Stretchable elastic nonwoven laminates

Abstract

There is provided an elastic nonwoven laminate. The elastic layer is laminated along at least one face to an extensible nonwoven web via strand spacer elements that extend in a first direction of the nonwoven web providing for a strengthening effect in the first direction. The elastic layer is attached to the extensible nonwoven web without any significant bonding of the extensible nonwoven web to the elastic layer between the spacer elements wherein the elastic nonwoven laminate is easily extensible in a second direction without activation.

1 . An elastic nonwoven laminate comprising an elastic layer having a first face and a second face, the elastic layer laminated along at least one face to an extensible nonwoven sheet, the extensible nonwoven sheet comprising an extensible nonwoven web having strand spacer elements that extend in a first direction of the extensible nonwoven web, providing for a strengthening effect in the first direction, the elastic layer attached to the extensible nonwoven sheet without any significant bonding of the extensible nonwoven web to the elastic layer between the spacer elements wherein the elastic nonwoven laminate is extensible in a second direction. 
     
     
         2 . The elastic nonwoven laminate of  claim 1  wherein the strand spacer elements are inelastic and there are from 2 to 30 continuous strands per centimeter, provided at a basis weight of 10 to 200 g/cm 2 . 
     
     
         3 . The elastic nonwoven laminate of  claim 2  wherein the strand spacer elements are inelastic and there are from 5 to 20 strands per centimeter, provided at a basis weight of 10 to 100 g/cm 2 . 
     
     
         4 . The elastic nonwoven laminate of  claim 2  wherein the strand spacer elements are extrusion laminated to the extensible nonwoven web. 
     
     
         5 . The elastic nonwoven laminate of  claim 1  wherein extensible nonwoven sheets are bonded to both faces of the elastic layer. 
     
     
         6 . The elastic nonwoven laminate of  claim 1  wherein the extensible nonwoven sheet can be extended in the second direction by 10 percent at a force of 50 g/cm or less and the force required to initially extend the elastic nonwoven laminate in the second direction by 20 percent is increased by 150 percent or less, versus the elastic layer without attached extensible nonwoven sheets or webs. 
     
     
         7 . The elastic nonwoven laminate of  claim 1  wherein the extensible nonwoven web can be extended in the second direction by 10 percent at a force of 5 g/cm or less and the force required to initially extend the elastic nonwoven laminate in the second direction by 20 percent is increased by 100 percent or less, versus the elastic layer without attached extensible nonwoven sheets or webs. 
     
     
         8 . The elastic nonwoven laminate of  claim 1  wherein the elastic layer is an elastic film. 
     
     
         9 . The elastic nonwoven laminate of  claim 8  wherein the elastic film is a multilayer film material. 
     
     
         10 . The elastic nonwoven laminate of  claim 8  wherein the basis weight of the elastic film is from 30 to 100 g/m 2 . 
     
     
         11 . The elastic nonwoven laminate of  claim 8  wherein the basis weight of the elastic film is from 40 to 80 g/m 2 . 
     
     
         12 . The elastic nonwoven laminate of  claim 4  wherein the extensible nonwoven web is a carded nonwoven web. 
     
     
         13 . The elastic nonwoven laminate of  claim 4  wherein the extensible nonwoven web is a carded asymmetric nonwoven web. 
     
     
         14 . The elastic nonwoven laminate of  claim 12  wherein the carded nonwoven web is not bonded except in the extrusion bonding process to the extruded spacer elements. 
     
     
         15 . The elastic nonwoven laminate of  claim 1  wherein the extensible nonwoven has a basis weight of from about 10 g/m 2  to about 50 g/m 2 . 
     
     
         16 . The elastic nonwoven laminate of  claim 1  wherein the extensible nonwoven has a basis weight of from about 10 g/m 2  to about 20 g/m 2 . 
     
     
         17 . The elastic nonwoven laminate of  claim 12  wherein the asymmetric nonwoven web has a CD tensile strength at break of less than 750 grams force per 50 mm, a MD tensile strength at break of at least 1000 grams force per 50 mm and an elongation at break of at least 50 percent in either direction. 
     
     
         18 . The elastic nonwoven laminate of  claim 12  wherein the asymmetric nonwoven web has a CD tensile strength at break of less than 600 grams force per 50 mm and MD tensile strength at break of at least 2000 grams force per 50 mm and an elongation at break of at least 50 percent in either direction. 
     
     
         19 . The elastic nonwoven laminate of  claim 1  wherein the force required to extend the elastic nonwoven laminate after the initial elongation in the second direction by 20 percent is increased by 50 percent or less, versus the elastic layer without attached extensible nonwoven sheets or webs. 
     
     
         20 . The elastic nonwoven laminate of  claim 2  wherein the force required to extend the elastic nonwoven laminate after the initial elongation in the second direction by 20 percent is increased by 20 percent or less, versus the elastic layer without attached extensible nonwoven sheets or webs. 
     
     
         21 . The elastic nonwoven laminate of  claim 2  wherein the force required to extend the elastic nonwoven laminate after the initial elongation in the second direction by 20 percent is increased by 10 percent or less, versus the elastic layer without attached extensible nonwoven sheets or webs. 
     
     
         22 . The elastic nonwoven laminate of  claim 4  wherein the extensible nonwoven web is a flat web. 
     
     
         23 . The elastic nonwoven laminate of  claim 4  wherein the extensible nonwoven has arcuate portions. 
     
     
         24 . The elastic nonwoven laminate of  claim 1  wherein the resulting laminate has an initial extension in a given first direction of at least 10 percent at 2.5 Kg force per 50 mm. 
     
     
         25 . The elastic nonwoven laminate of  claim 1  wherein the resulting laminate has an initial extension in a given first direction of at least 30 percent at 2.5 Kg force per 50 mm.