Elastic laminates prepared by multiple stretching steps

Abstract

Elastic laminates and methods of making same are provided, wherein the laminate includes an elastic film laminated to at least one substrate web, and wherein the elastic film has been stretched at least twice prior to bonding the film to the substrate layer. Such laminates possess improved bond strength between the film and the substrate web and have greater elongation versus laminates made with a film that has been stretched only once.

1 . A laminate comprising an elastic film laminated to at least one substrate web, wherein the elastic film has been stretched at least twice steps prior to being laminated to the at least one substrate web. 
     
     
         2 . The laminate of  claim 1 , wherein the elastic film comprises an elastic core and at least one skin layer. 
     
     
         3 . The laminate of  claim 1 , wherein said at least one substrate web comprises a nonwoven web. 
     
     
         4 . The laminate of  claim 1 , wherein said elastic film is perforated. 
     
     
         5 . A process of manufacturing a laminate, the process comprising the steps of
 (a) providing an elastic film;   (b) stretching the film in at least one direction;   (c) relaxing the film;   (d) stretching the film at least once more in at least said one direction;   (e) laminating the film to at least one substrate web while said film is stretched to form a laminate; and   (f) relaxing the laminate.   
     
     
         6 . The process of  claim 5 , wherein the film is stretched to an equal or lesser degree in step (d) than it is in step (b). 
     
     
         7 . The process of  claim 5 , wherein step (e) comprises laminating the film to at least one nonwoven web. 
     
     
         8 . The process of  claim 5 , wherein said elastic film comprises an elastic core and at least one skin layer. 
     
     
         9 . The process of  claim 8 , wherein said step (a) comprises co-extruding an elastic film having an elastic core and at least two skin layers. 
     
     
         10 . The process of  claim 5 , wherein steps (a) through (c) are performed by a film manufacturer and wherein steps (d) through (e) are performed by an article manufacturer. 
     
     
         11 . The process of  claim 10 , wherein at least a portion of steps (d) through (e) involve the use of a cut-and-place apparatus. 
     
     
         12 . The process of  claim 5 , further comprising the steps of
 (g) winding the film; and   (h) unwinding the film;   wherein steps (g) and (h) take place between steps (c) and (d).   
     
     
         13 . The process of  claim 5 , further comprising the step of
 (i) perforating the film;   wherein step (i) takes place between step (a) and step (d).   
     
     
         14 . The laminate made from the process of  claim 13 . 
     
     
         15 . The laminate made from the process of  claim 5 . 
     
     
         16 . An article comprising a laminate, said laminate comprising an elastic film laminated to at least one substrate web, wherein the elastic film has been stretched at least twice steps prior to being laminated to the at least one substrate web. 
     
     
         17 . The article of  claim 16 , wherein said laminate is prepared by a process comprising the steps of
 (a) providing an elastic film;   (b) stretching the film in at least one direction;   (c) relaxing the film;   (d) stretching the film at least once more in at least said one direction;   (e) laminating the film to at least one substrate web while said film is stretched to form a laminate; and   (f) relaxing the laminate.   
     
     
         18 . The article of  claim 16 , wherein said elastic film is perforated.