US4863779A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite elastomeric material
Assignee: Kimberly Clark Worldwide Inc
•
Filing: 1987-03-13
•
Granted: 1989-09-05
•
Expires: 2007-03-13
Abstract
Abstract Describes improved composite material comprising an elastic web preferably formed of collected, entangled, nonwoven fibers comprising a copolymer made of ethylene and at least one other vinyl monomer selected from the group including vinyl ester monomers and unsaturated aliphatic monocarboxylic acids and alkyl esters of these monocarboxylic acids, where the amount of monomer other than the ethylene in the copolymer is sufficient to impart elasticity to a cohesive nonwoven web formed from melt-blown fibers of the material. This elastic web is bonded to at least one other web, and preferably is interrelated between two other nonwoven webs of spun-bonded or melt-blown fibers. Discloses processes of making these composite materials. The composites are useful for protective covers and wraps, outerwear, undergarments, menstrual and incontinence control articles, and garments such as disposable diapers and the like.
Inventors
- 👤 Diego H. Daponte
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 07:56
CPC Classifications
B; B32; B32B; B32B7/00; B32B7/04; B32B7/12; B32B7/14; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B37/00; B32B37/14; B32B37/144; D; D04; D04H; D04H1/00; D04H1/40; D04H1/54; D04H1/559; B32B38/00; B32B38/0012; B32B2038/0028; B32B38/0036; B32B2038/0048; B32B2262/00; B32B2262/02; B32B2262/0223; B32B2262/0253; B32B2262/14; B32B2307/00; B32B2307/50; B32B2307/51; B32B2555/00; B32B2555/02; Y; Y10; Y10S; Y10S428/00; Y10S428/903; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24446; Y10T428/24802; Y10T428/24826; Y10T428/27
Claims Analysis
Total Claims: 80
Claim 1
Independent Claim
77 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising a copolymer made of ethylene and from about 10% by weight to about 50% by weight of at least one other vinyl monomer selected from the group consisting of vinyl ester monomers and unsaturated aliphatic monocarboxylic acids and alkyl esters of said monocarboxylic acids.
Claim 2
Dependent Claim
77 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising a copolymer made of ethylene and from about 10% by weight to about 50% by weight of at least one other vinyl monomer selected from the group consisting of vinyl ester monomers and unsaturated aliphatic monocarboxylic acids and alkyl esters of said monocarboxylic acids.
Claim 3
Dependent Claim
145 words
The composite material of claim 1, said composite being made by: (a) tensioning said elastic web to elongate it; (b) bonding said elastic web to at least one gatherable web under conditions that soften at least portions of said elastic web, to form a bonded composite web, and (c) relaxing said composite web immediately after the bonding step whereby said elongated elastic web can contract and the gatherable web is gathered to form said composite elastic material; wherein said elastic web further comprises at least 10% by weight of said web of said copolymer and from greater than 0% by weight up to about 90% by weight of at least one other compatible modifying polymer that, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 4
Dependent Claim
56 words
The composite material of claim 2 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and an ABA' block copolymer, where A and A' are each a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylene-butene) midblock, and mixtures thereof.
Claim 5
Dependent Claim
30 words
The composite material of claim 3 wherein said copolymer is present in an amount sufficient to impart elasticity to a coherent web formed by collecting melt-blown fibers of said composition.
Claim 6
Dependent Claim
31 words
The composite material of claim 2 wherein said modifying polymer comprises at least one polymer selected from the group consisting of ethylene, propylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 7
Dependent Claim
34 words
The composite material of claim 5 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 8
Dependent Claim
12 words
The composite material of claim 5 wherein said modifying polymer comprises polyethylene.
Claim 9
Dependent Claim
12 words
The composite material of claim 5 wherein said modifying polymer comprises polypropylene.
Claim 10
Dependent Claim
12 words
The composite material of claim 5 wherein said modifying polymer is polybutene.
Claim 11
Dependent Claim
14 words
The composite material of claim 5 wherein said modifying polymer is an isobutylene-butene copolymer.
Claim 12
Dependent Claim
18 words
The composite material of claim 1 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 13
Dependent Claim
18 words
The composite material of claim 5 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 14
Dependent Claim
141 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 50 to 200 at 190° C. and comprising from 18% by weight to about 36% by weight of vinyl acetate, said composite material being made by (a) tensioning said elastic web to elongate it; (b) bonding said elastic web to at least one gatherable web under conditions that soften portions of said elastic web at locations that are spaced from each other, to form a bonded composite web, and (c) relaxing said composite web immediately after the bonding step whereby said elongated elastic web contract and the gatherable web is gathered to form said composite elastic material.
Claim 15
Dependent Claim
141 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 50 to 200 at 190° C. and comprising from 18% by weight to about 36% by weight of vinyl acetate, said composite material being made by (a) tensioning said elastic web to elongate it; (b) bonding said elastic web to at least one gatherable web under conditions that soften portions of said elastic web at locations that are spaced from each other, to form a bonded composite web, and (c) relaxing said composite web immediately after the bonding step whereby said elongated elastic web contract and the gatherable web is gathered to form said composite elastic material.
Claim 16
Dependent Claim
18 words
The composite material of claim 13 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 17
Dependent Claim
15 words
The composite material of claim 14 further comprising secondary fibers intermixed with said melt-blown microfbers.
Claim 18
Dependent Claim
36 words
The composite material of claim 14 wherein said melt-blown microfibers are in the form of a nonwoven coherent web that exhibits the ability to be stretched to at least 150% of the web length as formed.
Claim 19
Dependent Claim
75 words
The composite material of claim 14 wherein said nonwoven elastomeric web comprises (a) microfibers comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 32 to 300 at 190° C. and comprising from 18% by weight to about 36% by weight of vinyl acetate; and (b) from greater than 0% by weight to about 80% by weight of at least one different secondary fiber that is generally uniformly distributed throughout said nonwoven web.
Claim 20
Dependent Claim
32 words
The composite material of claim 17 wherein said secondary fiber comprises a fibrous material selected from the group consisting of wood pulp fiber, staple natural fiber, staple artificial fiber, and mixtures thereof.
Claim 21
Dependent Claim
73 words
The composite material of claim 14 wherein said melt-blown fibers are formed form a blend of said poly(ethylene-vinyl acetate) with from greater than 0% by weight up to about 90% by weight of said fibers of at least one other compatible modifying polymer which, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 22
Dependent Claim
57 words
The composite material of claim 19 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and an ABA' block copolymer, where A and A' are each independently a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylene-butene) midblock, and mixtures thereof.
Claim 23
Dependent Claim
31 words
The composite material of claim 20 wherein said modifying polymer comprises at least one polymer selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 24
Dependent Claim
34 words
The composite material of claim 21 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 25
Dependent Claim
37 words
The composite material of claim 14 wherein said elastic web is bonded to the gatherable web at a plurality of spaced-apart locations in a repeating pattern and wherein the gatherable web is gathered between said bonded locations.
Claim 26
Dependent Claim
23 words
The composite material of claim 14 wherein said elastic web has a basis weight of up to about 300 grams per square meter.
Claim 27
Dependent Claim
46 words
The composite material of claim 13 wherein said gatherable web is a nonwoven coherent nonelastic material and is formed from an interlaced web of fibers selected from the group consisting of polyester fibers, polyolefin fibers, polyamide fibers, cellulosic fibers, and mixtures of two or more thereof.
Claim 28
Dependent Claim
28 words
The composite material of claim 25 wherein said gatherable web comprises spun-bonded or melt-brown fibers of polyethylene, polypropylene, a random copolymer of ethylene and propylene, and blends thereof.
Claim 29
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) comprising from about 10% by weight to about 50% by weight of vinyl acetate.
Claim 30
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) comprising from about 10% by weight to about 50% by weight of vinyl acetate.
Claim 31
Dependent Claim
18 words
The composite material of claim 27 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 32
Dependent Claim
15 words
The composite material of claim 28 further comprising secondary fibers intermixed with said melt-blown microfibers.
Claim 33
Dependent Claim
36 words
The composite material of claim 28 wherein said melt-blown microfibers are in the form of a nonwoven coherent web that exhibits the ability to be stretched to at least 150 percent of the web length formed.
Claim 34
Dependent Claim
77 words
The composite material of claim 28 wherein said nonwoven elastomeric web comprises (a) microfibers comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 32 to 300 at 190° C. and comprising from 10% by weight to about 50% by weight by weight of vinyl acetate; and (b) from greater than 0% by weight to about 80% by weight of at least one different secondary fiber that is generally uniformly distributed throughout said nonwoven web.
Claim 35
Dependent Claim
32 words
The composite material of claim 31 wherein said secondary fiber comprises a fibrous material selected from the group consisting of wood pulp fiber, staple natural fiber, staple artificial fiber, and mixtures thereof.
Claim 36
Dependent Claim
73 words
The composite material of claim 28 wherein said melt-blown fibers are formed from a blend of said poly(ethylene-vinyl acetate) with from greater than 0% by weight up to about 90% by weight of aid fibers of at least one other compatible modifying polymer which, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 37
Dependent Claim
57 words
The composite material of claim 33 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and an ABA' block copolymer, where A and A' are each independently a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylenebutene) midblock, and mixtures thereof.
Claim 38
Dependent Claim
34 words
The composite material of claim 34 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 39
Dependent Claim
23 words
The composite material of claim 28 wherein said elastic web has a basis weight of up to about 300 grams per square meter.
Claim 40
Dependent Claim
46 words
The composite material of claim 27 wherein said gatherable web is a nonwoven coherent nonelastic material and is formed form an interlaced web of fibers selected from the group consisting of polyester fibers, polyefin fibers, polyamide fibers, cellulosic fibers, and mixtures of two or more thereof.
Claim 41
Dependent Claim
28 words
The composite material of claim 37 wherein said gatherable web comprises spun-bonded or melt-blown fibers of polyethylene, polypropylene, a random copolymer of ethylene and propylene, and blends thereof.
Claim 42
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate comprising from about 18% by weight to about 36% by weight of vinyl acetate.
Claim 43
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate comprising from about 18% by weight to about 36% by weight of vinyl acetate.
Claim 44
Dependent Claim
18 words
The composite material of claim 39 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 45
Dependent Claim
15 words
The composite material of claim 40 further comprising secondary fibers intermixed with said melt-blown microfibers.
Claim 46
Dependent Claim
36 words
The composite material of claim 40 wherein said melt-blown microfibers are in the form of a nonwoven coherent web that exhibits the ability to be stretched to at least 150 percent of the web length formed.
Claim 47
Dependent Claim
77 words
The composite material of claim 40 wherein said nonwoven elastomeric web comprises (a) microfibers comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 32 to 300 at 190° C. and comprising from 18% by weight to about 36% by weight by weight of vinyl acetate; and (b) from greater than 0% by weight to about 80% by weight of at least one different secondary fiber that is generally uniformly distributed throughout said nonwoven web.
Claim 48
Dependent Claim
32 words
The composite material of claim 43 wherein said secondary fiber comprises a fibrous material selected from the group consisting of wood pulp fiber, staple natural fiber, staple artificial fiber, and mixtures thereof.
Claim 49
Dependent Claim
73 words
The composite material of claim 40 wherein said melt-blown fibers are formed from a blend of said poly(ethylene-vinyl acetate) with from greater than 0% by weight up to about 90% by weight of said fibers of at least one other compatible modifying polymer which, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 50
Dependent Claim
56 words
The composite material of claim 45 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and ABA' block copolymer, where A and A' are each independently a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylenebutene) midblock, and mixtures thereof.
Claim 51
Dependent Claim
34 words
The composite material of claim 46 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 52
Dependent Claim
23 words
The composite material of claim 40 wherein said elastic web has a basis weight of up to about 300 grams per square meter.
Claim 53
Dependent Claim
46 words
The composite material of claim 39 wherein said gatherable web is a nonwoven coherent nonelastic material and is formed form an interlaced web of fibers selected from the group consisting of polyester fibers, polyolefin fibers, polyamide fibers, cellulosic fibers, and mixtures of two or more thereof.
Claim 54
Dependent Claim
28 words
The composite material of claim 49 wherein said gatherable web comprises spun-bonded or melt-blown fibers of polyethylene, polypropylene, a random copolymer of ethylene and propylene, and blends thereof.
Claim 55
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) comprising from about 26% by weight to about 30% by weight of vinyl acetate.
Claim 56
Dependent Claim
50 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) comprising from about 26% by weight to about 30% by weight of vinyl acetate.
Claim 57
Dependent Claim
18 words
The composite material of claim 51 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 58
Dependent Claim
15 words
The composite material of claim 52 further comprising secondary fibers intermixed with said melt-blown microfibers.
Claim 59
Dependent Claim
36 words
The composite material of claim 52 wherein said melt-blown microfibers are in the form of a nonwoven coherent web that exhibits the ability to be stretched to at least 150 percent of the web length formed.
Claim 60
Dependent Claim
77 words
The composite material of claim 52 wherein said nonwoven elastomeric web comprises (a) microfibers comprising poly(ethylene-vinyl acetate) having a nominal melt index in the range from 32 to 300 at 190° C. and comprising from 26% by weight to about 30% by weight by weight of vinyl acetate; and (b) from greater than 0% by weight to about 80% by weight of at least one different secondary fiber that is generally uniformly distributed throughout said nonwoven web.
Claim 61
Dependent Claim
32 words
The composite material of claim 55 wherein said secondary fiber comprises a fibrous material selected from the group consisting of wood pulp fiber, staple natural fiber, staple artificial fiber, and mixtures thereof.
Claim 62
Dependent Claim
73 words
The composite material of claim 52 wherein said melt-blown fibers are formed from a blend of said poly(ethylene-vinyl acetate) with from greater than 0% by weight up to about 90% by weight of said fibers of at least one other compatible modifying polymer which, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 63
Dependent Claim
57 words
The composite material of claim 57 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and an ABA' block copolymer, where A and A' are each independently a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylene-butene) midblock, and mixtures thereof.
Claim 64
Dependent Claim
34 words
The composite material of claim 58 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 65
Dependent Claim
23 words
The composite material of claim 52 wherein said elastic web has a basis weight of up to about 300 grams per square meter.
Claim 66
Dependent Claim
46 words
The composite material of claim 51 wherein said gatherable web is a nonwoven coherent nonelastic material and is formed form an interlaced web of fibers selected from the group consisting of polyester fibers, polyolefin fibers, polyamide fibers, cellulosic fibers, and mixtures of two or more thereof.
Claim 67
Dependent Claim
28 words
The composite material of claim 61 wherein said gatherable web comprises spun-bonded or melt-blown fibers of polyethylene, polypropylene, a random copolymer of ethylene and propylene, and blends thereof.
Claim 68
Dependent Claim
52 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) consisting essentially of from about 26% by weight to about 30% by weight of vinyl acetate.
Claim 69
Dependent Claim
52 words
An elastic composite material comprising at least one elastic web joined at spaced-apart locations to at least one gatherable web, said gatherable web being gathered between said spaced-apart locations, said elastic web comprising poly (ethylene-vinyl acetate) consisting essentially of from about 26% by weight to about 30% by weight of vinyl acetate.
Claim 70
Dependent Claim
18 words
The composite material of claim 63 wherein said elastic web comprises a nonwoven coherent web of melt-blown microfibers.
Claim 71
Dependent Claim
15 words
The composite material of claim 64 further comprising secondary fibers intermixed with said melt-blown microfibers.
Claim 72
Dependent Claim
36 words
The composite material of claim 64 wherein said melt-blown microfibers are in the form of a nonwoven coherent web that exhibits the ability to be stretched to at least 150 percent of the web length formed.
Claim 73
Dependent Claim
80 words
The composite material of claim 64 wherein said nonwoven elastomeric web comprises (a) microfibers comprising poly(ehtylene-vinyl acetate) having a nominal melt index in the range from 32 to 300 at 190° C. and consisting essentially of from about 26% by weight to about 30% by weight by weight of vinyl acetate; and (b) from greater than 0% by weight to about 80% by weight of at least one different secondary fiber that is generally uniformly distributed throughout said nonwoven web.
Claim 74
Dependent Claim
32 words
The composite material of claim 67 wherein said secondary fiber comprises a fibrous material selected from the group consisting of wood pulp fiber, staple natural fiber, staple artificial fiber, and mixtures thereof.
Claim 75
Dependent Claim
73 words
The composite material of claim 64 wherein said melt-blown fibers are formed from a blend of said poly(ethylene-vinyl acetate) with from greater than 0% by weight up to about 90% by weight of said fibers of at least one other compatible modifying polymer which, when blended with said copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded, in blended form, with said copolymer.
Claim 76
Dependent Claim
57 words
The composite material of claim 69 wherein said modifying polymer is selected from the group including polyethylene, polypropylene, polybutene, polystyrene, copolymers and mixtures of these, and an ABA' block copolymer, where A and A' are each independently a thermoplastic polymer endblock that includes a styrenic moiety and where B is an elastomeric poly(ethylene-butene) midblock, and mixtures thereof.
Claim 77
Dependent Claim
34 words
The composite material of claim 70 wherein said modifying polymer comprises a blend of two or more polymers selected from the group consisting of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
Claim 78
Dependent Claim
24 words
The composite material of claim 64 wherein said elastic web has a basis of weight of up to about 300 grams per square meter.
Claim 79
Dependent Claim
46 words
The composite material of claim 63 wherein said gatherable web is a nonwoven coherent nonelastic material and is formed form an interlaced web of fibers selected from the group consisting of polyester fibers, polyolefin fibers, polyamide fibers, cellulosic fibers, and mixtures of two or more thereof.
Claim 80
Dependent Claim
28 words
The composite material of claim 73 wherein said gatherable web comprises spun-bonded or melt-blown fibers of polyethylene, polypropylene, a random copolymer of ethylene and propylene, and blends thereof.
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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) | 1992-09-04 | 1993-03-06 | 1993-09-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-09-04 | 1997-03-06 | 1997-09-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-09-04 | 2001-03-06 | 2001-09-05 | $7700.00 | Window Closed / Lapsed |