Tear resistant porous extensible web

Abstract

The present invention pertains to a porous, macroscopically-expanded, three-dimensional, elastomeric web suitable for use in elasticized portions of disposable absorbent articles such as bandages, diapers and pull-up diaper training pants. In a preferred embodiment the web has a continuous first surface and a discontinuous second surface remote from first surface. An elastomeric web of the present invention preferably comprises a formed film having at least two polymeric layers, with at least one of the layers being an elastomer and at least one of the other layers being a substantially less elastomeric skin layer. In a preferred embodiment the elastomeric web exhibits a multiplicity of primary apertures in the first surface of the web, the primary apertures being defined in the plane of the first surface by a continuous network of interconnecting members. Each interconnecting member exhibits an upwardly concave-shaped cross-section along its length. The interconnecting members terminate substantially concurrently with one another to form a secondary aperture in the plane of the second surface of the web. Also disclosed is a method of producing the elastomeric web of the present invention comprising providing a multilayer elastomeric film, supporting the film on a forming structure, and applying a fluid pressure differential across the thickness of the multilayer film. The fluid pressure differential is sufficiently great to cause the multilayer film to conform to the supporting structure and rupture in at least portions of the formed film.

1 . A process for making a macroscopically-expanded, three-dimensional, elastomeric web having a continuous first surface and a discontinuous second surface remote from said first surface, said process comprising: 
 (a) providing a multilayer elastomeric film, said multilayer film including at least one elastomeric layer and at least one skin layer;    (b) supporting said multilayer film on a forming structure, said forming structure exhibiting a multiplicity of apertures which place the exposed surfaces of said forming structure in fluid communication with one another; said forming structure moving in a direction parallel to the direction of travel of said multilayer film and carrying said multilayer film in said direction; and    (c) applying a fluid pressure differential across the thickness of said multilayer film along said direction of movement of said forming structure, said fluid pressure differential being sufficiently great to cause said multilayer film to conform with said forming structure and rupture in at least a portion of those areas coinciding with the apertures in said forming structure.    
     
     
         2 . The process of  claim 1 , wherein said multilayer elastomeric film is coextruded.  
     
     
         3 . The process of  claim 1 , wherein said multilayer film includes an elastomeric layer being disposed between two skin layers.  
     
     
         4 . The process of  claim 1 , said process further comprising: 
 (a) providing at least one fibrous nonwoven web material;    (b) bonding said nonwoven web material to said elastomeric web such that said nonwoven web material and said elastomeric web form a composite laminate; and    (c) incrementally stretching said composite laminate to impart elasticity to said composite laminate.