Articles comprising impregnated thermoplastic members and method of manufacturing the articles

Abstract

An article, including disposable articles and durable articles, includes one or more shaped thermoplastic members, which can be at least partially impregnated into one or more fibrous substrates forming a composite material of the article having regions of breathability, elasticity, and/or stiffening to provide desired functions of the article. The shaped thermoplastic members have a profiled thickness and/or basis weight providing variation in material properties. A percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%. A process for manufacturing the composite material of the present invention is also disclosed.

What is claimed is:  
     
         1 . An article comprising one or more shaped thermoplastic members at least partially impregnated into one or more fibrous substrates forming a composite material, wherein the shaped thermoplastic members have a profiled thickness providing variation in material properties, and wherein a percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%.  
     
     
         2 . The article of  claim 1 , wherein the percent variation varies from about 20% to about 80%.  
     
     
         3 . The article of  claim 1 , wherein the composite material comprises a stiffening region of the article having a modulus of elasticity from about 350 MPa to about 8000 MPa.  
     
     
         4 . The article of  claim 1 , wherein the composite material comprises a slot and tab fastening system having a modulus of elasticity from about 350 MPa to about 8000 MPa.  
     
     
         5 . The article of  claim 1 , wherein the composite material comprises a stiffening region having a tensile strength from about 25 MPa to about 6000 MPa.  
     
     
         6 . The article of  claim 1 , wherein the composite material forms a breathable region of the article having a moisture vapor transmission rate of about 2,000 grams per m 2  per 24 hours to about 10,000 grams per m 2  per 24 hours (MVTR).  
     
     
         7 . The article of  claim 1 , wherein the composite material forms a breathable and liquid impermeable region of the article having a hydrostatic head from about 50 mm of water to about 700 mm of water.  
     
     
         8 . The absorbent article of  claim 1 , wherein the composite material forms a breathable and liquid impermeable region of the article having a dynamic fluid transmission value from about 0 grams/m 2  to about 5 grams/m 2  at an impact energy of 1000 Joules/m 2 .  
     
     
         9 . The article of  claim 1 , wherein the composite material forms an elastic region of the article having an elastic force at 200% elongation from about 50 grams/25.4 mm width to about 1000 grams/25.4 mm width.  
     
     
         10 . The article of  claim 1 , wherein the composite material forms an elastic leg cuff region of the article having an elastic force at 200% elongation from about 50 grams/25.4 mm width to about 100 grams/25.4 mm width.  
     
     
         11 . The article of  claim 1 , wherein the composite material forms a waist elastic having an elastic force at 200% elongation from about 400 grams/25.4 mm width to about 1000 grams/25.4 mm width.  
     
     
         12 . The article of  claim 1 , wherein the composite material forms an elastic side panel having an elastic force at 200% elongation from about 100 grams/25.4 mm width to about 500 grams/25.4 mm width.  
     
     
         13 . The article of  claim 1 , wherein the shaped thermoplastic member has a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof.  
     
     
         14 . The article of  claim 1 , wherein the shaped thermoplastic member has at least one void defined by a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof.  
     
     
         15 . The article of  claim 1 , wherein the shaped thermoplastic member comprises a material selected from the group consisting of a thermoplastic polymer, a thermoplastic elastomer, a superabsorbent polymer, a polyolefin, a polyester, a polyamide, a polyurethane, a hot melt adhesive, and any mixture or combination thereof.  
     
     
         16 . The article of  claim 1 , wherein the fibrous substrate is selected from the group consisting of a polymeric material, a natural material, a woven fabric, a non-woven fabric, a knit fabric, cellulose material, and any combination thereof.  
     
     
         17 . The article of  claim 1 , wherein the article is selected from the group consisting of baby diapers, adult incontinence articles, feminine hygiene articles, baby swim diapers, dining bibs, wound dressings, sports wear, undergarments, outer wear, rain coats, hospital garments, and cleansing wipes.  
     
     
         18 . An article comprising one or more shaped thermoplastic members at least partially impregnated into one or more fibrous substrates forming a composite material, wherein the shaped thermoplastic members have a profiled basis weight providing variation in material properties, and wherein a percent variation of the profiled basis weight of the thermoplastic member can vary from about 5% to about 95%.  
     
     
         19 . A method of making a composite material comprising at least one shaped thermoplastic member impregnated into at least one fibrous substrate, the method comprising the steps of: 
 e) providing a first fibrous substrate;    f) depositing a first thermoplastic material on the first fibrous substrate to form at least one shaped thermoplastic member having a profiled thickness providing variation in material properties, wherein a percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%, and wherein the step of depositing is selected from a group consisting of intaglio printing, gravure printing, screen printing, ink jet printing, and flexographic printing;    g) providing a second substrate; and    h) combining the first substrate and the second substrate to form the composite material, wherein the thermoplastic member is at least partially impregnated into the first substrate.    
     
     
         20 . The method of  claim 19 , wherein the thermoplastic material is at least partially impregnated into the second substrate.  
     
     
         21 . The method of  claim 19 , wherein the percent variation varies from 20% to 80%.  
     
     
         22 . The method of  claim 19 , wherein the second substrate is not fibrous.  
     
     
         23 . The method of  claim 19 , wherein the second substrate is fibrous.  
     
     
         24 . The method of  claim 19  further comprising a step of depositing a second thermoplastic material on the second fibrous substrate to form a second shaped thermoplastic member, wherein the step of depositing is selected from a group consisting of intaglio printing, gravure printing, screen-printing, ink jet printing, and flexographic printing.  
     
     
         25 . The method of  claim 24 , wherein the first thermoplastic member and the second thermoplastic member are different materials.  
     
     
         26 . The method of  claim 19  further comprising a step of depositing a second thermoplastic material on the first fibrous substrate on top of the first shaped thermoplastic member, wherein the step of depositing is selected from a group consisting of gravure printing, screen-printing, ink jet printing, and flexographic printing.  
     
     
         27 . The method of  claim 26 , wherein the first shaped thermoplastic member and the second shaped thermoplastic member are different materials.  
     
     
         28 . The method of  claim 26 , wherein the first shaped thermoplastic member and the second shaped thermoplastic member are same materials.  
     
     
         29 . A composite material comprising one or more shaped thermoplastic members at least partially impregnated into one or more fibrous substrates forming the composite material, wherein the shaped thermoplastic members have a profiled thickness providing variation in material properties, and wherein a percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%.  
     
     
         30 . The composite material of  claim 29 , wherein the percent variation varies from about 20% to about 80%.  
     
     
         31 . The composite material of  claim 29 , wherein the shaped thermoplastic member has a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof.  
     
     
         32 . The composite material of  claim 29 , wherein the shaped thermoplastic member has at least one void defined by a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof.  
     
     
         33 . The composite material of  claim 29 , wherein the shaped thermoplastic member comprises a material selected from the group consisting of a thermoplastic polymer, a thermoplastic elastomer, a superabsorbent polymer, a polyolefin, a polyester, a polyamide, a polyurethane, a hot melt adhesive, and any mixture or combination thereof.  
     
     
         34 . The composite material of  claim 29 , wherein the fibrous substrate is selected from the group consisting of a polymeric material, a natural material, a woven fabric, a non-woven fabric, a knit fabric, cellulose material, and any combination thereof.  
     
     
         35 . The composite material of  claim 29 , comprising at least one region selected from the group consisting of a stiffening region having a modulus of elasticity from about 350 MPa to about 8000 MPa, a breathable region having a moisture vapor transmission rate of about 2000 grams/m2/24 hours to about 10000 grams/m2/24 hours, a breathable region having a liquid barrier hydrostatic head of about 50 mm of water to about 700 mm of water, a breathable region having a dynamic liquid impact from about 0 grams to about 5 grams, an elastic region having an elastic force at about 200% elongation from about 50 grams/25.4 mm to about 1000 grams/25.4 mm, and a stiffening region having a tensile strength from about 350 MPa to about 6000 MPa.