Stretch composites and methods of making the composite

Abstract

A stretch composite having one or more elastomeric members disposed on at least one region of an extensible fibrous substrate to provide stretch properties to a targeted region of the substrate. The composite has been incrementally stretched to at least partially break up the structure of the substrate in order to reduce its resistance to stretch. The stretch composites are useful for disposable and durable articles, such as disposable absorbent articles including diapers, pull-on diapers, training pants, incontinence briefs, catamenial garments, baby bibs, and the like, and durable articles like garments including sportswear, outerwear and the like. The present invention also relates to methods of forming such stretch composites.

What is claimed is:  
     
         1 . A stretch composite comprising: 
 an extensible first substrate having one or more first elastomeric members disposed on at least a portion of the substrate to form a first elasticized region,    wherein the first elastomeric member has an average width greater than about 0.2 mm, a melt viscosity of from about 1 to about 150 Pa.s, measured at 175° C. and 1 s −1 ; an elasticity of at least about 50 N/m; and a percent set of less than about 20%.    
     
     
         2 . The composite of  claim 1 , wherein the composite has the following properties in at least one direction: 
 (a) a directional load at 75% strain less than about 400 N/m;    (b) a directional percent set of less than about 20%; and    (c) a directional stress relaxation of less than about 30% after 2 minutes at room temperature and 75% strain.    
     
     
         3 . The composite of  claim 1 , wherein the composite comprises a plurality of rectilinear or curvilinear first elastomeric members.  
     
     
         4 . The composite of  claim 3  wherein at lease two of the first elastomeric members are non-parallel.  
     
     
         5 . The composite of  claim 1  further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.  
     
     
         6 . The composite of  claim 1  further comprising one or more second elastomeric members disposed in a second portion of the substrate to form a second elasticized region.  
     
     
         7 . The composite of  claim 6 , wherein the first elasticized region and the second elasticized region are adjacent or at least partially overlapping.  
     
     
         8 . The composite of  claim 6 , wherein at least a portion of the first or the second elasticized region has been incrementally stretched.  
     
     
         9 . The composite of  claim 6 , wherein the composite comprises a plurality of rectilinear or curvilinear second elastomeric member.  
     
     
         10 . The composite of  claim 6 , wherein at least one of the first elastomeric members and at least one of the second elastomeric members are non-parallel with respect to each other.  
     
     
         11 . The composite of  claim 6  further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.  
     
     
         12 . A stretch composite comprising: 
 an extensible fibrous substrate having    a plurality of first elastomeric members disposed on a first elasticized region; and    a plurality of second elastomeric members disposed on a second elasticized region;    the first and the second elastomeric members differ in a property selected from the group consisting of elasticity, melt viscosity, composition, shape, pattern, add-on level, and combinations thereof; wherein at least a portion of the composite within the first or the second elasticized region has been incrementally stretched resulting in permanent elongation of the substrate in said portion; the composite has the following properties in at least one direction: 
 a directional load at 75% strain less than about 400 N/m;  
 a directional percent set of less than about 20%; and  
 a directional stress relaxation of less than about 30% after 2 minutes at room temperature and 75% strain.  
   
     
     
         13 . The composite of  claim 12  further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates  
     
     
         14 . A stretch composite comprising: 
 an extensible fibrous substrate having    a plurality of first elastomeric members disposed on a first elasticized region; and    a plurality of second elastomeric members disposed on a second elasticized region;    the first and the second elastomeric members penetrate at least partially into the substrate;    wherein at least a portion of the composite within the first or the second elasticized region has been incrementally stretched resulting in permanently elongation of the substrate in said portion; and wherein the first and the second elastomeric members have different patterns such that at least one of the first elastomeric members and at least one of the second elastomeric members are non-parallel with respect to each other.    
     
     
         15 . The composite of  claim 14  further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.  
     
     
         16 . The composite of claims  1 ,  11 ,  12  or  14  comprising at least a portion of an absorbent article selected from the group consisting of an elasticized waist region, an elasticized cuff region, an elasticized side panel, an elastic ear portion, an elasticized outercover, an elasticated topsheet, a fastener system, and combinations thereof.