Multi-layer web with extensible and inextensible regions and methods of making same

Abstract

A multi-layered web is provided that includes an elastic web bonded to an inelastic web. The inelastic web has extensible and inextensible regions arranged along the machine direction. In the extensible regions, the inelastic web is bonded to the elastic web in a creped structure that is extensible by virtue of the creping. A continuous process is provided to manufacture a multi-layer web having extensible regions that are conjoined with regions that are inextensible by varying the tension that is applied during manufacture of the multi-layer web. The apparatus comprises an elastic web that is fed into a bonding nip, into which one or more inelastic webs are also provided. The elastic web is fed into the bonding nip under a tension that is alternated between a low value that is sufficient to ensure processing stability, and a higher value that provides an elongation to the elastic web. During the low tension phase of the bonding process the inextensible region is formed in the multi-layer web due to the inextensibility of the web.

1 . A multi-layer web extending in a longitudinal direction corresponding to a machine direction along which the multi-layer web travels during manufacture of the multi-layer web, the multi-layer web comprising: 
 a first web having inextensible and extensible regions arranged along the longitudinal direction which corresponds to the machine direction of the multi-layer web; and    a second web bonded to said first web in said extensible and inextensible regions, said second web being elastic.    
     
     
         2 . The multi-layer web of  claim 1 , wherein the multi-layer web exhibits an extensibility of at least 50% and recovery of at least 80% in regions of the multi-layer web containing said extensible regions of said first web.  
     
     
         3 . The multi-layer web of  claim 1 , wherein the multi-layer web exhibits an extensibility of at least 100% and a recovery of at least 80% in regions of the multi-layer web containing said extensible regions of said first web.  
     
     
         5 . The multi-layer web of  claim 1 , wherein said second web is more elastic than said first web.  
     
     
         6 . The multi-layer web of  claim 1 , wherein said first web is inelastic.  
     
     
         7 . The multi-layer web of  claim 1 , wherein said extensible and inextensible regions are formed alternating and continuous with one another along said longitudinal direction.  
     
     
         8 . The multi-layer web of  claim 1 , wherein the extensible region of the first web comprises a creped structure.  
     
     
         9 . The multi-layer web of  claim 1 , wherein the first web is a non-woven web.  
     
     
         10 . The multi-layer web of  claim 1 , wherein the second web is porous.  
     
     
         11 . The multi-layer web of  claim 1 , wherein the second web is a vacuum formed elastic film.  
     
     
         12 . A method for manufacturing a multi-layer web, comprising; 
 feeding first and second webs along a machine direction to a bonding station, the second web being elastic;    bonding the first and second webs to one another at the bonding station; and    operating upon at least one of the first and second webs, at a position upstream of the bonding station, to introduce extensible and inextensible regions into the first web, the inextensible and extensible regions being arranged along the machine direction.    
     
     
         13 . The method of  claim 12 , wherein said operating further comprises varying a tension in the second web prior to feeding the second web into the bonding station.  
     
     
         14 . The method of  claim 12 , wherein said operating further comprises alternately gripping and releasing the second web between a pair of rollers located upstream of the bonding station, the rollers traveling at a circumferential speed that differs from a speed at which the first web is fed to the bonding station.  
     
     
         15 . The method of  claim 12 , wherein said operating includes varying a tension in the second web by defining a staging area upstream of the bonding station and altering a length of a feed path along which the second web travels through the staging area before being fed to the bonding station.  
     
     
         16 . The method of  claim 12 , wherein said operating includes varying a tension in the second web by changing a speed at which the second web is fed to the bonding station.  
     
     
         17 . The method of  claim 12 , wherein said operating further comprises defining a staging area upstream of the bonding station and alternately introducing tension and releasing the second web with a cam roller that is driven in and out of a feed path along which the second web travels through the staging area.  
     
     
         18 . The method of  claim 12 , wherein the bonding includes one of thermal bonding, mechanical bonding, adhesive lamination, chemical bonding, ultrasonic bonding and any combination thereof.  
     
     
         19 . The method of  claim 12 , wherein the operating includes creping portions of the first web before bonding to the second web to define multiple extensible regions separated by inextensible regions.  
     
     
         20 . An absorbent article, comprising: 
 an article body having a dimension in a machine direction; and    an multi-layer web joined to said article body along the machine direction, the multi-layer web comprising first and second webs bonded to one another, the second web is elastic, the first web having extensible and inextensible regions arranged along the machine direction.    
     
     
         21 . The absorbent article of  claim 20 , wherein the extensible and inextensible regions are formed continuous with one another along the machine direction.  
     
     
         22 . The absorbent article of  claim 20 , wherein the article body comprises a waist area that is joined to the multi-layer web.  
     
     
         23 . The absorbent article of  claim 20 , wherein the first web is at least one of inelastic and non-woven.  
     
     
         24 . The absorbent article of  claim 20 , wherein the second web is porous.