Elastic Laminates and Methods of Manufacturing Same

Abstract

A method for forming an elastic laminate comprising: bonding a first nonwoven to an elastic film to form a laminate; activating the laminate to form an activated laminate; and bonding a consolidated nonwoven to the elastic film of the activated laminate to form the elastic laminate.

1 . A method for forming an elastic laminate comprising: 
 bonding a first nonwoven to an elastic film to form a laminate;    activating said laminate to form an activated laminate; and    bonding a consolidated nonwoven to said elastic film of said activated laminate to form said elastic laminate.    
     
     
         2 . The method of  claim 1 , wherein said elastic film is apertured.  
     
     
         3 . The method of  claim 2 , wherein said elastic film is bonded to said first nonwoven and apertured essentially simultaneously.  
     
     
         4 . The method of  claim 3 , wherein said first nonwoven and said elastic film are apertured essentially simultaneously.  
     
     
         5 . The method of  claim 3 , wherein vacuum lamination is used to bond said first nonwoven to said elastic film and to aperture said elastic film.  
     
     
         6 . The method of  claim 2  wherein the elastic film is apertured after the first bonding step.  
     
     
         7 . The method of  claim 2 , wherein the elastic film is apertured before the first bonding step.  
     
     
         8 . The method of  claim 1 , wherein activating said laminate comprises activating said laminate in the cross direction.  
     
     
         9 . The method of  claim 8 , wherein said laminate is activated using intermeshing gear activation.  
     
     
         10 . The method of  claim 1 , wherein said consolidated nonwoven is extensible in said cross direction.  
     
     
         11 . The method of  claim 1 , wherein at least one of said bonding steps comprises ultrasonic bonding.  
     
     
         12 . The method of  claim 11 , wherein said bonding of said consolidated nonwoven is performed ultrasonically.  
     
     
         13 . The method of  claim 1 , wherein said bonding of said consolidated nonwoven is performed at essentially the same line speed as said activation step.  
     
     
         14 . An elastic laminate comprising: 
 an elastic layer having a first side and a second side;    an activated nonwoven layer bonded to said elastic layer on said first side; and    a consolidated nonwoven layer bonded to said elastic layer on said second side.    
     
     
         15 . The elastic laminate of  claim 14 , wherein said elastic layer is breathable.  
     
     
         16 . The elastic laminate of  claim 15 , wherein said elastic layer is apertured.  
     
     
         17 . The elastic laminate of  claim 14 , wherein said activated nonwoven layer is a carded nonwoven.  
     
     
         18 . The elastic laminate of  claim 17 , wherein said activated nonwoven layer is polypropylene.  
     
     
         19 . The elastic laminate of  claim 14 , wherein said activated nonwoven layer is extensible in a first direction, and said consolidated nonwoven layer is extensible in said first direction.