Composite elastic laminate
AssigneeKimberly-Clark Worldwide, Inc.
InventorsJose Augusto Vidal De Siqueira, Michael R. Vaughan
Life of this patent
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Abstract
A method of making a composite elastic laminate is provided where an elastic layer is stretched in the machine-direction and while in a stretched state is fed into a grooved-roll assembly, together with outer facing layers, for imparting simultaneous cross-direction stretching forces to the superposed layers. The bi-directional stretching forces causes the elastic layer to tear and/or rupture allowing the laminate to be bonded in areas where the elastic layer has been displaced. Upon relaxation, a composite elastic laminate is provided having excellent breathability and elastic properties.
Claims20
A method of making an elastic laminate comprising:
- stretching an elastic sheet in a first direction so as to be in a stretched state, said elastic sheet having first and second sides and comprising a thermoplastic elastomer;
- superposing a first fabric with the elastic sheet wherein the first fabric lies adjacent the first side of the elastic sheet, said first fabric comprising thermoplastic polymer fibers;
- superposing a second fabric with the elastic sheet wherein the second fabric lies adjacent the second side of the elastic sheet, said second fabric comprising thermoplastic polymer fibers;
- heating at least one of the elastic sheet, first fabric or second fabric;
- while the elastic sheet is in a stretched state relative to the first direction, engaging the superposed elastic sheet, first fabric and second fabric with an inter-meshing first and second set of ridges wherein the inter-meshing first and second set of ridges (i) stretch discrete segments of the superposed elastic film, first fabric and second fabric in a second direction substantially orthogonal to the first direction, (ii) displace the first sheet in columnar regions extending substantially in the first direction and (iii) forms inter-layer bonds with the first and second fabrics thereby forming a laminate;
- allowing the laminate to retract in the machine direction wherein the first fabric and second fabric form gathers and thereby forming an elastic laminate.
The method of 11 further comprising heating the elastic sheet immediately prior to and/or during engagement with the ridges.
A method of making an elastic laminate comprising:
- providing a first sheet comprising an elastic film having first and second sides and comprising a thermoplastic polymer;
- providing a second sheet comprising a nonwoven web of thermoplastic polymer fibers;
- directing the first sheet through a first roller assembly, said first roller assembly rotating at a first circumferential speed;
- after the first sheet exits the first roller assembly, superposing the second sheet with the first sheet wherein the second sheet lies adjacent the first side of the first sheet, the superposed sheets forming a sheet stack;
- heating at least one of the first and second sheets;
- directing the sheet stack in to a second roller assembly including a pair of grooved rolls, wherein the grooved rolls are spaced apart from another and each of the grooved rolls have a series of inter-meshing ridges and grooves and wherein the grooved rolls rotate at a second circumferential speed that is higher than the speed of the first roller assembly, and further wherein the ridges engage the sheet stack and thereby (i) causing the first sheet to elongate in the machine direction as it travels between the first and second roller assemblies, (ii) stretching the first and second sheets in the cross direction, (iii) regionally displacing the first sheet, and (iv) thermally bonding the sheets to one another to form a laminate;
- removing the laminate from the second roller assembly and allowing the laminate to retract in the machine direction thereby forming gathers within the second sheet and an elastic laminate.
Dependencies are inferred from the claim text.