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  Cross-direction elasticized composite material and method of making itUSPTO Application #: 20070042663Title: Cross-direction elasticized composite material and method of making it Abstract: A cross-directional elasticized composite includes a facing layer and a plurality of elastic filaments disposed in the cross direction. A method for making the cross-direction elasticized composite by continuously disposing molten elastic filaments on the facing layer and in the cross direction, is also provided. (end of abstract) Agent: Maxwell J. Petersen Pauley Petersen & Erickson - Hoffman Estates, IL, US Inventor: Robert James Gerndt USPTO Applicaton #: 20070042663 - Class: 442328000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material), Nonwoven Fabric Has An Elastic Quality The Patent Description & Claims data below is from USPTO Patent Application 20070042663. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] Laminates having elasticity in the cross-direction have previously been prepared by bonding a neck-stretched ("necked") nonwoven web, such as a spunbond web, typically formed of inelastic filaments, to an elastic film or nonwoven web. These laminates, referred to as neck-bonded laminates, are formed by bonding the necked nonwoven web to the elastic film or nonwoven web when the former is in the neck-stretched state. [0002] Neck-bonded laminates are described in numerous patents to Morman et al. Representative patents include without limitation U.S. Pat. Nos. 5,226,992; 5,336,545; 5,514,470; 5,910,224 and 6,475,600, which are incorporated by reference. [0003] While neck-bonded laminates provide suitable cross-direction elasticity for a wide variety of applications, they typically involve use of a structurally integrated elastic nonwoven web or film (i.e. a layer which is elastic in all directions) to provide elasticity to the laminate, even when elasticity is required in only one direction, such as the cross-direction of the laminate. A full coverage layer of elastic web or film has disadvantages when used to produce a laminate that is elastic in only one direction, such as the cross direction. First, the amount of elastic polymer used may be more than what is required for the cross-direction elastic laminate since the requirement to form the web or film will dictate the minimum basis weight of the elastic material. Second, an elastic film may limit the laminate to a low amount of water vapor transmission (breathability). Third, elastic webs or films (more than individual filaments) are influenced by the physics of Poisson's ratio which retracts the web or film perpendicular to the direction of stretch. Fourth, webs or films which stretch in both directions require special processing techniques in converting machines because a machine direction stretch causes control problems in tension-controlled sections of the machines. For applications where elasticity is only needed in the cross-direction, there is a need or desire for a neck-bonded laminate which limits the amount of elastic material to that needed to obtain the unidirectional elasticity, and a method for making such a laminate. SUMMARY OF THE INVENTION [0004] The present invention is directed to a cross-directional elasticized composite material, and a method of making it. The composite material includes at least one facing material, which can be a nonwoven web having a machine direction (which is a direction of manufacture of the nonwoven web) and a cross-direction (which is perpendicular to the direction of manufacture). The facing layer can be a necked nonwoven web, which has been neck-stretched in the machine direction to cause narrowing (necking) in the cross direction. The nonwoven web can be formed of inelastic filaments. [0005] The composite material also includes elastic filaments which are disposed in the cross-direction of the facing layer, or significantly in the cross direction (i.e. within about 45 degrees of the cross direction) of the facing layer. The elastic filaments can be substantially parallel to each other, and can be spaced apart and non-intersecting with respect to each other. The elastic filaments are suitably bonded to the facing layer. [0006] The elastic composite material can be prepared by a method which includes the steps of: [0007] feeding a facing layer to a first mandrel at an angle relative to a longitudinal axis of the first mandrel; [0008] rotating the first mandrel in a first direction around the axis, while conveying the facing layer axially forward, causing the facing layer to wrap around the first mandrel in a spiral fashion; [0009] conveying the facing material between an extrusion die and an inner surface of a second mandrel; [0010] rotating the extrusion die in a second direction opposite the first direction while simultaneously extruding elastic polymer filaments from the extrusion die onto the facing layer, to form a laminate; and [0011] severing the elastic filaments along edges of the laminate to form the elastic composite material. [0012] The elastic polymer filaments are suitably bonded to the facing material by melt bonding immediately following their extrusion, without requiring a separate adhesive material. [0013] With the foregoing in mind, it is a feature and advantage of the invention to provide an improved, lower cost cross-direction elasticized composite material, and a method of making it. BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 schematically illustrates an elastic composite material of the invention and an apparatus and method for making it. [0015] FIG. 2 is a partial sectional view at the apparatus shown in FIG. 1, illustrating the rotating die and the joining of extruded elastic filaments to the facing layer. [0016] FIG. 3 is a perspective view of a second end of the apparatus shown in FIG. 1, with the rotating die removed. [0017] FIG. 4 is a sectional view of a first end of the apparatus shown in FIG. 1, emphasizing a gear box assembly. DEFINITIONS [0018] "Bonded" and "bonding" refer to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. [0019] "Melt bonding" refers to mechanical and/or chemical bonding of elastic filaments to a facing material via contact and/or penetration of the molten filament polymer into the surface of the facing material, resulting in bonding without the use of separate adhesive materials (i.e. separate from inherent adhesive properties of the molten filament polymer and additives compounded into the polymer). [0020] "Breathable film" or "breathable laminate" refers to a film or laminate having a water vapor transmission rate ("WVTR") of at least about 500 grams/m.sup.2-24 hours, using the WVTR Test Procedure described herein. Continue reading... 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