Stretchable Nonwoven Materials

Abstract

The present invention provides a nonwoven substrate comprising a fibrous web defining a surface; and a layer of a benefit agent wherein said benefit agent is selected from an additive composition, an enhancement component and combinations thereof; wherein said benefit agent is frothed and bonded to the fibrous web surface through a creping process and wherein said nonwoven substrate demonstrates improvements selected from enhanced tactile feel, enhanced printing, a decrease in hysteresis, an increase in bulk, an increase in elasticity/extensibility, an increase in retractability, a reduction in rugosities and combinations thereof when compared to an untreated substrate.

What is claimed: 
     
         1 . A nonwoven material comprising:
 a fibrous web defining a creped surface; and   an additive composition present on the creped surface of the fibrous web, the additive composition comprises a polyolefin copolymer combined with a nonionic surfactant, the additive composition comprising the nonionic surfactant in an amount up to 50% by weight.   
     
     
         2 . A nonwoven material as defined in  claim 1 , wherein the nonwoven material exhibits at least 30% elastic strain at 80% applied strain in a machine direction. 
     
     
         3 . A nonwoven material as defined in  claim 1 , wherein the additive composition forms a collapsed foam film layer on the creped surface. 
     
     
         4 . A nonwoven material as defined in  claim 1 , wherein the additive composition further comprises a copolymer of ethylene and acrylic acid. 
     
     
         5 . A nonwoven material as defined in  claim 1 , wherein the polyolefin copolymer comprises a polyethylene-octene copolymer. 
     
     
         6 . A nonwoven material as defined in  claim 3 , wherein the collapsed foam film layer is discontinuous. 
     
     
         7 . A nonwoven material as defined in  claim 1 , wherein the nonionic surfactant comprises an ethylene oxide adduct of a linear lauryl myristyl alcohol. 
     
     
         8 . A nonwoven material as defined in  claim 1 , wherein the nonionic surfactant comprises a seven mole ethylene oxide adduct of a linear lauryl myristyl alcohol. 
     
     
         9 . A nonwoven material as defined in  claim 1 , wherein the material exhibits an elongation at break of above about 45%. 
     
     
         10 . A nonwoven material as defined in  claim 1 , wherein the polyolefin copolymer and the nonionic surfactant are present in the additive composition at a weight ratio of from about 0.5:1 to about 3:1. 
     
     
         11 . A nonwoven material as defined in  claim 1 , wherein the nonwoven material exhibits at least 80% elastic strain at 100% applied strain in a machine direction. 
     
     
         12 . A nonwoven material as defined in  claim 1 , wherein the nonwoven material exhibits at least 50% elastic strain at 30% applied strain in a machine direction. 
     
     
         13 . A nonwoven material as defined in  claim 1 , wherein the nonionic surfactant has a cloud point. 
     
     
         14 . A nonwoven material as defined in  claim 13 , wherein the cloud point is from about 15° C. to less than 100° C. when combined with water in an amount of 1% by weight. 
     
     
         15 . A nonwoven material as defined in  claim 1 , wherein the nonionic surfactant includes hydrophilic segments and hydrophobic segments. 
     
     
         16 . A nonwoven material as defined in  claim 1 , wherein the fibrous web contains fibers comprised of a synthetic thermoplastic polymer. 
     
     
         17 . A nonwoven material as defined in  claim 1 , wherein the fibrous web comprises a tissue web comprised of pulp fibers. 
     
     
         18 . A nonwoven material as defined in  claim 1 , wherein the polyolefin copolymer comprises a copolymer of ethylene or propylene and an alkene. 
     
     
         19 . A nonwoven material as defined in  claim 1 , wherein the nonionic surfactant comprises an ethoxylate of an alkyl polyethylene glycol ether. 
     
     
         20 . A method for making a nonwoven material comprising:
 combining a nonionic surfactant and water mixture with a polyolefin copolymer to form an additive composition, the nonionic surfactant having a cloud point and wherein the nonionic surfactant and water mixture is formed at a temperature above the cloud point, the polyolefin copolymer and the nonionic surfactant being present in the additive composition at a weight ratio of from about 0.5:1 to about 3:1;   frothing the additive composition;   applying the frothed additive composition onto a heated dryer surface;   pressing a nonwoven substrate onto the coated heated dryer surface; and   creping the nonwoven substrate from the dryer surface.   
     
     
         21 . A method as defined in  claim 20 , wherein the nonwoven substrate comprises a tissue web comprised of pulp fibers or a fibrous web containing fibers comprised of a synthetic thermoplastic polymer. 
     
     
         22 . A method as defined in  claim 20 , wherein the nonionic surfactant comprises an ethoxylate of an alkyl polyethylene glycol ether. 
     
     
         23 . A process as defined in  claim 22 , wherein the polyolefin copolymer comprises a copolymer of ethylene or propylene and an alkene, and wherein the additive composition further comprises a copolymer of ethylene and acrylic acid.