Bidirectional stretch material and laminate made therefrom applications thereof, and methods of making same

Abstract

A method of producing a stretch material includes the steps of extruding a thermoplastic film ( 20 ); passing the extruded film through a nip of two rolls ( 30, 35 ) having first and second roll surfaces, where the first roll surface includes a raised closed shape pattern and the second roll surface is a flat anvil surface; forming a pattern in the film with the rolls, while chilling the film, such that there are thicker and thinner areas in the film, corresponding to the pattern on the first roll surface; and passing the patterned film under tension, by a heated air stream ( 45 ), whereby the polymer in the thinner patterned areas is removed, thereby creating a netting material. A bidirectional stretch laminate is produced by bonding a necked nonwoven material ( 75 ) to the netting material while the netting material is being stretched (under tension).

1 . A method of producing a laminate material comprising the steps of: 
 a. extruding or providing a thermoplastic film;    b. forming a pattern of shapes defined by thin and thick areas in said film;    c. exposing said film to heat while said film is under tension, such that said heat causes polymer within said film to flow from said thin areas to said thick areas, thereby creating a pattern of open spaces within said film;    d. bonding said film to at least one nonwoven material, whereby a netting and nonwoven material laminate is formed.    
     
     
         2 . A method of producing a bidirectional stretch material comprising the steps of: 
 a. extruding or providing a thermoplastic film;    b. forming a pattern of closed shapes within said film, such that there are thicker and thinner areas in said film, corresponding to the pattern;    c. bonding said patterned film to a sheet material that is extensible in at least two directions so as to create a film and nonwoven material laminate with bidirectional stretch.    
     
     
         3 . A method of producing a stretch material comprising the steps of: 
 a. extruding or providing a thermoplastic film;    b. forming a pattern of closed shapes within said film, such that there are thicker and thinner areas in said film, corresponding to the pattern;    c. exposing the patterned film to heat while said film is under tension, such that said heat causes polymer within said film to flow from said thin areas to said thick areas, thereby creating a pattern of open spaces within said film;    such that a netting material is formed;    d. bonding said netting material to a sheet material.    
     
     
         4 . The method of  claim 3  wherein said sheet material is bonded to said netting material while said netting material is under tension.  
     
     
         5 . The method of  claim 3 , wherein said sheet material is a nonwoven web.  
     
     
         6 . The method of  claim 5 , wherein said nonwoven web is a necked nonwoven web.  
     
     
         7 . A method of producing a stretch material comprising the steps of: 
 a. extruding a thermoplastic film;    b. passing said extruded film through a nip of two rolls having first and second roll surfaces, wherein said first roll surface includes a raised closed shape pattern and said second roll surface is a flat anvil surface;    c. forming a pattern in said film with said rolls, while chilling said film, such that there are thicker and thinner areas in said film, corresponding to the pattern on said first roll surface;    d. passing said patterned film under tension, by a heated air stream, whereby the polymer in the thinner patterned areas is removed, thereby creating a netting material.    
     
     
         8 . The method of  claim 7  further including the step of bonding said netting material to at least one other sheet material.  
     
     
         9 . The method of  claim 8  wherein said bonding step is accomplished while said netting is under tension.  
     
     
         10 . The method of  claim 8  wherein said at least one other sheet material is a nonwoven web.  
     
     
         11 . The method of  claim 8  wherein at least one other sheet material is at least two sheet materials, each bonded to opposite sides of the netting material.  
     
     
         12 . The method of  claim 10  wherein said nonwoven web is a necked nonwoven web.  
     
     
         13 . The method of  claim 7  wherein said closed shape pattern is elongated in the cross-machine direction.  
     
     
         14 . A netting material made in accordance with  claim 7 .  
     
     
         15 . A laminate made in accordance with  claim 8 .  
     
     
         16 . A personal care product, protective outerwear or protective outer covering comprising a netting material made in accordance with  claim 7 .  
     
     
         17 . A personal care product, protective outerwear or protective outer covering comprising a laminate made in accordance with  claim 8 .  
     
     
         18 . A method of producing a stretch material comprising the steps of: 
 a. extruding or providing a thermoplastic film;    b. forming a pattern of closed shapes within said film, such that there are thicker and thinner areas in said film, corresponding to the pattern;    c. bonding said patterned film to a sheet material that is extensible in at least one direction so as to create a film and nonwoven material laminate with stretch in at least one direction.