The present invention provides a composite elastic necked-bonded material including at least one necked material joined to at least one elastic sheet. The composite elastic necked-bonded material is stretchable in a direction generally parallel to the direction of constriction or necking of the necked material. Also disclosed is a method of producing a composite elastic necked-bonded material by necking a neckable material and then joining the necked material to an elastic sheet.

Process for forming a composite elastic necked-bonded material

An improved method and apparatus for incrementally stretching "zero strain" stretch laminate webs to impart elasticity thereto in the direction of initial stretching, at least up to the point of initial stretching. The "zero strain" stretch laminate material is formed of at least two plies of material which are either intermittently or substantially continuously secured to one another along at least a portion of their coextensive surfaces while in a substantially untensioned ("zero strain") condition. One of the plies is stretchable and elastomeric, while the second ply is elongatable, but not necessarily elastomeric. The second ply will, upon stretching of the laminate, be at least to a degree permanently elongated so that, upon release of the applied tensile forces, it will not return to its original undistorted configuration. This results in z-direction bulking of the laminate web when the applied tension is released as well as subsequent elastic extensibility in the direction of initial stretching, at least up to the point of initial stretching. In a particularly preferred embodiment of the present invention the opposed peripheral edge portions of the laminate web to be incrementally stretched are subjected to restraint to substantially prevent inwardly directed slippage or contraction thereof in a direction parallel to the direction of stretching. This maximizes the effectiveness of the incremental web stretching operation by forcing the "zero strain" stretch laminate web to undergo the fullest possible degree of elongation during the incremental stretching operation.

Method for incrementally stretching a zero strain stretch laminate web to impart elasticity thereto

A disposable absorbent article, such as a diaper, is disclosed. The topsheet of the diaper is elastically extensible and provides a relatively low contact pressure against the skin of the wearer at relatively high elongations. This arrangement provides a diaper topsheet which can be elongated to conform to the shape of the wearer without causing undue discomfort or irritation. The relatively low ultimate contact pressure at relatively high elongation may be accomplished either through a low contact force differential material, or through a material which exhibits stress relaxation over a relatively short period of time. The topsheet may be a laminate having one elastomeric lamina and an inelastic lamina. Also disclosed is a method for making such a laminate.

Disposable absorbent article having elastically extensible topsheet

Providing quality management and intelligent manufacturing with labels and smart tags in event-based product manufacturing. Some of the disclosed embodiments include a system, method, and computer-readable media for storing, during a process, data associated with a material. Also disclosed are a method of collecting, storing, and reporting machine productivity, waste, and delay information on an event basis in a manufacturing system, a method of capturing and storing material history, a method of automating tracking of positions of components used in a process and correlating portions of a component with production problems, an improved inventory management system, and a method of tracking and recording actions of specific operators of a process performed by a machine. The embodiments are operable in an intelligent manufacturing system including a process for converting raw materials to a product, a process control system including one or more sensors capable of generating an alarm in response to an event that results in one of waste, machine delay, or decrease product quality, a data logger associated with the process control system for obtaining event parameters associated with the event, a database on a server for recording event parameters obtained by the data logger, and a reporting system cooperatively associated with the database for reporting productivity parameters regarding the process derived at least in part from the event parameters.

Quality management and intelligent manufacturing with labels and smart tags in event-based product manufacturing

Disclosed herein is a breathable film and a breathable, cloth-like film/nonwoven composite made from the breathable film which is stretch-thinned and bonded to a fibrous polyolefin nonwoven web. Certain thermoplastic films such as, for example, linear low density polyethylene films are difficult to thermally bond to, for example, polypropylene nonwoven webs due to the incompatibility of the two polymers. The present invention incorporates a bonding agent into one or both of the two layers thereby making it easier to thermally bond the two layers together. Processes for forming the various composite are also disclosed.

Breathable, cloth-like film/nonwoven composite

A method of producing a composite elastic material comprises stretching an elastic web to elongate it, for example, elongating a nonwoven web of meltblown elastomeric fibers, and bonding the elongated web to at least one gatherable web, such as a spunbonded polyester fiber material, under conditions which soften at least a portion of the elastic web to form the bonded composite web of elastic material. The composite material is relaxed immediately after the bonding to prevent the elastic web from losing its ability to contract from the stretched dimensions which it assumed during the bonding step. Such immediate relaxation of the composite material after the bonding step results in the elastic web retaining its ability to contract so that, upon termination of the elongating force, the elastic web contracts to form gathers in the gatherable web. The bonding may be effectuated by pattern embossing overlaid elastic and gatherable webs with at least portions of the elastic web heated to at least its softening temperature. The resultant composite elastic material comprises a coherent elastic web which is bonded to at least one coherent gatherable web whereby the gatherable web is extensible and contractible with the elastic web upon stretching and relaxing of the composite material.

Composite elastomeric material and process for making the same

A laminate which is elastic in at least one direction, includes an elastic sheet having at least one nonelastic nonwoven web joined thereto at least at two areas. The nonelastic web is gathered between the two areas. The elastic sheet is formed from a polyetherester and the nonelastic nonwoven web includes spunlaced hydraulically entangled polyester fibers. The nonelastic nonwoven web may also include rayon or wood pulp fibers.

Spunlaced polyester-meltblown polyetherester laminate

Disclosed is an elastic nonwoven web containing a coherent matrix of fibers formed from an extrudable blend composed of an elastomeric A-B-A-B tetrablock copolymer where A is a thermoplastic polymer block and where B is an isoprene monomer unit hydrogenated to substantially a poly(ethylene-propylene) monomer unit. The elastic nonwoven web adapted to have an elastic modulus of less than about 1.25 which is locally constant during elongation of the web up to about 250 percent. The elastic nonwoven web may also include at least one type of nonelastic fibers and/or particulate materials distributed within or on the matrix of elastomeric fibers. The elastic nonwoven web may be incorporated into a multilayer material and/or may be a component of a composite elastic material in which the elastic web is joined to a gatherable layer at spaced apart locations so that the gatherable layer is gathered between the spaced-apart locations.

High performance elastomeric nonwoven fibrous webs

The present invention provides a composite elastic necked-bonded material including at least one necked material joined to at least one elastic sheet. The composite elastic necked-bonded material is stretchable in a direction generally parallel to the direction of constriction or necking of the necked material. Also disclosed is a method of producing a composite elastic necked-bonded material by extruding a film of substantially molten elastomer through a die tip; depositing the extruded elastomeric film onto a tensioned, necked material within from about 0.1 to about 1 second of exiting the die tip to form a multilayer material; and then immediately applying pressure to the multilayer material to bond the tensioned, necked material to the elastomeric film.

Composite elastic necked-bonded material

A laminate which is elastic in at least one direction, includes an elastic sheet having at least one nonelastic nonwoven web joined thereto at least at two areas. The nonelastic web is gathered between the two areas. The sheet is formed from an aromatic polyetherurethane and the nonelastic nonwoven web includes spunlaced hydraulically entangled polyester fibers. The nonelastic nonwoven web may also include rayon or wood pulp fibers.

Elastic spunlaced polyester-meltblown polyetherurethane laminate

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