Composite elastic material

Abstract

The present invention is directed to an elastic composite material having an elastic layer having a first side and a second side; at least one gatherable layer bonded to at least one of the first side and second side of the elastic layer; and a fibrous material entangled and intertwined with both the elastic layer and the gatherable layer. The resulting elastic composite provides a stretchable material which can conform to surfaces and has desirable properties of the fibrous material entangle and intertwined with both the elastic layer and the gatherable layer and does not suffer from the loss of the fibrous material from the stretchable substrate. The composite is usable in as bandages, durable wipes, durable mops and personal care products, such as diapers and feminine napkins. Also disclosed is a method for making the composite.

We claim:  
     
         1 . An elastic composite material comprising 
 a. an elastic layer having a first side and a second side;    b. at least one gatherable layer bonded to at least one of the first side and second side of the elastic layer; and    c. a fibrous material entangled with both the elastic layer and the gatherable layer.    
     
     
         2 . The elastic composite of  claim 1 , wherein the elastic layer is selected from the group consisting of an elastomeric film, an elastomeric nonwoven web, a plurality of substantially continuous elastomeric filaments arranged in substantially parallel rows, and a laminate of an elastomeric nonwoven web and a plurality of substantially continuous elastomeric filaments arranged in substantially parallel rows.  
     
     
         3 . The elastic composite of  claim 2 , wherein there is a gatherable layer bonded to both the first and second sides of the elastic layer.  
     
     
         4 . The elastic composite of  claim 1 , wherein the fibrous material entangled with both the elastic layer and the gatherable layer comprises an absorbent fiber, a non-absorbent fiber or a mixture thereof.  
     
     
         5 . The elastic composite of  claim 4 , wherein the fibrous material entangled with both the elastic layer and the gatherable layer comprises pulp.  
     
     
         6 . The elastic composite of  claim 5 , wherein the gatherable layer comprises a woven, knit or a nonwoven web.  
     
     
         7 . The elastic composite of  claim 6 , wherein the gatherable layer comprises a nonwoven web selected from the group consisting of a spunbond nonwoven web, a meltblown nonwoven web, a bonded carded web or a laminate of two or more of these webs.  
     
     
         8 . The elastic composite of  claim 7 , wherein the gatherable layer comprises a spunbond nonwoven web.  
     
     
         9 . The elastic composite of  claim 8 , wherein the elastic layer is selected from the group consisting of an elastomeric film, an elastomeric nonwoven web, a plurality of substantially continuous elastomeric filaments, and a laminate of an elastomeric nonwoven web and a plurality of substantially continuous elastomeric filaments.  
     
     
         10 . The elastic composite of  claim 9 , wherein there is a gatherable layer bonded to both the first and second sides of the elastic layer.  
     
     
         11 . The elastic composite of  claim 10 , wherein the elastic layer comprises an elastomeric polyester, elastomeric polyurethane, elastomeric polyamide, an elastomeric copolymers of ethylene and at least one vinyl monomer, or elastomeric A-B-A′ block copolymer wherein A and A′ comprise the same or different thermoplastic polymer, and B comprises an elastomeric polymer block.  
     
     
         12 . The elastic composite of  claim 1 , wherein the gatherable layer comprises a woven, knit or a nonwoven web.  
     
     
         13 . The elastic composite of  claim 12 , wherein the gatherable layer comprises a nonwoven web selected from the group consisting of a spunbond nonwoven web, a meltblown nonwoven web, a bonded carded web or a laminate of two or more of these webs.  
     
     
         14 . The elastic composite of  claim 13 , wherein the gatherable layer comprises a spunbond nonwoven web.  
     
     
         15 . The elastic composite of  claim 2 , wherein there is a gatherable layer bonded to both the first and second sides of the elastic layer.  
     
     
         16 . The elastic composite of  claim 2 , wherein the elastic layer comprises an elastomeric polyester, elastomeric polyurethane, elastomeric polyamide, an elastomeric copolymers of ethylene and at least one vinyl monomer, or an elastomeric A-B-A′ block copolymer wherein A and A′ comprise the same or different thermoplastic polymer, and B comprises an elastomeric polymer block.  
     
     
         17 . The elastic composite of  claim 16 , wherein the elastic layer comprises an elastomeric A-B-A′ block copolymer wherein A and A′ comprise the same or different thermoplastic polymer, and B comprises an elastomeric polymer block.  
     
     
         18 . The elastic composite of  claim 17 , wherein the elastic layer comprises a laminate of an elastomeric nonwoven web and a plurality of substantially continuous elastomeric filaments arranged in substantially parallel rows.  
     
     
         19 . The elastic composite according to  claim 1 , further comprising a cohesive layer is applied to the gatherable layer.  
     
     
         20 . A personal care product comprising the elastic composite of  claim 1 .  
     
     
         21 . A wipe comprising the elastic composite of  claim 1 .  
     
     
         22 . A bandage comprising the elastic composite of  claim 1 .  
     
     
         23 . A mop comprising the elastic composite of  claim 1 .  
     
     
         24 . A process of producing an elastic composite material comprising 
 an elastic layer having a first side and a second side; at least one gatherable layer bonded to at least one of the first side and second side of the elastic layer; and a fibrous material entangled and intertwined with the elastic layer and the gatherable layer, said process comprising    a. providing the elastic layer;    b. providing the gatherable layer;    c. applying a stretching force to the elastic layer to form a stretched elastic layer having a first side and a second side;    d. bonding the gatherable layer to the stretched elastic layer to at least the first side or the second side of the elastic layer to form a stretch bonded laminate;    e. providing the fibrous material onto the gatherable layer of the stretch bonded laminate;    f. entangling the fibrous material into the stretch bonded laminate; and    g. relaxing the stretching force.    
     
     
         25 . The process of  claim 24 , wherein the entangling comprises jetting a plurality of high pressure liquid streams towards the material so that the material is intertwined with both the elastic layer and the gatherable layer.  
     
     
         26 . The process of  claim 24 , wherein a gatherable layer is bonded to both the first side and the second side of the nonwoven web.