Composite webs with discrete elastic polymeric regions

Abstract

Composite webs and methods and systems for manufacturing composite webs including a substrate with one or more discrete polymeric regions located thereon are disclosed. At least some of the discrete polymeric regions are formed of an elastomeric thermoplastic composition that is transferred to the substrate in depressions formed on a transfer roll. The discrete elastomeric polymeric regions can be used to provide elasticity to a substrate that is not elastic or they may be used to adjust the elasticity of a substrate that is itself elastic.

1 . A method for producing a composite web, the method comprising: 
 providing a transfer roll comprising an exterior surface that comprises one or more depressions formed therein;    delivering a molten elastomeric thermoplastic composition onto the exterior surface of the transfer roll;    wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll, wherein a portion of the molten elastomeric thermoplastic composition enters the one or more depressions, and further wherein the portion of the molten elastomeric thermoplastic composition in the one or more depressions remains in the one or more depressions after wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll; and    transferring at least a portion of the molten elastomeric thermoplastic composition in the one or more depressions to a first major surface of a substrate by contacting the first major surface of the substrate to the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions, followed by separating the substrate from the transfer roll, wherein one or more discrete polymeric regions comprising the elastomeric thermoplastic composition are located on the first major surface of the substrate after separating the substrate from the transfer roll.    
     
     
         2 . A method according to  claim 1 , wherein the transferring further comprises forcing the first major surface of the substrate against the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions.  
     
     
         3 . A method according to  claim 1 , wherein the first major surface of the substrate comprises a porous surface, and wherein the transferring further comprises forcing a portion of the first major surface of the substrate into the one or more depressions, wherein a portion of the molten elastomeric thermoplastic composition in the one or more depressions infiltrates the porous surface within the one or more depressions.  
     
     
         4 . A method according to  claim 3 , wherein the porous surface of the substrate comprises fibers, and further wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition.  
     
     
         5 . A method according to  claim 1 , wherein the first major surface of the substrate comprises fibers, and further wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition by forcing the first major surface of the substrate against the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions.  
     
     
         6 . A method according to  claim 1 , wherein substantially all of the one or more depressions are substantially filled with the molten elastomeric thermoplastic composition after the wiping and before the transferring.  
     
     
         7 . A method according to  claim 1 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions comprises a shape extending continuously along a length of the substrate.  
     
     
         8 . A method according to  claim 1 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions comprises a shape extending continuously across a width of the substrate.  
     
     
         9 . A method according to  claim 1 , wherein the one or more depressions comprise a plurality of depressions comprising depressions having at least two different shapes.  
     
     
         10 . A method according to  claim 1 , wherein each depression of the one or more depressions comprises a depression volume of about 3 cubic millimeters or more.  
     
     
         11 . A method according to  claim 1 , wherein each depression of the one or more depressions defines a depression volume, and further wherein the one or more depressions comprises at least two depressions that define different depression volumes.  
     
     
         12 . A method according to  claim 1 , wherein a footprint of each depression of the one or more depressions comprises an area of about 4 square millimeters or more.  
     
     
         13 . A method according to  claim 1 , wherein the substrate comprises at least one pleat, and further wherein at least one discrete polymeric region of the one or more discrete polymeric regions spans the at least one pleat.  
     
     
         14 . A method according to  claim 1 , wherein the substrate comprises a plurality of pleats, and further wherein at least one discrete polymeric region of the one or more discrete polymeric regions spans two or more pleats of the plurality of pleats.  
     
     
         15 . A method according to  claim 1 , further comprising providing one or more lines of separation in the composite web, wherein the one or more lines of separation define boundaries of a plurality of distinct articles, each article comprising at least one of the one or more discrete polymeric regions on the first major surface of the first substrate.  
     
     
         16 . A method according to  claim 15 , further comprising separating the composite web along at least one of the one or more lines of separation.  
     
     
         17 . A method for producing a composite web, the method comprising: 
 providing a transfer roll comprising an exterior surface that comprises one or more depressions formed therein;    delivering a molten elastomeric thermoplastic composition onto the exterior surface of the transfer roll;    wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll, wherein a portion of the molten elastomeric thermoplastic composition enters the one or more depressions, and further wherein the portion of the molten elastomeric thermoplastic composition in the one or more depressions remains in the one or more depressions after wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll; and    forcing a portion of a first major surface of a substrate into the one or more depressions, wherein the first major surface comprises a porous surface comprising fibers, and wherein a portion of the elastomeric thermoplastic composition in the one or more depressions infiltrates the porous surface, and still further wherein the molten elastomeric thermoplastic composition encapsulates at least a portion of at least some of the fibers; and    separating the substrate from the transfer roll, wherein one or more discrete polymeric regions comprising the elastomeric thermoplastic composition are located on the first major surface of the substrate after separating the substrate from the transfer roll.    
     
     
         18 . A method according to  claim 17 , wherein each depression of the one or more depressions defines a depression volume, and further wherein the one or more depressions comprises at least two depressions that define different depression volumes.  
     
     
         19 . A method according to  claim 17 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions comprises a shape extending continuously along a length of the substrate.  
     
     
         20 . A method according to  claim 17 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions comprises a shape extending continuously across a width of the substrate.  
     
     
         21 . A method according to  claim 17 , wherein the one or more depressions comprise a plurality of depressions comprising depressions having at least two different shapes.  
     
     
         22 . A method according to  claim 17 , wherein each depression of the one or more depressions comprises a depression volume of about 3 cubic millimeters or more.  
     
     
         23 . A method according to  claim 17 , wherein a footprint of each depression of the one or more depressions comprises an area of about 4 square millimeters or more.  
     
     
         24 . A method for producing a composite web, the method comprising: 
 providing a transfer roll comprising an exterior surface that comprises one or more depressions formed therein;    delivering a molten elastomeric thermoplastic composition onto the exterior surface of the transfer roll;    wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll, wherein a portion of the molten elastomeric thermoplastic composition enters the one or more depressions, and further wherein the portion of the molten elastomeric thermoplastic composition in the one or more depressions remains in the one or more depressions after wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll;    transferring at least a portion of the molten elastomeric thermoplastic composition in the one or more depressions to a first major surface of a first substrate by contacting the first major surface of the first substrate to the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions, followed by separating the first substrate from the transfer roll, wherein one or more discrete polymeric regions comprising the elastomeric thermoplastic composition are located on the first major surface of the first substrate after separating the first substrate from the transfer roll; and    laminating a second substrate to the first major surface of the first substrate, wherein the one or more discrete polymeric regions on the first substrate are located between the first substrate and the second substrate after laminating the second substrate to the first substrate.    
     
     
         25 . A method according to  claim 24 , wherein the transferring further comprises forcing the first major surface of the first substrate against the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions.  
     
     
         26 . A method according to  claim 24 , wherein the first major surface of the first substrate comprises a porous surface, and wherein the transferring further comprises forcing a portion of the first major surface of the first substrate into the one or more depressions, wherein a portion of the molten elastomeric thermoplastic composition in the one or more depressions infiltrates the porous surface within the one or more depressions.  
     
     
         27 . A method according to  claim 26 , wherein the porous surface of the first substrate comprises fibers, and wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition.  
     
     
         28 . A method according to  claim 24 , wherein the first major surface of the first substrate comprises fibers, and wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition.  
     
     
         29 . A method according to  claim 24 , wherein the second substrate comprises one or more discrete polymeric regions located on the second substrate, and wherein the one or more discrete polymeric regions on the second substrate are exposed on the second substrate after laminating the second substrate to the first substrate.  
     
     
         30 . A method according to  claim 29 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions on the second substrate comprises a plurality of structures formed thereon.  
     
     
         31 . A method according to  claim 30 , wherein the plurality of structures comprise stems.  
     
     
         32 . A method according to  claim 30 , wherein the plurality of structures comprise hooks.  
     
     
         33 . A method according to  claim 29 , further comprising providing one or more lines of separation in the composite web, wherein the one or more lines of separation define boundaries of a plurality of elastic articles, each elastic article comprising at least one of the one or more discrete polymeric regions on the first major surface of the first substrate and at least one of the one or more discrete polymeric regions exposed on the second substrate after the laminating.  
     
     
         34 . A method according to  claim 33 , further comprising separating the composite web along at least one of the one or more lines of separation.  
     
     
         35 . A method for producing a composite web, the method comprising: 
 providing a first substrate comprising a first major surface and a second major surface, a plurality of discrete elastomeric polymeric regions formed of an elastomeric thermoplastic composition located on the first major surface of the first substrate, wherein each discrete elastomeric polymeric region of the plurality of discrete elastomeric polymeric regions infiltrates the first major surface of the first substrate;    providing a second substrate comprising a first major surface and a second major surface, a plurality of discrete polymeric regions formed of a thermoplastic composition located on the first major surface of the second substrate, wherein each discrete polymeric region of the plurality of discrete polymeric regions infiltrates the first major surface of the second substrate; and    laminating the first substrate to the second substrate.    
     
     
         36 . A method according to  claim 35 , wherein the plurality of discrete elastomeric polymeric regions on the first major surface of the first substrate are located between the first substrate and the second substrate after the laminating.  
     
     
         37 . A method according to  claim 35 , wherein the laminating further comprises forcing a portion of the elastomeric thermoplastic composition of each discrete elastomeric polymeric region of the plurality of discrete elastomeric into a porous surface of the second substrate.  
     
     
         38 . A method according to  claim 37 , wherein the porous surface of the second substrate comprises fibers, and wherein the laminating further comprises encapsulating at least a portion of at least some of the fibers in the elastomeric thermoplastic composition.  
     
     
         39 . A method according to  claim 35 , wherein the plurality of discrete elastomeric polymeric regions on the first major surface of the first substrate are located between the first substrate and the second substrate after the laminating, and wherein the laminating comprises attaching the second major surface of the second substrate to the first substrate.  
     
     
         40 . A method according to  claim 39 , wherein at least one discrete polymeric region of the one or more discrete polymeric regions on the second substrate comprises a plurality of structures formed thereon.  
     
     
         41 . A method according to  claim 40 , wherein the plurality of structures comprise stems.  
     
     
         42 . A method according to  claim 40 , wherein the plurality of structures comprise hooks.  
     
     
         43 . A method according to  claim 35 , wherein providing the first substrate comprises: 
 providing a transfer roll comprising an exterior surface that comprises one or more depressions formed therein;    delivering a molten elastomeric thermoplastic composition onto the exterior surface of the transfer roll;    wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll, wherein a portion of the molten elastomeric thermoplastic composition enters the one or more depressions, and further wherein the portion of the molten elastomeric thermoplastic composition in the one or more depressions remains in the one or more depressions after wiping the molten elastomeric thermoplastic composition from the exterior surface of the transfer roll; and    transferring at least a portion of the molten elastomeric thermoplastic composition in the one or more depressions to a first major surface of a first substrate by contacting the first major surface of the first substrate to the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions, followed by separating the first substrate from the transfer roll to form the plurality of discrete elastomeric polymeric regions on the first major surface of the first substrate.    
     
     
         44 . A method according to  claim 43 , wherein the transferring further comprises forcing the first major surface of the first substrate against the exterior surface of the transfer roll and the molten elastomeric thermoplastic composition in the one or more depressions.  
     
     
         45 . A method according to  claim 43 , wherein the first major surface of the substrate comprises a porous surface, and wherein the transferring further comprises forcing a portion of the first major surface of the first substrate into the one or more depressions, wherein a portion of the molten elastomeric thermoplastic composition in the one or more depressions infiltrates the porous surface within the one or more depressions.  
     
     
         46 . A method according to  claim 45 , wherein the porous surface of the first substrate comprises fibers, and further wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition.  
     
     
         47 . A method according to  claim 43 , wherein the first major surface of the first substrate comprises fibers, and wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the molten elastomeric thermoplastic composition.  
     
     
         48 . An elastic fastening article comprising: 
 a substrate comprising first and second major surfaces;    one or more mechanical fasteners attached to the first major surface of the substrate, wherein each mechanical fastener of the one or more mechanical fasteners comprises a discrete thermoplastic region infiltrating the first major surface of the substrate, and wherein each mechanical fastener of the one or more mechanical fasteners further comprises a plurality of fastening structures located thereon, the fastening structures facing away from the first major surface of the substrate; and    one or more elastic elements attached to the substrate, wherein each elastic element of the one or more elastic elements comprises a discrete elastomeric thermoplastic region infiltrating a portion of the substrate.    
     
     
         49 . An article according to  claim 48 , wherein each elastic element of the one or more elastic elements is located between the first major surface and the second major surface of the substrate.  
     
     
         50 . An article according to  claim 48 , wherein at least one elastic element of the one or more elastic elements is located on the first major surface of the substrate.  
     
     
         51 . An article according to  claim 48 , wherein at least one elastic element of the one or more elastic elements is located on the second major surface of the substrate  
     
     
         52 . An article according to  claim 48 , further comprising an elongation axis extending through at least one mechanical fastener of the one or more mechanical fasteners, wherein each elastic element of the one or more elastic elements comprises a length greater than a width, and wherein the length of each elastic element of the one or more elastic elements is aligned with the elongation axis.  
     
     
         53 . An article according to  claim 52 , wherein the amount of elastomeric thermoplastic in each elastic element of the one or more elastic elements increases when moving away from the one or more mechanical fasteners along the elongation axis.  
     
     
         54 . An elastic article comprising: 
 a substrate comprising first and second major surfaces;    one or more elastic elements attached to the substrate, wherein each elastic element of the one or more elastic elements comprises a discrete elastomeric thermoplastic region infiltrating a portion of the substrate; and    one or more bonding sites located on the first major surface of the substrate.    
     
     
         55 . An article according to  claim 54 , wherein each elastic element of the one or more elastic elements is located between the first major surface and the second major surface of the substrate.  
     
     
         56 . An article according to  claim 54 , wherein at least one elastic element of the one or more elastic elements is located on the first major surface of the substrate.  
     
     
         57 . An article according to  claim 54 , wherein at least one elastic element of the one or more elastic elements is located on the second major surface of the substrate  
     
     
         58 . An elastic article comprising: 
 a substrate comprising first and second major surfaces;    one or more elastic elements attached to the substrate, wherein each elastic element of the one or more elastic elements comprises a discrete elastomeric thermoplastic region infiltrating a portion of the substrate; and    one or more slits formed through the substrate, wherein at least one of the one or more elastic elements spans each slit of the one or more slits.    
     
     
         59 . An article according to  claim 58 , wherein each elastic element of the one or more elastic elements is located between the first major surface and the second major surface of the substrate.  
     
     
         60 . An article according to  claim 58 , wherein at least one elastic element of the one or more elastic elements is located on the first major surface of the substrate.  
     
     
         61 . An elastic article comprising: 
 a substrate comprising first and second major surfaces;    one or more elastic elements attached to the substrate, wherein each elastic element of the one or more elastic elements comprises a discrete elastomeric thermoplastic region infiltrating a portion of the substrate; and    one or more pleats formed in the substrate, wherein at least one of the one or more elastic elements spans at least one pleat of the one or more pleats.    
     
     
         62 . An article according to  claim 61 , wherein at least some elastic elements of the one or more elastic elements spans only one pleat of the one or more pleats.  
     
     
         63 . An article according to  claim 61 , at least some elastic elements of the one or more elastic elements span two or more pleats of the one or more pleats.