Hydroentangled elastic film-based, stretch-bonded composites and methods of making same

Patent metadata

Field	Value
Publication number	US-2016332418-A1
Application number	US-201415105545-A
Country	US
Kind code	A1
Filing date	Dec 19, 2014
Priority date	Dec 20, 2013
Publication date	Nov 17, 2016
Grant date	—

Abstract

A stretch-bonded elastic nonwoven composite includes a machine-direction elastic apertured film-based, stretch-bonded laminate layer that has been hydroentangled throughout all of its laminate layers with a hydrophilic fibrous layer. The elastic apertured film-based, stretch-bonded laminate layer includes a middle elastic film layer positioned between one or two inelastic layers, each of which layers includes hydrophilic fibers from the hydrophilic fibrous layer.

First claim

What is claimed is:

1 . A process for making a stretch-bonded elastic nonwoven composite includes the steps of:
a) providing a machine-direction elastic, apertured film-based, stretch-bonded nonwoven laminate layer, itself having an apertured elastic film layer and at least one inelastic layer; b) stretching the stretch-bonded laminate layer in the machine direction such that the at least one inelastic layer is in a generally flattened configuration, and no rupture of the inelastic layer occurs; c) providing a hydrophilic fibrous layer on the stretched, apertured film-based, stretch-bonded nonwoven laminate layer, the fibrous layer including either staple fibers, substantially continuous fibers, pulp fibers or a combination thereof; d) hydroentangling the fibers of the hydrophilic fibrous layer into the elastic stretched, apertured film-based, stretch-bonded nonwoven laminate layer to produce a hydroentangled stretch-bonded elastic nonwoven composite that is absorbent to both aqueous and oil-based liquids; e) allowing the hydroentangled stretch-bonded elastic nonwoven composite to dry and relax; f) storing said hydroentangled stretch-bonded elastic nonwoven composite or moving said composite to a further product manufacturing process.

2 . The process of claim 1 , wherein said machine direction elastic apertured film-based, stretch-bonded laminate includes an elastic apertured mono-layered or multi-layered film.

3 . The process of claim 2 , wherein said elastic apertured monolayered or multilayered film includes apertures configured in multiple directions along said film dimensions.

4 . The process of claim 2 , wherein said elastic apertured monolayered or multi-layered film includes apertures having a longer dimension primarily along the cross-machine direction.

5 . The process of claim 1 , wherein said machine direction elastic apertured film-based, stretch bonded laminate includes two inelastic layers, one of each inelastic layer bonded to a separate side of a middle elastic apertured film layer.

6 . The process of claim 1 , wherein the stretching step is accomplished by a series of progressively faster moving rolls.

7 . The process of claim 6 , wherein the stretching step is accomplished by a pair of rolls in an S-wrap arrangement in which the ratio of speeds between the second roll farthest from the laminate source and the first roll closer to the laminate source is between about 1.1:1 and 5:1.

8 . The process of claim 7 , wherein the ratio of speeds is between about 1.5:1 and 3:1.

9 . The process of claim 1 , wherein the hydrophilic fibrous layer is cellulosic based.

10 . The process of claim 9 , wherein the hydrophilic fibrous layer is present initially in a basis weight range of between about 2 and 200 gsm.

11 . The process of claim 1 , wherein the pressure of fluid utilized in the hydroentanglement step is between about 500 and 5000 psi, alternatively between about 1400 and 3000 psi.

12 . The process of claim 1 , wherein the hydroentangled webs are moved passed a hydroentanglement manifold at a distance of between about 0.25 inch and 2 inches.

13 . The process of claim 1 , wherein the elastic apertured film layer of the elastic apertured film-based, stretch-bonded laminate has an open aperture area in the film layer of between about 2 and 40 percent before hydroentanglement.

14 . The process of claim 13 , wherein the open aperture area in the film layer is between about 10 and 30 percent.

15 . A stretch-bonded elastic nonwoven composite including a machine-direction elastic apertured film-based, stretch-bonded laminate layer that has been hydroentangled throughout all of its laminate layers with a hydrophilic fibrous layer.

16 . The stretch-bonded elastic nonwoven composite of claim 15 , wherein said apertured film-based, stretch-bonded laminate layer is comprised of a middle apertured, machine-direction elastic film that has been laminated between two inelastic nonwoven layers.

17 . The stretch-bonded elastic nonwoven composite of claim 16 , wherein said two inelastic nonwoven layers are selected from the group consisting of spunbond, meltblown, and bonded carded webs.

18 . The stretch-bonded elastic nonwoven composite of claim 17 , wherein said hydrophilic fibrous layer has a basis weight of between about 2 and 200 gsm and includes cellulosic fibers.

19 . A stretch-bonded elastic nonwoven composite that is absorbent to both aqueous and oil-based liquids made from the method of claim 1 .

20 . A wipe, medical product or personal care product made from the stretch-bonded elastic nonwoven composite of claim 19 .

Assignees

• Kimberly Clark Co

Inventors

• Jenkins Shawn E
• Baker Joseph K

Classifications

• B32B27/12 Primary

  next to a fibrous or filamentary layer · CPC title

• B32B5/06 Primary

  characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper · CPC title

• B32B2262/062

  Cellulose fibres, e.g. cotton · CPC title

• B32B2037/1072

  using a fluid jet · CPC title

• D10B2509/026

  Absorbent pads; Tampons; Laundry; Towels · CPC title