US4657802A Expired / Lapsed US ⏱️ 0.0 years remaining

Composite nonwoven elastic web

Assignee: Kimberly Clark Worldwide Inc

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Filing: 1985-07-30

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Granted: 1987-04-14

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Expires: 2005-07-30

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Abstract

Abstract A process for producing a composite nonwoven elastic web including a nonwoven elastic web joined to a fibrous nonwoven gathered web is disclosed. The process includes the steps of (a) providing a nonwoven elastic web having a relaxed unbiased length and a stretched, biased length; (b) stretching the nonwoven elastic web to its stretched, biased length; (c) forming a fibrous nonwoven gatherable web directly upon a surface of the nonwoven elastic web while maintaining the nonwoven elastic web at its stretched, biased length; (d) forming a composite nonwoven elastic web by joining the fibrous nonwoven gatherable web to the nonwoven elastic web while continuing to maintain the nonwoven elastic web at its stretched length; and (e) relaxing the nonwoven elastic web to its relaxed length to gather the fibrous nonwoven gatherable web. In some embodiments, joining of the fibrous nonwoven gatherable web to the nonwoven elastic web occurs simultaneously with formation of the gatherable web on the surface of the elastic web. The composite elastic web formed by the disclosed process is also disclosed and described.

Inventors

👤 Michael T. Morman

Bibliographic Details

Application Number —

Jurisdiction US

Data Source google_patents

Last Synchronized 2026-10-23 22:35

CPC Classifications

D; D04; D04H; D04H1/00; D04H1/40; D04H1/54; D04H1/56; D04H1/559; B; B32; B32B; B32B2255/00; B32B2255/02; B32B2255/26; B32B2262/00; B32B2262/02; B32B2262/0207; B32B2262/0223; B32B2262/023; B32B2262/0253; B32B2262/14; B32B2307/00; B32B2307/50; B32B2307/51; B32B2307/54; B32B2307/70; B32B2307/724; B32B2307/726; B32B2307/7265; B32B27/00; B32B27/12; B32B3/00; B32B3/26; B32B3/266; B32B5/00; B32B5/02; B32B5/022; B32B5/08; B32B5/22; B32B5/24; B32B5/26; B32B7/00; B32B7/04; B32B7/12; Y; Y10; Y10S; Y10S428/00; Y10S428/903; Y10S428/913; Y10T; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24331; Y10T428/24355; Y10T428/24446; Y10T428/24479; Y10T428/24521; Y10T428/24562; Y10T442/00; Y10T442/60; Y10T442/601

Claims Analysis

Total Claims: 49

Claim 1

Independent Claim 87 words

Claim 2

Dependent Claim 87 words

Claim 3

Dependent Claim 25 words

The process according to claim 1, wherein the step of providing said nonwoven elastic web comprises forming a fibrous nonwoven elastic web of meltblown microfibers.

Claim 4

Dependent Claim 21 words

The process according to claim 1, wherein the step of providing said nonwoven elastic web comprises providing an apertured elastic film.

Claim 5

Dependent Claim 30 words

The process according to claim 2, wherein the fibrous nonwoven elastic web is stretched to at least about 125 percent of a relaxed length of the fibrous nonwoven elastic web.

Claim 6

Dependent Claim 42 words

The process according to claim 4, wherein the fibrous nonwoven elastic web is stretched from at least about 125 percent of the relaxed length of the fibrous nonwoven web to about 700 percent of the relaxed length of the nonwoven elastic web.

Claim 7

Dependent Claim 26 words

The process according to claim 1, wherein the step of forming said fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of meltblown microfibers.

Claim 8

Dependent Claim 26 words

The process according to claim 1, wherein the step of forming said fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of spunbonded microfibers.

Claim 9

Dependent Claim 21 words

The process according to claim 1, wherein the step of forming said fibrous nonwoven gatherable web comprises forming a carded web.

Claim 10

Dependent Claim 25 words

The process according to claim 1, wherein the step of joining the fibrous nonwoven gatherable web to the nonwoven elastic web is achieved by heat-bonding.

Claim 11

Dependent Claim 64 words

The process according to claim 9, wherein the step of heat-bonding the fibrous nonwoven gatherable web to said nonwoven elastic web is achieved by heat-bonding within the temperature range of from about 50 degrees centigrade below a melting temperature of a material utilized to form either of the webs to about the melting temperature of a material utilized to form either of the webs.

Claim 12

Dependent Claim 13 words

A composite nonwoven elastic web formed by the process according to claim 1.

Claim 13

Dependent Claim 78 words

The composite nonwoven elastic web formed by the process according to claim 11, wherein the nonwoven elastic web comprises elastomeric fibers formed from a material selected from the group consisting essentially of A-B-A' block copolymers, where A and A' are each a thermoplastic polymer endblock comprising a styrenic moiety and where A may be the same thermoplastic endblock as A' and where B is an elastomeric polymer midblock selected from the group consisting of poly(ethylene-butylene), polyisoprene or polybutadiene.

Claim 14

Dependent Claim 59 words

A composite nonwoven elastic web formed by the process according to claim 11, wherein the nonwoven elastic web comprises elastomeric fibers formed from a material selected from the group consisting essentially of blends of one or more polyolefins with S-EB-S block copolymers, where "S" is selected from the group consisting of polystyrene and polystyrene homologs and "EB" is poly(ethylene-butylene).

Claim 15

Dependent Claim 53 words

The composite nonwoven elastic web formed by the process according to claim 11, wherein the nonwoven elastic web comprises elastomeric fibers formed from a material consisting essentially of blends of poly(alpha-methyl styrene) with S-I-S block copolymers, where "S" is selected from the group consisting of polystyrene and polystyrene homologs and "I" is polyisoprene.

Claim 16

Dependent Claim 35 words

The composite nonwoven elastic web according to claim 13, wherein the polyolefin is selected from the group consisting of at least one polymer, including copolymers, selected from the group consisting of ethylene, propylene and butene.

Claim 17

Dependent Claim 14 words

The composite nonwoven elastic web according to claim 13, where the polyolefin is poyethylene.

Claim 18

Dependent Claim 13 words

A composite nonwoven elastic web formed by the process according to claim 2.

Claim 19

Dependent Claim 80 words

The composite nonwoven elastic web formed by the process according to claim 17, wherein the fibrous nonwoven elastic web comprises meltblown elastomeric microfibers formed from a material selected from the group consisting essentially of A-B-A' block copolymers where "A" and "A'" are each a thermoplastic polymer endblock containing a hstyrenic moiety and where "A" may be the same thermoplastic block as "A'" and where "B" is an elastomeric polymer midblock selected from the group consisting of poly(ethylene-butylene), polyisoprene or polybutadiene.

Claim 20

Dependent Claim 59 words

The composite nonwoven elastic web formed by the process according to claim 17, wherein the nowoven elastic web comprises elastomeric microfibers formed from a material selected from the group consisting essentially of blends of one or more polyolefins with S-EB-S block copolymers, where "S" is selected from the group consisting of polystyrene and polystyrene homologs and "EB" is poly(ethylene-butylene).

Claim 21

Dependent Claim 53 words

The composite nonwoven elastic web formed by the process according to claim 17, wherein the nonwoven elastic web comprises elastomeric microfibers formed from a material consisting essentially of blends of poly(alpha-methyl styrene) with S-I-S block copolymers, where "S" is selected from the group consisting of polystyrene and polystyrene homologs and "I" is polyisoprene.

Claim 22

Dependent Claim 35 words

The composite nonwoven elastic web according to claim 19, wherein the polyolefin is selected from the group consisting of at least one polymer, including copolymers, selected from the group consisting of ethylene, propylene, and butene.

Claim 23

Dependent Claim 14 words

The composite nonwoven elastic web according to claim 19, where the polyolefin is polyethylene.

Claim 24

Dependent Claim 19 words

The composite nonwoven elastic web according to claim 11, wherein the fibrous nonwoven gatherable web comprises nonelastic meltblown microfibers.

Claim 25

Dependent Claim 43 words

The composite nonwoven elastic web according to claim 23, wherein the fibrous nonwoven gatherable web comprises nonelastic meltblown microfibers selected from the group consisting of polyester microfibers, polyolefin microfibers or blends of one or more polyester microfibers with one or more polyolefin microfibers.

Claim 26

Dependent Claim 17 words

The composite nonwoven elastic web according to claim 24, wherein the polyester microfibers comprise polyethylene terephthalate microfibers.

Claim 27

Dependent Claim 22 words

The composite nonwoven elastic web according to claim 24, wherein the polyolefin microfibers comprising the fibrous nonwoven gatherable web comprise polypropylene microfibers.

Claim 28

Dependent Claim 19 words

The composite nonwoven elastic web according to claim 11, wherein the fibrous nonwoven gatherable web comprises nonelastic spunbonded microfibers.

Claim 29

Dependent Claim 43 words

The composite nonwoven elastic web according to claim 27, wherein the fibrous nonwoven gatherable web comprises nonelastic spunbonded microfibers selected from the group consisting of polyester microfibers, polyolefin microfibers or blends of one or more polyester microfibers with one or more polyolefin microfibers.

Claim 30

Dependent Claim 17 words

The composite nonwoven elastic web according to claim 28, wherein the polyester microfibers comprise polyethylene terephthalate microfibers.

Claim 31

Dependent Claim 22 words

The composite nonwoven elastic web according to claim 28, wherein the polyolefin microfibers comprising the fibrous nonwoven gathered web comprise polypropylene microfibers.

Claim 32

Dependent Claim 136 words

A process for producing a composite nonwoven elastic web comprising a nonwoven elastic web joined to a fibrous nonwoven gathered web, said process comprising the steps of: providing a tacky nonwoven elastic web; stretching the tacky nonwoven elastic web; forming a composite nonwoven elastic web by forming a fibrous nonwoven gatherable web directly upon a surface of the stretched nonwoven elastic web and simultaneously joining said nonwoven gatherable web to the surface of the stretched nonwoven elastic web wherein joining of the tacky nonwoven elastic web to the fibrous nonwoven gatherable web is achieved by adhesion of the two webs to each other during formation of the fibrous nonwoven gatherable web on the surface of the stretched fibrous nonwoven elastic web; and relaxing the tacky composite nonwoven elastic web to gather the fibrous nonwoven gatherable web.

Claim 33

Dependent Claim 136 words

Claim 34

Dependent Claim 25 words

The process according to claim 31, wherein the adhesion of the two webs to each other is improved by applying pressure to the joined webs.

Claim 35

Dependent Claim 26 words

The process according to claim 31, wherein the step of providing said tacky nonwoven elastic web comprises forming a fibrous nonwoven elastic web of meltblown microfibers.

Claim 36

Dependent Claim 106 words

A composite nonwoven elastic web formed by the process according to claim 33, wherein the tacky fibrous nonwoven elastic web comprises tacky meltblown elastomeric microfibers formed from a material selected from the group consisting essentially of (a) A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and where "B" is an elastomeric polymer midblock consisting of polyisoprene or (b) blends of poly(alpha-methylstyrene) with A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and B is an elastomeric polymer midblock consisting of polyisoprene.

Claim 37

Dependent Claim 21 words

The composite nonwoven elastic web according to claim 34, wherein A and A' are selected from the group consisting of polystyrene.

Claim 38

Dependent Claim 35 words

The process according to claim 33, wherein the step of forming said fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of meltblown microfibers on the surface of said fibrous nonwoven elastic web.

Claim 39

Dependent Claim 106 words

A composite nonwoven elastic web formed by the process according to claim 36, wherein the tacky fibrous nonwoven elastic web comprises tacky meltblown elastomeric microfibers formed from a material selected from the group consisting essentially of (a) A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and where "B" is an elastomeric polymer midblock consisting of polyisoprene or (b) blends of poly(alpha-methylstyrene) with A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and "B" is an elastomeric polymer midblock consisting of polyisoprene.

Claim 40

Dependent Claim 15 words

The composite nonwoven elastic web according to claim 35, wherein A and A' are polystyrene.

Claim 41

Dependent Claim 35 words

The process according to claim 33, wherein the step of forming said fibrous nonwoven gatherable web comprises forming a fibrous nonwoven gatherable web of spunbonded microfibers on the surface of said fibrous nonwoven elastic web.

Claim 42

Dependent Claim 106 words

A composite nonwoven elastic web formed by the process according to claim 39, wherein the tacky fibrous nonwoven elastic web comprises tacky meltblown elastomeric microfibers formed from a material selected from the group consisting essentially of (a) A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and where "B" is an elastomeric polymer midblock consisting of polyisoprene or (b) blends of poly(alpha-methylstyrene) with A-B-A' block copolymers, where "A" and "A'" are thermoplastic polymer endblocks selected from the group consisting of polystyrene or polystyrene homologs and "B" is an elastomeric polymer midblock consisting of polyisoprene.

Claim 43

Dependent Claim 15 words

The composite nonwoven elastic web according to claim 40, wherein A and A' are polystyrene.

Claim 44

Dependent Claim 139 words

A process for producing a composite nonwoven elastic web comprising a nonwoven elastic web joined to a fibrous nonwoven gathered web, said process comprising the steps of: providing a nonwoven elastic web; stretching said nonwoven elastic web; forming a composite nonwoven elastic web by forming a fibrous nonwoven gatherable web directly upon a surface of the stretched nonwoven elastic web and simultaneously joining the fibrous nonwoven gatherable web to the surface of the stretched nonwoven elastic web wherein joining of the nonwoven elastic web to the fibrous nonwoven gatherable web is achieved by entanglement of the individual fibers of the nonwoven gatherable web with the nonwoven elastic web during formation of the fibrous nonwoven gatherable web on the surface of the stretched nonwoven elastic web; and relaxing the composite nonwoven elastic web or gather the fibrous nonwoven gatherable web.

Claim 45

Dependent Claim 139 words

A process for producing a composite nonwoven elastic web comprising a nonwoven elastic web joined to a fibrous nonwoven gathered web, said process comprising the steps of: providing a nonwoven elastic web; stretching said nonwoven elastic web; forming a composite nonwoven elastic web by forming a fibrous nonwoven gatherable web directly upon a surface of the stretched nonwoven elastic web and simultaneously joining the fibrous nonwoven gatherable web to the surface of the stretched nonwoven elastic web wherein joining of the nonwoven elastic web to the fibrous nonwoven gatherable web is achieved by entanglement of the individual fibers of the nonwoven gatherable web with the nonwoven elastic web during formation of the fibrous nonwoven gatherable web on the surface of the stretched nonwoven elastic web; and relaxing the composite nonwoven elastic web or gather the fibrous nonwoven gatherable web.

Claim 46

Dependent Claim 25 words

The process according to claim 42, wherein the step of providing said nonwoven elastic web comprises forming a fibrous nonwoven elastic web of meltblown microfibers.

Claim 47

Dependent Claim 37 words

The process according to claim 43, wherein said joining is achieved solely by entanglement of the individual fibers of the fibrous nonwoven gatherable web with the individual fibers of the fibrous nonwoven elastic web of meltblown microfibers.

Claim 48

Dependent Claim 22 words

The process according to claim 42, wherein the step of providing said nonwoven elastic web comprises providing an apertured nonwoven elastic film.

Claim 49

Dependent Claim 33 words

The process according to claim 45, wherein said joining is achieved solely by entanglement of the individual fibers of the fibrous nonwoven gatherable web with the apertures of the apertured nonwoven elastic film.

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USPTO Annuity & Maintenance Windows

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1990-04-13	1990-10-13	1991-04-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1994-04-13	1994-10-13	1995-04-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1998-04-13	1998-10-13	1999-04-14	$7700.00	Window Closed / Lapsed

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