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Elastic-laminated-fabric-material-and-method-of-making-same

Nonwoven polypropylene fabric

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Elastic laminated fabric material and method of making same

Details

Inventors: Morman, Michael Tod; Milicevic, Cindy Janja;
Assignee: Kimberly-Clark Worldwide, Inc. (Neenah, WI)
Primary Examiner: Edwards; Newton
Assistant Examiner: Gray; J. M.
Attorney, Agent or Firm: Robinson; James B.

A laminate material formed of an elastomeric polymer sheet and a nonwoven fabric sheet. The sheets are passed through a niproll assembly during lamination, one of the niprolls having a series of embossing points protruding therefrom, and the other niproll being substantially flat. The embossing points press selective areas of the preferably molten polymer sheet into the fabric sheet, encapsulating the fabric fibers and bonding thereto. The resulting material has points of bonding where penetration has occurred and areas of nonpenetration, providing adherence of the two sheets while permitting independent movement of the fibers and elastic properties. Preferably, a release agent is added to the elastomeric polymer to reduce the possibility of the elastomer layer sticking to the nonwoven layer when the laminate is wound onto a supply roll.

DETAILED DESCRIPTION The present invention provides an elastic laminated fabric having at least two sheets comprising a first sheet of an elastomeric polymer and a second sheet of a preferably spunbond nonwoven fabric, whereby during lamination portions of said first sheet are selectively attached to said second sheet by point bonding.
The attachment or bonding of the two layers is achieved by pushing portions of the first sheet into the fabric structure of the second sheet so that the portions of the first sheet encapsulate areas of the second sheet and bond thereto.
The areas of nonpenetration preserve independent movement of fibers, thus maintaining elasticity properties, while bonded areas improve laminate peel strength.
The elastomeric polymer sheet preferably contains a release agent so after the laminate has cooled and solidified, it will not stick to other surfaces, such as the spunbond faces of the next wrap on a roll.
A method of forming an elastic laminated fabric is provided comprising (a) providing first sheet; (b) providing a second sheet; and, (c) selectively bonding portions of said first sheet to said second sheet by point embossing.

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