The fibers and / or filaments constituting the nonwoven layer extend predominantly in the direction perpendicular to the main stretch direction. However, without departing from the scope of the invention, any other predominant orientation of the fibers and / or filaments could be envisaged.

[0146] Figure 4 shows another embodiment of an elastomeric material layer T according to the invention.

[0147] The elastomeric layer T comprises a rectangular base portion 4', which is longer than it is wide. Specifically, the length corresponds to the MD direction of extension of the extruded profile during the manufacturing of the elastomeric layer.

[0148] Oblong or elongated ribs 5' protrude from an upper face 6' of the base part 4' of the elastomeric layer T.

[0149] The ribs have a length greater than their width, in particular in a ratio of at least 1.2, in particular at least 2, in particular at least 5, the length extending in a direction making a non-zero angle with the MD direction, namely, in the example shown, an angle of approximately 45° with the MD direction. Other values ​​of the angle are possible without departing from the scope of the invention, only a rib parallel to the MD direction of the elastomeric material layer T is not as described in the invention.

[0150] The 5' ribs are arranged in at least two columns extending in the MD direction and are regularly spaced. However, they may not be regularly spaced.

[0151] The ribs of the two columns are oriented so that the ribs of one column are symmetrical to the ribs of the other column with respect to the central MD axis, which intersects the elastomer T layer at its midpoint. However, other arrangements are possible, including identical columns or a greater number of columns. Furthermore, the ribs are all identical in shape and size. However, they could have different shapes and / or dimensions from each other, even within the same column.

[0152] Figure 5 shows a top view of a 3' laminate comprising a 2' layer of non-woven material and the elastomeric material layer of Figure 4, the elastomeric material layer being represented by dotted lines.

[0153] The 3' laminate has the greatest elasticity in its width direction. This direction is called the principal stretch direction. It can, in particular, correspond to the CD direction, as shown. perpendicular to the manufacturing MD direction. However, the laminate could also have its principal stretch direction along its length, which may or may not correspond to the manufacturing MD direction.

[0154] Figure 6 shows a cross-sectional view along line AA of Figure 5. The non-woven layer 2' and the elastomeric layer T were bonded together by hot lamination. An adhesive layer, such as glue, or ultrasonic welding or a similar method could have been used instead.

[0155] The fibers and / or filaments constituting the nonwoven layer extend predominantly in the direction perpendicular to the main stretch direction. However, without departing from the scope of the invention, any other predominant orientation of the fibers and / or filaments could be envisaged.

[0156] The 3' laminate of figures 5 and 6 comprises a 2' top non-woven layer and a 7' bottom non-woven layer, the two layers being either the same type of non-woven or two different types of non-woven.

[0157] The laminate 3 shown in Figures 2 and 3 comprises only one non-woven layer 2. It could, as in the embodiment shown in Figures 5 and 6, also comprise two layers. Similarly, the laminate 3' could comprise only the upper non-woven layer 2'.

[0158] The 2' nonwoven layer has corrugations which, in cross section CD, form a kind of accordion with curved sections in inverted U, or inverted V or omega O shape or inverted V shape with the two feet squeezed together, the attachment of the elastomeric layer T to each 2' and 7' nonwoven layer being effected along a plurality of continuous or discontinuous lines extending along the MD direction, some of the plurality of attachment lines being fixed to one or more ribs.

[0159] One could also provide for the embodiment shown in Figures 2 and 3 such an accordion-folded layer of non-woven fabric, and similarly, one could also provide an unfolded accordion-style non-woven material for one or both layers of non-woven material in the embodiment shown in Figures 5 and 6.

[0160] Figure 7 shows an embodiment of a laminate manufacturing installation according to the invention, comprising a manufacturing station 100 of a layer 1 of elastomer material followed by a lamination station 105 of layer 1 with a non-woven layer 2.

[0161] Station 100 includes an extruder 101 which delivers to the outer surface of a conveyor roller 102 a profile 103 of elastomer material in a softened form, in particular at a temperature that can be between 80 °C and 200 °C, a speed that can be between 50 and 250 m. / min and a pressure that can be between 10 N / mm and 150 N / mm, depending in particular on the desired shape of the reliefs, the desired number of reliefs as well as the elastomer material used, for example for the specific case of a layer of elastomer material based on Polyolefin elastomer of the Vistamaxx® family, a temperature of 150°C, a speed of 120 m. / min and a pressure of 22 N / mm can be used for a pattern according to figure 1.The elastomeric material profile deposited on the roller 102 is conveyed by the roller 102 along its outer surface to a gap formed between the conveying roller 102 and a calendering roller 104 having reliefs on its outer surface, in particular grooves oriented in the direction CD, so that, at the exit of the gap, reliefs are formed on the face of the profile 103 facing the calendering roller, in particular ribs extending lengthwise in the direction CD, thus obtaining the elastomeric material layer 1.

[0162] As an example, the elastomer material in softened form is generally at a temperature above 45°C (at atmospheric pressure) and at a temperature below the processing (extrusion) temperature of the elastomer material, in particular the processing (extrusion) temperature of the elastomer material reduced by 30°C or 50°C.

[0163] The rolling station 105 consists of the calendering roller 104 and a rolling roller 106 through which the non-layer 2 is conveyed woven up to the gap between the calendering roller 104 and the laminating roller 106, where layer 1 and layer 2 are laminated, in particular according to an example of operating conditions in which roller 106 is at 50°C and roller 104 at 90° with a speed of 120 m / min and a pressure of 110 N / mm for a relief shape corresponding to figure 7. A laminate 3 or 3' according to the invention is then obtained at the output.

[0164] The calendering roller 104 can be made by stacking discs forming the reliefs on the outer surface of the calendering roller 104 or by machining the outer surface of the calendering roller 104 or by a sleeve fitted to the outer surface of the calendering roller 104, which sleeve includes reliefs.

[0165] According to an alternative embodiment of Figure 7, the roller 102 can be omitted so that the extruder 101 delivers softened material directly onto the outer surface of the calendering roller 104. For example, the elastomeric layer comprising the base and the reliefs, or alternatively, the elastomeric layer comprising only the reliefs (without a base), can be formed by simply filling the grooves arranged on the surface of the roller 104.

[0166] Figure 8 shows an embodiment of an installation 200 for manufacturing a layer of elastomeric material according to the invention.

[0167] At the exit of installation 200, the layer obtained can be sent to a (not shown) rolling installation in which it is laminated, for example by calendering, to one or more layers of non-woven material to obtain a laminate according to the invention.

[0168] The installation 200 includes an extruder (not shown) delivering a profile 203 of elastomer material in a softened form, in particular at a temperature of 120°C, a speed of 50 m / min and an air vacuum on the suction sector of 4 to 10 times lower than atmospheric pressure, to the outer surface of a forming roller 201 having cavities 202 of complementary or substantially complementary shape to the ribs that are to be formed on the surface of the layer of elastomer material, in particular grooves oriented in the direction CD.

[0169] Preferably, a vacuum-generating system 204 is provided to draw the profile into the cavities 202 on a corner sector of the roller. In addition, a hot air generation system 205 may be provided to maintain the profile in a sufficiently softened state to allow it to easily penetrate the cavities 202.

[0170] At the end of the suction sector, the elastomer material layer 1 is obtained at the outlet, which can then be sent to the laminating installation with one or more layers of non-woven material to obtain a laminate according to the invention.

[0171] Figure 9 shows an embodiment of a laminate manufacturing installation according to the invention, comprising a station 300 for manufacturing a layer 1 of elastomer material followed by a station 304 for laminating the layer 1 with a layer 2 of non-woven material.

[0172] Station 300 includes an extruder 301 which delivers to an endless conveyor belt 302 a profile 303 of elastomer material in a softened form, in particular at a temperature of 210°C and a speed of 150 m / min.

[0173] The endless belt 302 has notches 305 spaced at regular intervals along its length, the notches being formed to extend in the transverse or CD direction of the belt. In the curved sections 306 of the endless belt 302, the notches, due to the inherent elasticity of the belt material, tend to flare out to form a V-groove, which can thus receive a portion of the material from the profile extruded by the extruder 301 positioned to deliver the extruded profile to a curved section 306 of the endless belt.

[0174] When the notches close at the exit of the curved section 306, the material of the profile is expelled from the notches and then forms corresponding ribs on the face of the profile turned away from the mat, thus obtaining a layer 1 of elastomer material according to the invention.

[0175] Layer 1 is then laminated by a 307 roller at a temperature of 50°C, a speed of 150 m / min and a pressure of 18 N / mm, with a non-woven layer 2 in a lamination gap formed between the mat 302 wireless and a laminating roller 307, the non-woven layer 2 being pre-conveyed by an infeed roller 308.

[0176] The processes described above for manufacturing layer 1 of figures 1 to 3 are adaptable without difficulty to produce layers of elastomeric material according to the invention with reliefs different from the ribs of layer 1, in particular to manufacture layer T of figures 4 to 6 or the layers of elastomeric material of the laminates of figures 10 to 19, only the dimensions and shapes of the cavities of the forming rollers or endless conveyor belts need to be adapted to the desired shape of the reliefs on the final layer, in particular the ribs of layer T.

[0177] Furthermore, according to a variant embodiment of each of the embodiments, an elastomeric material layer can be made without a base portion, so that only the reliefs are present, in particular directly arranged, on the non-woven layer.

[0178] According to the invention, an adhesive such as a non-reactive PSA (Pressure Sensitive Adhesive), for example Bostik's H2465, or a reactive PU adhesive, in particular Bostik's XPU18314, can be used. Preferably, these adhesives will have a chemical nature similar to the elastomeric layer. For example, if one of these adhesives is analyzed with an infrared spectrometer to identify the chemical functional groups, or with liquid chromatography to separate and quantify the substances, traces of one or more components or their derivatives of the material(s) of the elastomeric layer will preferably be found.

[0179] Preferably, these adhesives are based on SIS, SBS, SEBS and SEPS, allowing good affinity with the elastomeric material layer through similar chemical substances.

[0180] Preferably the glue layer has a weight of less than 15g / m² 2 , in particular less than 12g / m³ 2 , preferably less than 9g / m 2 , even more preferably less than 6g / m 2 .

[0181] In the present invention, a nonwoven fabric is defined as a product obtained by consolidating a web of fibers and / or filaments. Consolidation may be mechanical, chemical, or thermal. This translates to the presence of bonding between the fibers and / or filaments. This bonding can be direct, meaning it is achieved directly between the fibers and / or filaments by welding, or it can be indirect, meaning it is achieved through an intermediate layer between the fibers and / or filaments, such as a layer of glue or a layer of binder. The term nonwoven refers to a ribbon-like or sheet-like structure of fibers and / or filaments that are interwoven in a non-uniform, irregular, or random manner. A nonwoven can have a single-layer or multi-layer structure. A nonwoven can be made from various synthetic and / or natural materials. Natural materials, for example, are cellulose fibers, such as cotton, jute, paper pulp, flax, and similar materials, and can also include reprocessed cellulose fibers, such as rayon or viscose (cellulose acetate).Natural fibers for a nonwoven material can be prepared using various processes such as carding. Synthetic materials by way of example include, but are not limited to, synthetic thermoplastic polymers, which are known to form fibers and / or filaments that include, but are not limited to, polyolefins, for example polyethylene, polypropylene, polybutylene and similar; polyamide, for example polyamide 6, polyamide 6.6, polyamide 10, polyamide 11, polyamide 12 and similar; polyesters, for example polyethylene terephthalates, polybutylene terephthalates, polylactic acids (PLA) and similar, polycarbonates, polystyrenes, thermoplastic elastomers, polymeric vinyls, polyurethanes and mixtures and copolymers thereof.Some of these materials can be bioplastic, for example, bio-based (e.g., Bio-PE, PLA or PHA (Polyhydroxyalkanoates), polyamide 11, viscose (cellulose acetate), and similar materials) and / or biodegradable (PLA and similar materials). Generally, fibers and filaments differ primarily in their length and manufacturing process.

[0182] The term "continuous filaments" refers to unit elements, of very long lengths relative to the diameter in which their cross-section is inscribed, extruded continuously to directly form a sheet of non- woven material that can then be consolidated by thermal bonding or any other means to achieve the desired performance and / or facilitate transport. Preferably, the continuous filaments have a length greater than 120 mm.

[0183] The term "fiber" refers to a generic term for a textile material or element of textile material of short length, less than the length of continuous filaments, and capable of being spun and / or used in the production of nonwovens. Two types of fibers are distinguished: short fibers, formed from discontinuous material of short length less than 50 mm (preferably 25 mm to 50 mm), and long fibers, formed discontinuously and of greater length than 50 mm (preferably 60 mm to 120 mm).

[0184] Unlike continuous filaments, which are consolidated directly after extrusion, fibers are commonly oriented and arranged into a web during a carding step well known to those skilled in the art. This web can then be consolidated by thermal bonding or any other means to achieve the desired performance and / or facilitate transport.

[0185] Examples of elastomeric materials include, but are not limited to: styrene / isoprene (SI), styrene / isoprene / styrene (SIS), styrene / butadiene / styrene (SBS), styrene-ethylene / butylene-styrene (SEBS), styrene-ethylene / propylene-styrene (SEPS), and SIBS copolymers. Blends of these elastomers with each other or with non-elastomers that modify certain characteristics other than elasticity may also be considered. For example, up to 50% by mass but preferably less than 30% by mass of polymer may be added in order to modify certain characteristics of the base materials (elasticity, heat resistance, processability, UV resistance, color, etc.), such as polystyrenes or poly α-methyl styrene, epoxy polyesters, polyolefins, for example polyethylenes or certain ethylene / vinyl acetates, preferably those with higher molar masses.

[0186] The elastomeric material may be, in particular, a styrene-isoprene-styrene compound, available, for example, from Kraton Polymers under the name KRATON D (Registered Trademark), or from DEXCO POLYMERS LP (in the USA) or TSRC (in Europe) under the name VECTOR SBC 4211 (Registered Trademark) and / or VECTOR SBC 4111 (Registered Trademark) and / or VECTOR SBC 4411 (Registered Trademark), or a mixture of at least two of these materials. Thermoplastic elastomer (TPE) materials may also be used, in particular a thermoplastic polyurethane elastomer, notably ESTANE (Registered Trademark) 2102-75A-TPU from LUBRIZOL. A styrene-butadiene-styrene compound can also be used, in particular VECTOR SBC 4461 (Registered Trademark) from Dexco Polymers a TSRC COMPANY LP. A styrene-ethylene / butylene compound, or a sequence styrene-ethylene-butylene-styrene (SEBS) copolymer, can also be used.

[0187] The list, while not exhaustive, can be supplemented by the use of all hydrogenated polyisoprene polymers such as styrene-ethylene-propylene-styrene (SEPS), styrene-ethylene-propylene-styrene-ethylene-ethylene-propylene (SEPSEP), hydrogenated polybutadiene polymers such as styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-butylene-styrene-ethylene-ethylene-butylene-ethylene-butylene-butylene (SEBSEB), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-isoprene-butadiene-styrene (SIBS), hydrogenated polyisoprene / butadiene polymers such as styrene-ethylene-ethylene-ethylene-propylene-styrene (SEEPS), and triblock vinyl-hydrogenated polyisoprene / polyisoprene polymers. hydrogenated / polyisoprene / polystyrene, such as HYBRAR 7311, commercially available (Kuraray America, Inc., Houston, Tex.), and their combinations.

[0188] Polymer block configurations such as diblock, triblock, multiblock, multiblock, star, and radial are also considered in this disclosure. In some cases, sequenced copolymers with higher molar masses may be desirable. Sequenced copolymers are available from Kraton Polymers US LLC of Houston, Texas. The designations, for example Kraton D1184, Kraton FG1901 and Kraton FG1924, are sold under the name Septon 8007 by Kuraray. Dynasol is another potential supplier of these polymers.

[0189] One can also use a copolymer of isooctyl acrylate and acrylic acid with monomer ratios of 90 / 10, which is a thermoplastic with physical crosslinking in the absence of a crosslinker.

[0190] Other possible materials are polyolefin polymers, mainly copolymers of ethylene and / or propylene, having characteristics of elastomers, especially those produced by metallocene catalysis, such as VISTAMAXX VM-1120 (Trademark), available from Exxon Mobil Chemical, or polymers filled with rubber.

[0191] Examples of thermoplastic polyolefin-based elastomers usable in elastomeric material layers include, among others, a crystalline polyolefin, for example, a homopolymer or copolymer of an alpha-olefin having 1 to 20 carbon atoms, and comprising 1 to 12 carbon atoms.

[0192] The homopolymers and copolymers described below are examples of crystalline polyolefins.

[0193] (1) Ethylene homopolymer. Ethylene homopolymer can be prepared by any of the low-pressure and high-pressure processes.

[0194] (2) Ethylene copolymers and not more than 10 mole percent of alpha-olefins other than ethylene or vinyl monomers; for example, ethylene octene copolymer, available under the brand names Engage 8407 or Engage 8842 (Dow Chemical, Houston, Tex.).

[0195] (3) Polypropylene copolymers; examples include polypropylene impact copolymer PP7035E4 and polypropylene random copolymer PP9574E6 (Exxon Mobil, Houston, Tex, or polypropylene homopolymers).

[0196] (4) Random copolymers of polypropylene and not more than 10 mole percent of alpha-olefins - olefins other than propylene.

[0197] (5) Sequenced copolymers of polypropylene and not more than 30 mole percent of alpha-olefins other than propylene.

[0198] (6) Homopolymer of butene-1-butene.

[0199] (7) Random copolymers of 1-butene and not more than 10 mole percent of alpha-olefins - olefins other than 1-butene.

[0200] (8) 4-methyl-1-pentene homopolymer 4-methyl- 1-pentene.

[0201] (9) Random copolymers of 4-methyl-1-pentene and not more than 20 mole percent of alpha-olefins other than 4-methyl-1-pentene.

[0202] Alpha-olefins include, for example, ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene.

[0203] Among the commercially available polyolefin-based thermoplastic elastomers intended for use in elastomeric material layers are VISTAMAXX.TM. (propylene and / or ethylene-based elastomer, available from ExxonMobil Chemical, Houston, Texas), INFUSE.TM. (block olefin copolymers, available from Dow Chemical Company, Midland, Michigan), VERSIFY.TM. (propylene / ethylene elastomer, notably obtained via "INSITE technology") such as VERSIFY.TM. 4200 (Dow Chemical Company, Midland, Michigan), ENGAGE.TM. (ethylene octane copolymer, available from Dow Chemical, Houston, Texas), NOTIO 0040 and NOTIO 3560 (available from Mitsui Chemical (USA), New York, NY), and Adflex XWO G (available from LyondellBasell). The following materials could also be used: - a propylene elastomer, in particular the "Vistamaxx" range from EXXON MOBIL under references 6000 and / or 6102 and / or 6102FL and / or 6202 and / or 6202FL and / or 6502, 7050BF and / or 7810, and / or - a block olefin copolymer, in particular the "Infuse" range from DOW CHEMICAL under references 9000 and / or 9007 and / or 9010 and / or 9077 and / or 9100 and / or 9107, and / or - a polyolefin elastomer, in particular the "Engage" range from DOW CHEMICAL under references 8402 and / or 8401 and / or 8411 and / or 8407 and / or 8137 and / or 8200 and / or 8207, and / or a propylene-ethylene copolymer, in particular the "Versify" range from DOW CHEMICAL under references 3200 and / or 3300 and / or 3401 and / or 4200.

[0204] In a particularly suitable embodiment, the polyolefin-based thermoplastic elastomer is VISTAMAXX.TM. 6102FL or VISTAMAXX 7050 BF (available from ExxonMobil Chemical, Houston, Texas). The ".TM" designation for registered trademarks stands for "Trade Mark".

[0205] In another case, the thermoplastic elastomer may be a thermoplastic ester / ether elastomer.

[0206] The term "elastomeric material" refers to a material that can be stretched without breaking under a tensile force applied in a given direction and that can substantially return to its original shape and dimensions after the tensile force is released. For example, this could be an elastomeric layer that retains a residual deformation or set after elongation and release (residual deformation also called "permanent set" or "SET") of 30% or less, preferably 20% or less, and even more preferably 10% or less, of its initial dimension (before elongation) for an elongation of 100% of its initial dimension, at room temperature (23°C).The elastomeric material may be a thermoplastic elastomeric material, in particular a physically crosslinked thermoplastic elastomeric material, such as those described in this disclosure, or a chemically crosslinked thermoplastic elastomeric material.

[0207] The elastic laminate and / or the non-woven material(s) and / or the elastomeric material layer can be perforated, for example in the base part and / or in the relief(s).

[0208] Figures 20 to 22 define the thickness of the base part of the elastomeric layer, namely ef, the thickness of the upper ribs er1, which can vary depending on the rib considered, and the thickness of the lower ribs er2, which can vary depending on the rib considered.

[0209] Figure 23 illustrates yet another embodiment of the invention. The laminate of Figure 23 comprises a 2" layer of nonwoven fabric extending over a greater length in the MD direction and over a lesser width in the CD direction (horizontal in the figure). Rectangular, parallel 5" strips of elastomeric material are attached to the upper surface of the 2' layer. The strips run lengthwise in the CD direction. The parallel 5" strips are spaced apart. The 5" strips do not extend across the entire width of the 2' layer, so as to form two selvedges, left and right. However, without departing from the scope of the present invention, only one selvage or no selvage could be provided. Furthermore, again without departing from the scope of the present invention, 5" strips could be provided on each of the upper and lower surfaces of the 2' layer.We could also provide 5” strips on one of the two faces and one of the layers of elastomer material of the embodiments of figures 1 to 22 on the other face.

[0210] Figure 23 shows rectangular 5" strips, which in themselves form reliefs within the meaning of the invention. However, without departing from the scope of the present invention, different oblong shapes could be used, in particular the same shapes as those shown for the reliefs in Figures 1 to 22.

[0211] A raised feature of the invention is an element that protrudes (directly or optionally with the interposition of an adhesive or similar material) from the non-woven layer, or an element that protrudes (indirectly) from the non-woven layer. woven and protruding (directly or possibly with the interposition of an adhesive or similar material) from the base part.

Claims

Demands

1. Elastic (3; 3') laminate, extending widthwise in a first direction, in particular CD, and lengthwise in a second direction, in particular MD, the elasticity of the laminate being greatest in at least one stretching direction (F), for example direction CD, comprising: - at least one layer (2; 2', 7') of non-woven fabric; and - at least one layer (1; T) of elastomeric material fixed by an upper, or respectively lower, face to an upper, or respectively lower, face of at least one layer of non-woven fabric; characterized in that, - in the unstretched state of the laminate in said at least one stretching direction, the at least one elastomeric material layer comprises a plurality of reliefs (5; 5'; 5") in elastomeric material spaced apart in the second direction, each relief being delimited by a peripheral relief edge, having a greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, a greatest relief width; - the ratio of the greatest relief length, particularly in the first direction, particularly CD, to the greatest relief width, particularly in the second direction, particularly MD, or aspect ratio being strictly greater than 1, particularly being at least equal to 1.2, preferably greater than or equal to 2, and even more preferably greater than or equal to 5; and - the longitudinal direction of relief is not perpendicular to the at least one direction (F) of stretching, in particular makes an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

2. Laminate according to claim 1, characterized in that at least one layer of elastomeric material comprises at least one part (4; 4') base, in particular rectangular, the reliefs (5; 5') being formed on an inferior and / or superior face of at least a part of the base.

3. Laminate according to claim 1, characterized in that the reliefs (5”) are fixed directly, optionally with interposition of an adhesive or similar, on a lower and / or upper face of at least one layer of non-woven material.

4. Laminate according to any one of claims 1 to 3, characterized in that the majority of the reliefs, in particular each relief, has the form of a rib (5; 5'; 5") and / or a hollow and / or a band.

5. Laminate according to any one of the preceding claims, characterized in that at least one layer (2; 2', 7') of nonwoven comprises fibers and / or filaments oriented predominantly in a direction perpendicular to at least one direction (F) of stretching.

6. Laminate according to any one of the preceding claims, characterized in that at least one layer (2; 2', 7') of nonwoven has undulations which, in cross-section along the first direction, in particular in cross-section CD, in particular along a direction parallel to at least one stretching direction, form inverted U and / or inverted V and / or Q curved sections.

7. Laminate according to any one of the preceding claims, characterized in that the attachment of at least one elastomeric material layer to at least one non-woven layer is carried out along a plurality of lines, in particular continuous lines, extending along the second direction and / or in a direction perpendicular to the at least one stretching direction.

8. Laminate according to any one of the preceding claims, characterized in that at least one nonwoven layer comprises continuous filaments.

9. A laminate according to any one of the preceding claims, characterized in that at least one nonwoven layer comprises at least one meltblown nonwoven layer, in particular a Spunbond layer (S), in particular a Spunbond nonwoven, in particular a Spunbond based on crimped filaments (or "crimped" according to the English term commonly used in the field), or a Meltblown layer (M), or a combination of several of these layers (e.g. SM, SMS, SMMS, SSMMS, SSSMMS, SSSMMSS).

10. A layer (1; 1') of elastomeric material intended to form part of an elastic laminate comprising the elastomeric material layer attached to at least one nonwoven layer, the elastomeric material layer extending widthwise in a first direction, in particular CD, and lengthwise in a second direction, in particular MD, comprising a plurality of reliefs, in the unstretched state of the layer, each relief being delimited by a peripheral relief edge, having a greatest relief length along a relief length direction and, measured along the direction perpendicular to the relief length direction, a greatest relief width, the ratio of the greatest relief length, in particular in the first direction, in particular CD, to the greatest relief width, in particular in the second direction, in particular MD, or aspect ratio being strictly greater than 1, in particular being at least equal to 1.2,preferably greater than or equal to 2, even more preferably greater than or equal to 5, and the longitudinal direction of relief not being perpendicular to the first direction, in particular making an angle greater than or equal to 0° and / or less than or equal to 70°, preferably greater than or equal to 0° and / or less than or equal to 45°, with it.

11. A method for manufacturing an elastomeric layer according to claim 10, comprising the steps in which - a layer of elastomeric material, preferably without raised features, in a softened state, is extruded from an extrusion nozzle; and - the elastomeric material layer, in a softened state, is passed over a roller or an endless conveyor belt having cavities and / or protrusions to form, in particular on a surface of the elastomeric material layer, reliefs of complementary shape to the cavities and / or protrusions.

12. A method according to claim 11, characterized in that the extruded elastomer layer, preferably without reliefs, in its softened state, is sent onto a conveyor belt having on its surface notches which open in the rounded areas of its path and the layer of extruded elastomer material being deposited on the carpet in one of these rounded areas, to form reliefs, in particular on a surface of the layer of elastomer material.

13. A method according to claim 11, characterized in that the extruded elastomer layer, preferably without reliefs, in the softened state is sent onto a forming roller having cavities, the elastomer layer exiting the roller having ribs of complementary shape to the cavities.

14. A method according to claim 13, characterized in that it provides a vacuum system for sucking material from the layer of extruded elastomer material, preferably without reliefs, into the cavities.

15. A method according to claim 13 or 14, characterized in that it provides for heating by hot air on the outer surface of the extruded elastomer layer, preferably without reliefs, to soften it and / or keep it in the softened state during its passage over the forming roller.

16. A method according to claim 11, characterized in that the layer of extruded elastomer material, preferably without reliefs, in the softened state is sent directly or indirectly, onto an engraving roller, the engraving roller having calendering ribs, the layer exiting the roller having hollows of a shape complementary or substantially complementary to the calendering ribs.

17. A method for manufacturing a laminate according to any one of claims 1 to 9, consisting of obtaining an elastomeric material layer according to claim 10 by the method according to any one of claims 11 to 16 and fixing the elastomeric material layer obtained onto a non-woven layer, in particular by lamination and / or ultrasonic welding.

18. The method according to claim 17, characterized in that, before fixing the non-woven layer to the elastomeric layer, a layer is deposited on the elastomeric layer and / or on the a layer of non-woven material is coated with a strip of adhesive, in particular glue, and then the non-woven layer is laminated onto the elastomeric material layer.

19. A method according to claim 17 or 18, characterized in that the extruded elastomer layer is kept hot after the reliefs have been formed and is sent into a gap between two rollers between which the non-woven layer also passes.

20. Absorbent article, for example a baby diaper or an adult incontinence diaper comprising at least one laminate according to any one of claims 1 to 9, in particular for forming the hook tabs from laterally from the back waistband of the diaper or incontinence diaper, so that the hooks cooperate with loops from the front face of the waistband of the diaper, to achieve the closure of the diaper or incontinence diaper.

21. Elastic hook laminate, comprising a laminate according to any one of claims 1 to 9 and at least one web of hooks fixed to the laminate, in particular on the upper non-woven layer, preferably in an area without inverted U and / or inverted V and / or Q.

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