Patent US6537930B1 successfully refreshed from Google Patents.
US6537930B1
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US
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Three-dimensional highly elastic film/non-woven composite
Assignee: Fitesa Film Products LLC
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Filing: 2000-05-18
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Granted: 2003-03-25
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Expires: 2020-05-18
Abstract
Abstract A three-dimensional highly elastic film/non-woven composite having a fluid and air impervious core layer and a first and second consolidated layer. The consolidated layers have unidirectional and non-unidirectional fibers. The composite is formed by laminating the air and fluid impermeable elastic core layer between the two layers of consolidated non-wovens. The resulting composite stretches only in the cross-machine direction due to the unidirectional properties of the consolidated non-woven material. The layers are then point bonded or welded together. Preferably the layers are welded by passing the composite between an ultrasonic horn and an ultrasonic bond roll having raised areas for effecting the weld points. A thin inelastic membrane is formed at each of the weld points. The welded composite may then be pre-stretched to rupture the membranes, thereby creating apertures, which makes the composite permeable.
Inventors
- 👤 Jeff A. Middlesworth
- 👤 James W. Cree
- 👤 Steve D. Bruce
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:28
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/02; B32B5/022; A; A61; A61F; A61F13/00; A61F13/15; A61F13/51; A61F13/514; A61F13/51456; A61F13/51464; A61F13/51458; A61F13/5146; B32B27/00; B32B27/12; B32B37/00; B32B37/06; B32B5/08; B32B7/00; B32B7/04; B32B38/00; B32B38/0012; B32B2038/0028; B32B2262/00; B32B2262/14; B32B2307/00; B32B2307/50; B32B2307/51; B32B2307/54; B32B2307/582; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1052; Y10T156/1056; Y10T156/1057; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24802; Y10T428/2481; Y10T428/24826; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/164; Y10T442/166; Y10T442/60; Y10T442/601; Y10T442/602; Y10T442/643; Y10T442/654; Y10T442/659; Y10T442/66; Y10T442/674; Y10T442/681
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
97 words
A three dimensional highly elastic film/non-woven composite, comprising: a fluid and air impervious core film layer having a first side and a second side; a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer; a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer; and wherein said weld points are substantially inelastic and the weld points rupture to form apertures when the composite is stretched in a cross-machine direction to an elongation of about 200% or less.
Claim 2
Dependent Claim
97 words
A three dimensional highly elastic film/non-woven composite, comprising: a fluid and air impervious core film layer having a first side and a second side; a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer; a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer; and wherein said weld points are substantially inelastic and the weld points rupture to form apertures when the composite is stretched in a cross-machine direction to an elongation of about 200% or less.
Claim 3
Dependent Claim
33 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said core layer comprised of a material selected of a group consisting of an elastomeric film, a foam, and a multi-layer film.
Claim 4
Dependent Claim
32 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of bicomponent fibers that have at least two distinct meltpoints.
Claim 5
Dependent Claim
32 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of blended fibers that have at least two distinct meltpoints.
Claim 6
Dependent Claim
40 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second consolidated layer are comprised of unidirectional fibers and non-unidirectional fibers; and said first non-woven layer is comprised of fibers that are anisotropic.
Claim 7
Dependent Claim
40 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first consolidated layer and said second consolidated layer are comprised of unidirectional fibers and non-unidirectional fibers; and said second consolidated layer is comprised of fibers that are anisotropic.
Claim 8
Dependent Claim
30 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said weld points occupy between about 2% to about 10% of a total surface area of the film/non-woven composite.
Claim 9
Dependent Claim
41 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , further comprising: membranes formed in said weld points wherein said membranes rupture to form apertures when the composite is stretched in a transverse direction to an elongation greater than about 50%.
Claim 10
Dependent Claim
31 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: the composite provides sufficient resistance to forces greater than about 1500 grams per inch to prevent tearing of the composite.
Claim 11
Dependent Claim
29 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: the composite has an ultimate tensile direction elongation percentage in the range of about 400% to about 650%.
Claim 12
Dependent Claim
17 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , further comprising: stretchable regions and non-stretchable regions.
Claim 13
Dependent Claim
62 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and said unidirectional and non-unidirectional fibers of said first non-woven layer have a tensile to break ratio in a machine direction to a cross direction in the range of about 3:1 to about 1.8:1.
Claim 14
Dependent Claim
57 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and wherein a tensile to break ratio for said unidirectional and non-unidirectional fibers in a machine direction to a cross direction of said first non-woven layer is about 1.8:1.
Claim 15
Dependent Claim
57 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and wherein a tensile to break ratio for said unidirectional and non-unidirectional fibers in a machine direction to a cross direction of said first non-woven layer is about 3:1.
Claim 16
Dependent Claim
51 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: said first non-woven layer and said second non-woven layer are comprised of unidirectional fibers and non-unidirectional fibers; and wherein the tensile to break ratio for said first non-woven layer for a machine direction to a cross direction is about 1.8:1.
Claim 17
Dependent Claim
33 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: the tensile to break ratio forces of said first non-woven layer in a machine direction to a cross direction is about 3:1.
Claim 18
Dependent Claim
162 words
A three-dimensional highly elastic film/non-woven composite, comprising: a fluid and air impervious core film layer having a first side and a second side; a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer, said first non-woven layer having unidirectional fibers and non-unidirectional fibers, wherein said unidirectional and non-unidirectional fibers of said first non-woven layer have a tensile to break ratio for a machine direction to a cross direction in the range of about 3:1 to about 1.8:1; a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer, said second non-woven layer having unidirectional fibers and non-unidirectional fibers; and a plurality of bond regions formed by said weld points that bond said first non-woven layer, said second non-woven layer and said core layer together; inelastic membranes within said bond regions, said membranes adapted to tear upon stretching of the composite, thereby forming apertures.
Claim 19
Dependent Claim
162 words
A three-dimensional highly elastic film/non-woven composite, comprising: a fluid and air impervious core film layer having a first side and a second side; a first non-woven layer point bonded by a plurality of weld points to said first side of said core layer, said first non-woven layer having unidirectional fibers and non-unidirectional fibers, wherein said unidirectional and non-unidirectional fibers of said first non-woven layer have a tensile to break ratio for a machine direction to a cross direction in the range of about 3:1 to about 1.8:1; a second non-woven layer point bonded by a plurality of weld points to said second side of said core layer, said second non-woven layer having unidirectional fibers and non-unidirectional fibers; and a plurality of bond regions formed by said weld points that bond said first non-woven layer, said second non-woven layer and said core layer together; inelastic membranes within said bond regions, said membranes adapted to tear upon stretching of the composite, thereby forming apertures.
Claim 20
Dependent Claim
65 words
The three-dimensional highly elastic film/non-woven composite of claim 17 , wherein: the unidirectional fibers and non-unidirectional fibers have a tensile to break ratio of a machine direction to a cross direction in the range of about 3:1 to about 1.8:1, wherein the unidirectional fibers of said second consolidated layer are oriented in the same direction as the unidirectional fibers of said first consolidated layer fibers.
Claim 21
Dependent Claim
27 words
The three-dimensional highly elastic film/non-woven composite of claim 5 , wherein: said first consolidated layer is comprised of bicomponent fibers that have at least two distinct meltpoints.
Claim 22
Dependent Claim
27 words
The three-dimensional highly elastic film/non-woven composite of claim 5 , wherein: said first consolidated layer is comprised of blended fibers that have at least two distinct meltpoints.
Claim 23
Dependent Claim
35 words
The three-dimensional highly elastic film/non-woven composite of claim 1 , wherein: the weld points rupture to form apertures when the composite is stretched in a cross-machine direction to an elongation of at least about 20%.
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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) | 2006-03-24 | 2006-09-23 | 2007-03-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2010-03-24 | 2010-09-23 | 2011-03-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2014-03-24 | 2014-09-23 | 2015-03-25 | $7700.00 | Window Closed / Lapsed |