Abstract: A composite fabric includes a nonwoven fabric layer having non-bonded areas and a structured film layer discontinuously bonded to the nonwoven fabric layer. The discontinuously bonded nonwoven fabric layer and the structured film layer share an overlapping area with at least one set of coincident bond sites. The discontinuously bonded nonwoven fabric does not have another bonding pattern in the overlapping area distinct from the at least one set of coincident bond sites. A method of forming a composite fabric is also described. The method includes forming a fiber layer including a mat of at least partially unconsolidated fibers, positioning a structured film layer and the fiber layer such that they overlap, and discontinuously bonding the mat into a discontinuously bonded nonwoven fabric while simultaneously bonding the structured film layer to the nonwoven fabric layer. An apparatus for forming a composite fabric is also described.

Abstract: The composite elastic material (22) includes an elastic layer (4) and a structured film layer (15) having first and second opposing surfaces, with the second surface bonded to the elastic layer (4). The first surface of the structured film layer (15) has upstanding male fastening elements. The structured film layer (15) is gathered such that the upstanding male fastening elements point in multiple directions. The composite elastic material (22) can also be called a stretch-bonded laminate, which include an elastic layer (4) stretch-bonded to a second surface of a structured film layer (15). A first surface of the structured film layer (15), opposite the second surface, has upstanding male fastening elements. A process for making the composite elastic material (22) is also described. An absorbent article including the composite elastic material (22) is also described.

Abstract: The method of making a laminate (100) includes stretching a thermoplastic layer (102) so that it plastically deforms, relaxing the plastically deformed thermoplastic layer (102) to reduce its tensile strain, and subsequently laminating the thermoplastic layer (102) to a substrate (104) to make the laminate (100). The stretching, relaxing, and laminating are completed in-line. The thermoplastic layer has a first surface and a second surface opposite the first surface, with the first surface of the thermoplastic layer bearing a plurality of male fastening elements. The second surface of the thermoplastic layer (100) is laminated to the substrate (104).

Abstract: The article includes a thermoplastic layer having opposing first and second side edges and a first surface bearing male fastening elements. The thermoplastic layer is plastically deformed and has a retardance profile having an average retardance along a line from the first edge to a location 500 micrometers from the first edge and a distance from the first edge where 75% of the average retardance is observed of at least 10 micrometers. In some cases, a distance between the first and second side edges is up to 50 millimeters. In some cases, the article is a fastening tab. The method includes providing a thermoplastic film having opposing first and second side edges, with a distance between the opposing side edges of up to 50 millimeters, and stretching the thermoplastic film to form the thermoplastic layer, which is plastically deformed. The first surface of the thermoplastic film bears male fastening elements.

Abstract: The method includes stretching a thermoplastic layer so that it plastically deforms and decreases in width and subsequently laminating the thermoplastic layer to a substrate to make the laminate. The stretching and laminating are completed in-line. The thermoplastic layer has a first surface and a second surface opposite the first surface, with the first surface of the thermoplastic layer bearing a plurality of male fastening elements. The second surface of the thermoplastic layer is laminated to the substrate. In some cases, the thermoplastic layer decreases in width by at least 25 percent, and after the stretching, the thermoplastic layer has a width of up to 60 millimeters. In some cases, stretching is carried out by first and second rolls, and the second roll is faster than the first roll. The thermoplastic layer is typically not directed onto a third roll slower than the second roll before laminating.

Abstract: The method of making a laminate (100) includes stretching a thermoplastic layer (102) so that it plastically deforms, relaxing the plastically deformed thermoplastic layer (102) to reduce its tensile strain, and subsequently laminating the thermoplastic layer (102) to a substrate (104) to make the laminate (100). The stretching, relaxing, and laminating are completed in-line. The thermoplastic layer has a first surface and a second surface opposite the first surface, with the first surface of the thermoplastic layer bearing a plurality of male fastening elements. The second surface of the thermoplastic layer (100) is laminated to the substrate (104).

Abstract: The article includes a thermoplastic layer having opposing first and second side edges and a first surface bearing male fastening elements. The thermoplastic layer is plastically deformed and has a retardance profile having an average retardance along a line from the first edge to a location 500 micrometers from the first edge and a distance from the first edge where 75% of the average retardance is observed of at least 10 micrometers. In some cases, a distance between the first and second side edges is up to 50 millimeters. In some cases, the article is a fastening tab. The method includes providing a thermoplastic film having opposing first and second side edges, with a distance between the opposing side edges of up to 50 millimeters, and stretching the thermoplastic film to form the thermoplastic layer, which is plastically deformed. The first surface of the thermoplastic film bears male fastening elements.

Abstract: A composite fabric includes a nonwoven fabric layer having non-bonded areas and a structured film layer discontinuously bonded to the nonwoven fabric layer. The discontinuously bonded nonwoven fabric layer and the structured film layer share an overlapping area with at least one set of coincident bond sites. The discontinuously bonded nonwoven fabric does not have another bonding pattern in the overlapping area distinct from the at least one set of coincident bond sites. A method of forming a composite fabric is also described. The method includes forming a fiber layer including a mat of at least partially unconsolidated fibers, positioning a structured film layer and the fiber layer such that they overlap, and discontinuously bonding the mat into a discontinuously bonded nonwoven fabric while simultaneously bonding the structured film layer to the nonwoven fabric layer. An apparatus for forming a composite fabric is also described.

Abstract: A method of making a breathable, elastic film laminate comprising the steps of stretching an elastic film in a first direction, spot welding at least one nonwoven web to the film while it is stretched, and stretching the film laminate in a second direction to create apertures in the film. Articles derived from the method are also described.

Abstract: A method of making extensible web laminates comprising a multilayer film and at least one web layer and the use of such extensible web laminates in personal care articles. The method generally includes activating the multilayer film in a first direction by stretching at least a portion of the multilayer film past the elastic deformation limit of the skin layers and recovering the skin layers with the elastomeric core layer to produce a multilayer film that is elastic in the first direction. The activated multilayer film is subsequently stretched beyond the deformation limit of the skin layers in a second direction substantially perpendicular to the first direction. At least one web layer is applied to the multilayer film while in the stretched state. The multilayer film is then recovered to produce an extensible web laminate.

Abstract: A method of making extensible web laminates comprising a multilayer film and at least one web layer and the use of such extensible web laminates in personal care articles. The method generally includes activating the multilayer film in a first direction by stretching at least a portion of the multilayer film past the elastic deformation limit of the skin layers and recovering the skin layers with the elastomeric core layer to produce a multilayer film that is elastic in the first direction. The activated multilayer film is subsequently stretched beyond the deformation limit of the skin layers in a second direction substantially perpendicular to the first direction. At least one web layer is applied to the multilayer film while in the stretched state. The multilayer film is then recovered to produce an extensible web laminate.