Stretchable composite sheet

A process for producing a stretchable composite sheet comprising a stretch sheet and a nonstretch sheet laminated with the stretch sheet, having a first direction and a second direction perpendicular to the first direction, and having in its natural, relaxed state a large number of ridges all over the area or in at least part of the nonstretch sheet side thereof, the stretch sheet having a first zone with elastic stretchability and a second zone with less elastic stretchability than that of the first zone, and the first and second zones extending in the first direction and alternate in the second direction,

• the process comprising bonding the stretch sheet and the nonstretch sheet to each other via an adhesive while the stretch sheet is in its stretched state such that the two sheets are bonded on their facing sides over substantially the entire area of a portion where the large number of ridges are to form;
• wherein a pitch of the ridges is 0.5 to 5 mm and a height of the ridges is 0.5 to 5 mm;
• wherein the stretch sheet is obtained by stretching a precursor sheet of the stretch sheet between a pair of intermeshing toothed surfaces each having alternate ridges and grooves to form the first and the second zones on the precursor sheet;
• wherein the stretch sheet is bonded to the nonstretch sheet while the stretch sheet is in a stretched state;
• wherein the stretch sheet comprises an extensible nonwoven fabric and a large number of elastic filaments bonded to the nonwoven fabric in their substantially nonstretched state over the whole length thereof, the elastic filaments being arranged to extend in the same direction without intersecting with each other, and the stretch sheet having stretchability in the direction in which the elastic filaments extend;
• wherein the elastic filaments are formed by drawing a filamentous elastic resin in a molten or softened state;
• wherein the precursor sheet comprises webs of the nonwoven fabric that are inextensible;
• and
• wherein a large number of elastic filaments extruded from a spinning nozzle are fusion bonded to the nonwoven fabric before solidifying while being drawn at a predetermined speed and oriented in one direction without intersecting with each other in order to form the stretch sheet.