Abstract: A diaper outer cover of a layered nonwoven material having an outer meltblown fiber layer of a meltblown material having an average basis weight in the range of about 1 g/m.sup.2 to about 7 g/m.sup.2 disposed on an inner nonwoven material layer, preferably a spunbond web.

Abstract: A laminate material formed of an elastomeric polymer sheet and a nonwoven fabric sheet. The sheets are passed through a niproll assembly during lamination, one of the niprolls having a series of embossing points protruding therefrom, and the other niproll being substantially flat. The embossing points press selective areas of the preferably molten polymer sheet into the fabric sheet, encapsulating the fabric fibers and bonding thereto. The resulting material has points of bonding where penetration has occurred and areas of nonpenetration, providing adherence of the two sheets while permitting independent movement of the fibers and elastic properties. Preferably, a release agent is added to the elastomeric polymer to reduce the possibility of the elastomer layer sticking to the nonwoven layer when the laminate is wound onto a supply roll.

Abstract: A soft, breathable elastic laminate of an elastic film loaded with a filler having a particle size suitable for pore formation and stretched in at least two directions to form a plurality of micropores bonded to a nonwoven web. In accordance with one embodiment, the elastic film is water vapor impermeable prior to being stretched.

Abstract: A method of making a stretchable composite by applying an elastomeric precursor to a neckable material, neck-stretching the neckable material and heating the elastomeric precursor such as by heating, while the neckable material is in a necked condition. The elastomeric precursor can comprise a latex or thermoset elastomer which is applied to the fibrous neckable material in an amount between 5 g/m.sup.2 to about 50 g/m.sup.2.

Abstract: A breathable elastic laminate is formed by bonding a film including an elastic water vapor-soluble polymer to a neckable nonwoven web such that when the film is relaxed, the web is in a necked state. The breathable laminate is stretchable in a direction parallel to the narrowing or necking of the web. The laminate possesses excellent water vapor permeability but acts as a barrier to the passage of odor-causing chemicals including ammonia.

Abstract: Transversely stretchable elastic laminated fabric with cloth-like facings was made by a two-step process. In the first step an inelastic laminate was made by continuously extruding an elastomer sheet between two plies of a fibrous sheet and joining the plies by applying pressure on them between a closed gap niproll assembly. Two longitudinal slits were made into the laminate. Then the rolls of inelastic laminate so made were taken to an oven and the laminate was unwound and pulled through the oven at an elevated temperature, while tension on the web was increased until the slits necked. The necked laminate was wound up on a takeup roll. When samples were unwound, surprisingly they did not grow in width, and they showed good CD-elasticity (elongation and springback). Breathability of the laminate was superior to the laminate formed using an open niproll assembly gap.

Abstract: A multi-layered structure having improved liquid barrier properties is provided. The multi-layered structure includes a porous hydrophobic layer and a spacing layer adjacent to and in juxtaposition with the porous hydrophobic layer. The function of the spacing layer is to provide sufficient channels for a liquid while supporting all or substantially all of a compressive pressure exerted against the spacing layer. As such, when the spacing layer is contacted with a liquid, such as water, saline or a bodily fluid such as blood, and subjected to a compressive pressure, of at least 2 psi, applied generally perpendicularly to the spacing layer, the channels are available within the bulk of the spacing layer for such liquid to flow therein or therebetween, while all or substantially all of the compressive pressure is supported by the spacing layer. In this way, the liquid in contact with the spacing layer flows into these channels without passing through the porous hydrophobic layer.