Abstract: A three-dimensional highly elastic film/non-woven composite having a fluid and air impervious core layer and a first and second consolidated layer. The consolidated layers have unidirectional and non-unidirectional fibers. The composite is formed by laminating the air and fluid impermeable elastic core layer between the two layers of consolidated non-wovens. The resulting composite stretches only in the cross-machine direction due to the unidirectional properties of the consolidated non-woven material. The layers are then point bonded or welded together. Preferably the layers are welded by passing the composite between an ultrasonic horn and an ultrasonic bond roll having raised areas for effecting the weld points. A thin inelastic membrane is formed at each of the weld points. The welded composite may then be pre-stretched to rupture the membranes, thereby creating apertures, which makes the composite permeable.

Abstract: A tough low set elastic film exhibiting surprisingly high tear resistance and method of making the same. The film of the invention is especially beneficial when holes form on the films during manufacturing or normal wear and method of making. The film has activated and non-activated zones formed during an activation process. The activated zones allow the film to expand without generating excessive tensional forces. The film has M-polypropylene or M-polyethlyene skin layers and a core layer having an elastomeric polyurethane, ethylene copolymer such as ethylene vinyl acetate, an ethylene/propylene copolymer elastomer or ethylene/propylene/diene terpolymer elastomer. The activation process allows the skin layers to behave more like the core layer.

Abstract: A tough low set elastic film exhibiting surprisingly high tear resistance and method of making the same. The film of the invention is especially beneficial when holes form on the films during manufacturing or normal wear and method of making. The film has activated and non-activated zones formed during an activation process. The activated zones allow the film to expand without generating excessive tensional forces. The film has M-polypropylene or M-polyethylene skin layers and a core layer having an elastomeric polyurethane, ethylene copolymer such as ethylene vinyl acetate styrenic elastomer, an ethylene/propylene copolymer elastomer or ethylene/propylene/diene terpolymer elastomer. The activation process allows the skin layers to behave more like the core layer.