Mechanically extensible substrates

Abstract

The present invention is directed to mechanically extensible substrates, and more specifically relates to engineered substrates that exhibit functionality upon application of an external force, which in turn actuates the substrate, optionally releasing an underlying functional agent that assists a specific task or exposing an underlying layer. In accordance with the present invention, the mechanically extensible substrates exhibit a degree of controlled regional disentanglement, an expandable and retractable valve system, a limited degree of rupture, or a combination thereof.

1 . A method of making a mechanically extensible substrate exhibiting regionally controlled disentanglement upon extension comprising the steps of:  
     providing a continuous filament substrate; 
 a. providing an entanglement apparatus comprising jets that extend the width of said substrate;  
 b. advancing said substrate onto said apparatus; and  
 c. variably entangling said substrate, whereby one or more jets exhibit dissimilar jet pressures.  
 
   
   
       2 . A method of making a mechanically extensible substrate comprising one or more three-dimensional profiled elements and a stretch and recovery performance comprising the steps of: 
 a. providing a nonwoven web comprising staple length fibers;    b. hydroentangling said nonwoven web, wherein said web is imparted with one or more three-dimensionally profiled elements; and    c. applying a polymeric binder composition substantially uniformly to said nonwoven web, wherein said binder composition comprising between about 17% and 31%, by weight, of acrylic binder.    
   
   
       3 . A method of making a mechanically extensible partial depth reticulated film substrate with one or more localized thin areas prone to rupture upon exerting an external force comprising the steps of: 
 a. providing a conventional extrusion apparatus;    b. providing a polymeric melt;    c. extruding said melt from said apparatus;    d. collecting said melt as a formable substrate onto a heated surface; and    e. embossing said substrate so as to impart localized thinned areas into said substrate.    
   
   
       4 . A method of making a mechanically extensible substrate as in any one of the aforementioned claims, wherein said substrate comprises an internal functional agent, topical functional agent, or a combination thereof.