Abstract: Differential basis weight nonwoven webs and a process for producing the webs is disclosed. In particular, the webs contain areas of higher basis weight and areas of lower basis weight. For instance, in one embodiment, the higher basis weight areas and the lower basis weight areas form alternating columns. The webs can be made according to a spunbond process or a meltblown process using a thermoplastic polymer or an air laid process using pulp fibers. The nonwoven webs are particularly well suited for use in diapers and other liquid absorbent products.

Abstract: A series of nips (200, 202, 204, 412, 414) formed by intermeshing grooves (22, 24, 26, 28) provides for a higher degree of stretch, particularly for lightweight webs (100) by stretching in stages in multiple grooved nips. The ability to adjust the degree of stretch at each nip can provide a high degree and variability of stretch with reduced web damage compared to a single step application of the same stretch. Improvements to the manufacture of lightweight components of personal care products such as diaper backing components are obtained.

Abstract: An extendable laminate having cross-directional extendability includes a film layer laminated to at least one neckable facing layer. The laminate can be made by attaching the film layer to the neckable facing layer to form the laminate, longitudinally slitting the laminate into a plurality of laminate strips, and necking the plurality of laminate strips. The laminate may be incorporated into an absorbent garment as an outer cover material, for example.

Abstract: A film laminate having cross-directional elasticity includes an elastomeric film laminated to at least one neckable facing layer such that fibers of the facing layer are attached to the elastomeric film. The laminate can be made by applying an elastic polymer, such as a liquid elastic polymer, onto a neckable nonwoven web to form a laminate; longitudinally slitting the laminate into a plurality of laminate strips; and necking the plurality of laminate strips. The method may be timed such that a setting of elastic memory in the elastic polymer occurs after the plurality of laminate strips are necked.

Abstract: A method for producing a machine direction and cross-machine direction elastic laminate includes the steps of providing a one direction elastic laminate material including at least one elastic layer and one facing layer and having a single direction of elasticity and coursing the one direction elastic laminate material through at least one stretching apparatus, such that the stretching apparatus stretches the laminate material in a direction perpendicular to the single direction of elasticity of the elastic laminate material, thereby producing a material that extends in a direction perpendicular to the direction of elasticity and also extends the elastic performance of the laminate in the single direction of elasticity.

Abstract: The present invention provides an elastic necked-bonded laminate material or elastic neck stretched bonded laminate material including at least one necked material joined to at least one elastic sheet that has been stretched in the cross-machine direction and allowed to relax prior to joining with the necked material. The elastic sheet can be stretched prior to being joined with the necked material or following the joining to the necked material. Also disclosed is a method of producing a elastic necked-bonded laminate material including the step of stretching the elastic sheet in a macroscopic stretching apparatus, such as between the nip of a series of spaced apart discs on two axles.

Abstract: In a particular embodiment, an absorbent article incorporates a material having a necked base layer of a generally fluid permeable material and at least two strips or regions of elastomeric material attached to the necked base layer material with a space therebetween such that a center region of the necked base layer material is bordered on at least two sides by composite regions of the elastomeric materials and the base layer material. The center region of necked base layer material is maintained in its necked condition and attached to an absorbent body of the article. The composite side regions are stretchable in at least a first direction as a result of tensioning and necking-in the base layer material prior to attaching the elastomeric materials. The material may be incorporated as a bodyside liner in the absorbent article.

Abstract: In a particular embodiment, an absorbent article incorporates a material having an inherently extensible base layer of a generally fluid permeable material and at least two strips or regions of elastomeric material attached to the extensible base layer material with a space therebetween such that a center region of the extensible base layer material is bordered on at least two sides by composite regions of the elastomeric materials and the base layer material. The center region of extensible material is maintained in an untensioned condition and attached to an absorbent body of the article. The composite side regions are stretchable in at least a first direction because of the extensible nature of the base layer material. The composite material may be incorporated as a bodyside liner in the absorbent article.

Abstract: The present invention provides a bodyside liner for a disposable absorbent article that is a nonwoven fabric laminate that includes a thin layer of fine fibers that has a basis weight of less than 2.5 grams per square meter. The present invention also provides disposable absorbent garments, such as diapers, that in such a nonwoven fabric laminate to reduce the migration of particles in absorbent garments.

Abstract: The present invention provides a nonwoven fabric laminate that comprises a thin layer of fine fibers that has a basis weight of less than 1.5 grams per square meter. The present invention also provides disposable absorbent garments, such as diapers, that in such a nonwoven fabric laminate to reduce the migration of particles in absorbent garments.