Absorbent Article With Double-Sided Soft And Elastic Components

Abstract

The present invention relates to absorbent articles and non-absorbent articles which comprise at least one improved double-sided soft and elastic material composite. The composites according to the invention may also be breathable. The composites are produced by incrementally stretching a laminate of an elastic layer between two non-elastic cloth-like layers. The non-elastic cloth-like layers tear during stretching such that the elasticity of the laminate after stretching is substantially the same as the elasticity of the film elastic layer.

1 .- 34 . (canceled) 
     
     
         35 . A method of making an elastic composite, the method comprising:
 bonding a first non-elastic cloth-like material to a first side of an elastic layer, wherein the first non-elastic cloth-like material has a first elongation at break and the elastic layer has an elongation at break of at least 50%;   bonding a second non-elastic cloth-like material to a second side of the elastic layer, wherein the second non-elastic cloth-like material has a second elongation at break that is substantially different than the first elongation at break; and   passing the composite through intermeshing gear rolls for breaking.   
     
     
         36 . The method of  claim 35 , wherein at least one of the first non-elastic cloth-like material or the second non-elastic cloth-like material are bonded to the elastic layer in at least one of the following: a vacuum lamination system, a point-bonding system, or an extrusion lamination system. 
     
     
         37 . The method of  claim 35 , wherein the elastic layer is at least one of extruded or coextruded from a film die before being bonded to the first non-elastic cloth-like material. 
     
     
         38 . The method of  claim 35 , further comprising: aperturing the elastic material to impart breathability thereto, wherein the elastic layers is configured to be apertures via at least one of the following: vacuum aperturing, heated pin aperturing, un-heated pin aperturing, or stretching. 
     
     
         39 . The method of  claim 38 , wherein the elastic material is apertured to impart breathability thereto via vacuum aperturing. 
     
     
         40 . The method of  claim 38 , wherein the elastic material is apertured to impart breathability thereto via stretching, and wherein the elastic layer comprises a filler material and interconnection voids around the filler material when stretched. 
     
     
         41 . The method  claim 35 , wherein the second non-elastic cloth-like material is bonded to the elastic layer adhesively via point bonding. 
     
     
         42 . The method of  claim 41 , wherein the point bonding comprises thermal or ultrasonic bonding. 
     
     
         43 . The method of  claim 35 , wherein the intermeshing gear rolls are at least one of the following: heated or cooled. 
     
     
         44 . The method of  claim 35 , wherein the intermeshing gear rolls have a draw ratio from about 4.28 to about 4.60. 
     
     
         45 . The method of  claim 35 , wherein the intermeshing gear rolls operate at a speed of about 15.2 meters per second to about 30.5 meters per second. 
     
     
         46 . The method of  claim 35 , wherein the intermeshing gears have a depth of engagement of about 2.67 mm or less. 
     
     
         47 . The method of  claim 35 , wherein passing the composite through the intermeshing gear rolls for breaking comprising stretching the composite to break the first non-elastic cloth-like material and the second non-elastic cloth-like material in a traverse direction. 
     
     
         48 . The method of  claim 35 , wherein at least one of the first non-elastic cloth-like material or the second non-elastic cloth-like material comprise a nonwoven material. 
     
     
         49 . The method of  claim 35 , further comprising incorporating the composite into at least one of the following: a topsheet, a backsheet, a fastener, a waistband, a side panel, or a leg cuff.