MXPA00002558A - Elastic film laminates - Google Patents

Abstract

An elastic liquid impermeable laminate is disclosed having an extensible barrier film;an 8 g/m2 to 100 g/m2 elastomeric nonwoven web comprising fibers of low density polyethylene having a density less than 0.89 g/cm3;and an extensible cloth-like outer layer, such as a nonwoven web of spunbonded fibers. The barrier laminate can be laminated by thermal point bonding to create patterns having improved loft, excellent hand and while achieving peel strengths in excess of 1000 grams.

Description

LAMINATE OF ELASTIC FILM Field of the Invention The present invention relates to film laminates. More particularly, the present invention relates to elastic laminates of films and non-woven fabrics.

Background of the Invention Film laminates that have become an important trade item, which has found a wide variety of applications including use as an outer cover for personal care items such as diapers, underpants, incontinence garments, the products for the hygiene of the woman similar. In addition, film laminates have found use in outdoor fabrics, tarpaulins, protective clothing, infection control products, similar garments. The films can provide the desired barrier properties to the article while other materials laminated thereto can provide additional features such as reinforcement, abrasion resistance and / or good feel.

Many articles incorporating film laminates are desirably at least partially elastic. For example, an outer covering of a diaper that is elastic will have an improved body conformation relative to inelastic articles. However, achieving the desired elasticity while maintaining other desired characteristics such as the ability to breathe, good aesthetics and low cost is problematic. Low cost film laminates, such as those used in disposable articles, often suffer from poor peel strengths. - Delamination of the film laminate is undesirable since the appearance of a lesser quality article often increases the risk of creating a tear or tear in the film.

Thus there is a need for a film laminate which exhibits elasticity but retains the desired characteristics such as breathability, good feel and excellent peel resistance. In addition, there is a need for such a laminate having very well defined bonding patterns, fluffiness and overall improved aesthetics. Furthermore, there is a need for such a barrier laminate which has a cloth-like outer surface, which is durable and which can also employ a variety of film and laminate structures. Furthermore, there is a need for such a film laminate that can be manufactured by a robust process which is functional under a wide latitude of processing conditions and parameters, Synthesis of the Invention The aforementioned needs are filled with the problems experienced by those skilled in the art by an elastic laminate of the present invention comprising an extendable base film, an elastic intermediate nonwoven fabric and an outer fibrous material extending therefrom. The first laminate of the elastomeric intermediate fabric is attached to the base film and the second layer is attached to the outer fibrous material. In a further aspect, the elastomeric intermediate fabric comprises amorphous polymer. As an example the amorphous polymer can comprise a low density ethylene elastomer component which comprises a copolymer of ethylene and an alphadefine. In a further aspect, the low density polyethylene elastomer desirably has a density d between about 0.86 g / cubic centimeter and about 0.8 g / cubic centimeter. In addition, the amorphous polymer can comprise a mixture having a second polyolefin polymer, such as a second ethylene polymer having a higher density. Desirably the low density polyethylene elastomer comprises at least about 50% by weight of the fiber. The elastic intermediate fabric desirably comprises a woven fabric such as a fabric of meltblown fibers.

The stretchable base film may comprise an elastic film and desirably comprises a film coapacity to breathe. In one aspect of the present invention the film may comprise a barrier with elastic breathing capacity such as, for example a stretched filled film comprising an elastomeric polyethylene polymer a filler. The base film, the elastic intermediate fabric and the outer fibrous material preferably have a collective basis weight of less than about 100 g / square meter. The outer fibrous material layer comprises a thermoplastic nonwoven fabric. Desirably, the outer non-woven layer comprises a cloth-like fabric, which has excellent touch and fall. In one aspect of the invention, the outer non-woven hood comprises a non-woven web that is reversibly tapered. The laminate of the present invention desirably has a peel strength in excess of 20 g / square centimeter and even more desirably an excess of 50 g / square centimeter. In addition, the barrier laminate with capacity to breathe can have a water vapor transmission rate in excess of 300 g / square meter / day, 800 g / square meter / day and even 1,500 g / square meter / day. The outer fibrous material may comprise a non-woven fabric and, in a further aspect may be laminated to the binding layer by laminating the respective layers together. Suitable methods for laminating the layers include, but are not limited to, the thermal point junction, the ultrasonic junction and the like.

Definitions As used herein the term woven or "woven" fabric means a fabric having a fiber structure of individual yarns which are interleaved but not in an identifiable manner as in a woven or mesh fabric. Fabrics or non-woven fabrics have been formed by many processes such as, for example, meltblowing processes, spinning processes, hydroentanglement, placement by air and carded and bonded tissue processes.

As used herein, "microfiber fabric" means a fabric comprising fibers having an average fibr diameter of less than about 10 μm in at least one dimension.

As used herein the term "coiled bonded fibers" refers to small diameter fibers of a polymeric material oriented in essentially molecular form. Spunbonded fibers can be formed by extruding the molten thermoplastic material as filaments from a plurality of fine, usually circular, capillary vessels of a spinner with the diameter of the filaments extruded then being rapidly reduced as indicated, eg , in the patents of the United States of America number 4,340,563 granted to Appel and others, and 3,692,618 granted Dorschner and others, 3,802,817 granted to Matsuki and others, 3,338,992 and 3,341,394 granted to Kinney, 3,502,763 granted Hartman, 3,542,615 granted to Dobo and others, and 5,382,400 awarded to Pike and others. Yarn bonded fibers are not generally sticky when they are deposited on a collecting surface and are generally continuous. Fibers bonded with yarn are often about 10 millimeters or more in diameter. However, the material bonded with microfiber yarn can be achieved through various methods including, but not limited to, those described in commonly assigned United States of America patent applications numbers 08 / 756,426 filed on November 26, 1996 by Marmon and others and application number 08 / 565,261 filed on November 30, 1995 on behalf of Pike and others, whose contents are incorporated herein by reference.

As used herein, the term "meltblown fibers" means fibers of polymeric material which are generally formed by extruding a molten thermoplastic material through a plurality of thin, usually circular, capillary blood vessels, such as melted filaments or filaments. inside streams of gas (for example air), usually hot and high speed which attenuate the filaments of molten thermoplastic material to reduce its diameter. Then, the melt blown fibers can be carried by the gas stream at high speed and are deposited on a collecting surface to form or weave meltblown fibers and randomly dispersed. The process is described, for example, in US Pat. No. 3,849,241 issued to Butin et al. And US Pat. No. 5,271.88 issued to Timmons et al. Fusible blown fibers can be continuous or discontinuous and are generally tacky when deposited on the collecting surface. Meltblown fibers can include microfiber fabrics.

As used herein, an "SMS laminate" means laminate bonded with spinning / meltblowing / spunbonding (SMS). Examples of multi-layer non-woven laminates are described in United States of America patents Nos. 4,041,203 issued to Brock et al., 5,178.93 issued to Perkins et al. And 5,188,885 issued to Timmons others. Such a laminate can be sequentially deposited on a movable forming web first a layer of spunbonded fabric, then a layer of melt blown fabric and at least one other layer bonded with spinning and then bonding the laminate such as by thermal bonding as is described below. Alternatively, the fabric layers can be individually made, collected in rolls and combined in a separate bonding country.

As used herein the term "polymer" generally includes but is not limited to homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. In addition, unless specifically limited otherwise, the term "polymer" includes all possible spatial configurations of the molecule. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

As the term "amorphous polymer" is used herein when used herein to describe a tie layer as either an intermediate layer or a separately applied layer, it means a thermoplastic polymer such as certain polyolefins with a density in the range of from about 0.85 to about 0.89 g / cubic centimeter and a low crystallinity, for example, of less than about 30.

As used herein, the term "machine direction" or MD means the length of a fabric in the direction in which it is produced. The term "cross machine direction" or CD means the width of the fabric, for example an address generally perpendicular to the machine direction.

As used herein, "ultrasonic bonding" means a process carried out, for example, by passing the fabric between a sonic horn and an anvil roll as illustrated in U.S. Patent No. 4,374.88 granted to Bomslaeger or in the United States patent of America number 5,591,278 granted to Goodman and others.

As used herein, "point union" means joining one or more fabrics into a plurality of discrete points. For example, the thermal point joint generally involves passing one or more layers to be joined between heated rolls such as, for example, an engraved pattern roll and a smooth calender roll. The engraved roller has some form of pattern so that the entire fabric is not attached over its entire surface, and the anvil roller is usually flat. As a result of this, several patterns have been developed for the engraved rolls for functional as well as aesthetic reasons. An example of a pattern that has points is the Hansen Pennings pattern or "H &P" with about 30% area bonded when new and with about 200 joints / square inch as taught in the United States Patent of America number 3,855,046 awarded to Hansen & Pennings. The H &P pattern has bolt or square point joining areas where each bolt has a side dimension of 0.965 millimeters, a separation of 1,778 millimeters between bolts, and a joint depth of 0.584 millimeters. The resulting pattern has a bound area of about 29.5% when it is new. Another typical point union pattern is the Hansen Pennings pattern or "EHP" which produces a 15% united area when new with a square bolt having a side dimension of 0.94 millimeters, a spacing of 2,464 millimeters of bolts. and a depth of 0.991 millimeters. Another typical point union pattern is designated by the designation "714" which has square bolt union areas e where each bolt has a side dimension of 0.023 inches, a gap of 0.062 inches (1.575 mm) between the bolts, and a Bonding depth of 0.033 inches (0.838 millimeters). The resulting pattern has a bound area d around 15% when it is new. Another common pattern is the star-C pattern which has, when new, a united area of about 16.9%. The star-C pattern has a bar in the transverse direction or a "corduroy" design interrupted by shooting stars. Other common patterns include a diamond pattern with slightly off-centered and repetitive diamonds with around a 16% area and a wire weave pattern that looks like the name suggests, for example, as a window grid, with around of a united area of 15%. An additional pattern is the "S-wave" pattern that has around a 17% area when it is new. Typically the percent of bonded area varies from about 10% to about 30% of the area of the fabric laminated fabric.

As used herein, the term "barrier" means a film, a laminate or other fabric which is essentially impermeable to the transmission of liquids and which has a hydro head of at least 50 mbar of water. The hydro head as used herein refers to a measure of the liquid barrier properties of a fabric. However, it should be noted that the barrier fabrics of the present invention may have a hydro head value greater than 80 mbar, 150 mbar or even 30 mbar of water.

As used herein, the term "ability to breathe" refers to a material which is permeable to water vapor having a minimum water vapor transmission rate of about 300 g / square meter / 24 hours. The rate of water vapor transmission of a fabric is a rate of water vapor transmission which, in one aspect, gives an indication of how comfortable a fabric can be to use it. L WVTR (water vapor transmission rate) is measured as indicated below and the results are reported in grams / square meter / day. However, frequent applications of breathable barriers desirably have higher water vapor transmission rates and the breathable laminates of the present invention may have water vapor transmission rates that exceed about 800 g. / square meter / day, of 1,500 g / square meter / day or even exceed 3,000 g / square meter / day.

As used herein the term "stretchable" means stretchable or stretchable in at least one direction.

As used herein, "elastic" means a material which, with the application of a pressing, stretchable force, is extendable, to a stretched pressed length which is at least 150% of its length pressed and relaxed, and which will retract at least 50 of its elongation with the release of the lengthening force. hypothetical example would be a 1-inch sample of a materi which is stretchable to at least 1.50 inches and which, with the release of the pressing force, will retract to a length of no more than 1.25 inches.

As used herein, the term "inelastic" or "n-elastic" refers to any material which does not fall within the definition of "elastic" indicated above.

As used herein the term "monocomponent fiber" refers to a fiber formed with one or more extruders using only one polymer. This does not mean that they exclude the fibers formed from a polymer to which small amounts of additives have been added for coloring antistatic properties, lubrication, hydrophilicity, etc.

As used herein the term "multi-component fibers" refers to fibers which have formed at least two extruded polymers from separate extruders per yarn together to form a fiber. Multicomponent fibers are also sometimes referred to as conjugated or bicomponent fiber. The polymers of a multicomponent fiber are arranged in different zones placed essentially constant across the cross section of the fiber and extend continuously along the length of the fiber. The configuration of such a fiber may be, for example, a pod / core arrangement where one polymer is surrounded by another or may be a side-by-side arrangement, or cake arrangement or an arrangement of "islands in the sea" type. . Multicomponent fibers are taught in U.S. Patent No. 5,108,820 issued to Kaneko et al., And U.S. Patent No. 4,795.66 to Krueger and to the U.S. Patent Number of America. 5,336,552 granted to Strack and others. Conjugated fibers are also taught in U.S. Patent No. 5,382,400 issued to Pike et al. And may be used to produce crimped fibers by employing the different crystallization rates of the two (or more) polymers. For bicomponent fibers, the polymers can be present in proportions of 75/25, 50/50, 25/75 or any other desired proportions. The fibers may also have shapes such as those described in U.S. Patent Nos. 5,277,976 issued to Hogle et al., 5,466,410 issued to Hills and 5,069,970 and 5,057,368 issued to Largman et al., Which describe fibers with conventional n-forms.

As used herein the term "mixture" means a mixture of two or more polymers while the term "alloy" means a subclass of mixtures wherein the components are immiscible but have been compatibilized.

As used herein, the term "biconstituent fibers" or "multi-constituent fibers" refers to fiber which has been formed from at least two polymers extruded from the same extruder as a mixture. The term "mixture" is defined above. The biconstituent fibers do not have the various polymer components arranged in different zones placed relatively constant across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber; instead, they usually form fibrils or protofibrils which start and end at random. Bicomponent and biconstituent fibers are also discussed in the textbook Mixtures and Polymer Compounds by John A. Manson and Leslie H. Sperling, copyright 1976 by Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0 -306-30831-2, pages 273 to 277.

As used herein, the term "joining window" means the temperature range of the mechanism, for example a pair of heated bonding rolls, used to join the non-woven fabric together, upon which such a union is successful.

As used herein, the term "canvas" meant a light weight fabric used as a backing material. Canvases are often used as the base fabric for coated or laminated products.

As used herein, the term "pledge" means any type of clothing which may be worn. It includes industrial workwear and coveralls, undergarments, pants, shirts, coats, gloves, socks and the like.

As used herein the term "infection control product" means medically oriented articles such as surgical covers and suits, face masks, head covers such as caps, caps and surgical layers, foot articles such as such as shoe covers, boot covers and slippers, bandages for wounds, bandages, sterilization wraps, wipes, garments, lab coats, covers, aprons and bags, bedding for patients, bed sheets and cribs and the like.

As used herein, the term "personal care product" means diapers, underpants, absorbent underwear, adult incontinence products, and women's hygiene products.

As used herein, the term "protective cover means a cover for vehicles such as cars, trucks, boats, airplanes, motorcycles, bicycles, golf carts, etc., covers for equipment frequently left outdoors such as grills, playground equipment and of garden (blinding, rototrilladoras, etc.) and furniture for meadow, as well as covers for floor, tablecloths and covers for lunch area.

Brief Description of the Drawings Figure 1 is a cross-sectional view of a laminate of the present invention.

Figure 2 is a cross-sectional view of a laminate of the present invention.

Figure 3 is a schematic diagram of a process line for making a laminate of the present invention.

Figure 4 is a view of a bonding pattern suitable for use with the present invention.

Figure 5 is a view of a joint pattern suitable for use with the present invention.

Detailed description of the invention With reference to Figure 1, the present invention is directed to a multilayer laminate 10 comprising a film 12, an outer fibrous layer 20 and an intermediate elastic nonwoven fabric. The intermediate nonwoven fabric 14 has a first side 16 and a second side 18. The outer fibrous layer 20 is attached to the second side 18 of the intermediate elastic fibrous nonwoven fabric 14 and the film 12 is attached to the first side 16 of the fabric intermediate elastic nonwoven 14.

The intermediate elastic nonwoven fabric comprises a layer of amorphous polymer fibers. The polymer composition desirably comprises an elastomer and may further include a glutinizer or other bonding aid for improving adhesion between the intermediate nonwoven fabric and the opposite film and the outer nonwoven layer or layers. Examples of suitable polymers include, but are not limited to, elastomeric polyolefins, ethylene-vinyl acetate (EVA), EPDM rubbers, ethylene-ethyl acrylate (EEA), ethylene acrylic acid (EAA), ethylene methyl acrylate (EMA), polyurethane (PU), polyether polyamide block copolymers, block copolymers having the general formula ABA 'or AB as a copoly (styrene / ethylene-butylene), styrene-poly (ethylene propylene) ) -styrene, styrene-poly (ethylene-butylene) -styrene, similar.

In a preferred embodiment, the amorphous polymer comprises one or more elastic polyolefins such as a low density polyethylene elastomer, an elastic polypropylene, flexible polyolefins and glutinized polymers such as styrenic block copolymers, polyurethanes and block polyamide polyethers. In one aspect of the present invention the intermediate elastic nonwoven fabric comprises, at least in part, a low density elastomeric polyolefin polymer component such as, for example, a low density ethylene elastomer component having a density less than 0.89 g / cubic centimeter. Desirably the ethylene elastomer comprises an essentially linear ethylene which has a density of less than 0.89 g / cubic centimeter, desirably from about 0.86 g / cubic centimeter to about 0.88 g / cubic centimeter and even more desirably about 0.87. g / cubic centimeter. The ethylene elastomer preferably comprises at least about 50% by weight of the polymer portion of the fibers, and more desirably from about 70% to about 100% by weight. Preferably the ethylene elastomer comprises a polymer wherein the ethylene monomers are polymerized with an alpha olefin so that the resulting polymer composition has a narrow molecular weight distribution (Mw / Mn), a homogeneous branching and a long chain controlled branch. Suitable alphadefines include, but are not limited to 1-octene, 1-butene, 1-hexene and 4-methyl-pentene. Exemplary polymers include those which are known in the art as "metallocene", "constrained geometry" or "single site" catalyzed polymers such as those described in U.S. Patent Nos. 5,472,775 issued to Obijeski. and others; 5,451,450 awarded to Erderly and others; 5,539,124 granted to Etherton and others 5,554,775 granted to Krishnamurti and others; whose full contents of these are incorporated herein by reference.

The metallocene process generally uses a metallocene catalyst which is activated, for example, by means of a co-catalyst. Examples of the metallocene catalysts include bis (n-butylcyclopentadienyl) titanium dichloride, bis (n-buyl-1-cyclopentin-1-oi) -di-1-zirconium-zirconium bis (cyclopentadienyl) -scandium chloride, bis (indenyl) dichloride of zirconium, bis (methylcyclopentadienyl) titanium dichloride bis (methylcyclopentadienyl) zirconium dichloride, cobalcenone cyclopentadienyltitanium trichloride, ferricenne, d-hafnocene dichloride, isopropyl (cyclopentadienyl, -1-fluoroenyl) zirconium dichloride, molybdocene dichloride, niquelocene, dichloride d niobocene, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirconocene dichloride, etc. A more exhaustive list of such compounds is included in United States Patent No. 5,374.99 issued to Rosen et al. and assigned to Dow Chemical Company. Tale compounds are also discussed in U.S. Patent No. 5,064,802 issued to Stevens and others also assigned to Dow. However, numerous other metallocene catalysts, single site catalysts, constrained geometry catalysts and / or comparable catalyst systems are known in the art.; see, for example, Kirk-Othmer's chemical technology encyclopedia, fourth edition, volume 17, Olefin Polymers, pages 765-767 (John Wiley &Sons 1996); the contents of which are incorporated herein by reference.

In relation to elastomeric polymers, U.S. Patent No. 5,204,429 to Kaminsky et al. Describes a process which can produce elastic copolymers of cycloolefins and linear olefins using a catalyst which is a metallocene transition metal compound. chiral stereorigid and an aluminoxane. U.S. Patent Nos. 5,278,272 and 5,272,236, both issued to Lai et al, and assigned to Dow Chemical and entitled "Essentially Linear Olefin Polymers and Elastic" describe polymers having particular elastic properties, the complete contents of which are incorporated herein. by reference. Suitable low density ethylene elastomers are commercially available from Do Chemical Company of Midland, Michigan under the trade name AFFINITY1"3 ™ 3, including AFFINITY" 1"03 EG8200 (5 MI), XU 58200.02 (3 MI), XU 58300.00 (10 MI) and Exxon Chemical Company of Houston, Texas under the trademark EXACT1 ™ "* 4049 (4.5 MI, 0.87 g / cm3); 4011 (2.2 MI, 0.888 g / cm3); 4041 (3 MI, 0.878 g / cm3); 400 (10 MI, 0.88 g / cm3).

Furthermore, it is believed that the intermediate elastomeric fibrous layer may comprise a polymer blend of the amorphous polymer with one or more other polymers which comprises up to about 75% by weight of the fiber and more desirably up to about 50% of the fiber . It is believed that the fibers may comprise a low density polyethylene elastomer and the additional thermoplastic polymers, desirably more crystalline and / or higher density polyolefins. Polyolefins that may be suitable for use with the present invention include, but are not limited to linear low density polyethylene (density between about 0.90 g / cubic centimeter-0.92 g / cubic centimeter), low density polyethylene (0.915-). 0.925 g / cubic centimeter, ethylene-propylene copolymers, ethylene vinyl acetate, ethylene ethyl acrylate, ethylene acrylic acid, ethylene methyl acrylate and the like.

Examples of additional commercially available elastic polymers include, but are not limited to, Himont CATALLOY KS350, KS357 and KS359. The polymer Himont Catalloy is a reactive olefinic multiple step product in which a random copolymer of propylene ethylene amorphous is dispersed molecularly in a continuous matrix of predominantly low-level ethylene monomer / propylene monomer, as described in the patent. of the United States of America number 5,300.36 granted to Ogale. In addition, useful elastomeric resins include block copolymers having the formula ABA 'or AB, where A and A' are each a thermoplastic polymer end block which contains a styrenic moiety such as a poly (vinyl arene) ) and wherein B is a middle block of elastomeric polymer such as a conjugated diene or a lower alkene polymer. Block copolymers of type A-B-A 'may have different or same thermoplastic block polymers for blocks A and A', and the block copolymers present are intended to encompass linear, branched and radial block copolymers. In this aspect, radial block copolymers can be designated (A-B) m-X, e where X is a polyfunctional atom or molecule and in which each (A-B) ra-radiates from X in a way that A is an end block.

In the radial block copolymer, X can be an organic or inorganic polyfunctional atom or molecule and m is an integer having the same value as the functional group originally present in X. This is usually at least 3, and is frequently of 4 or 5, but it is not limited to this. Therefore, in the present invention, the expression "block copolymer" and particularly block copolymer of "ABA '" and "AB" is intended to encompass all block copolymers having rubberized blocks and thermoplastic blocks as discussed above, which can be extruded (for example by meltblowing) and without limitation as to the number of blocks. The elastomeric nonwoven fabric can be formed from, for example, elastomeric block copolymers of (polystyrene / poly (ethylene-butylene) / polystyrene). Commercial examples of such elastomeric copolymers are, for example, those known as KRATON materials which are available from the Shell Chemical Company of Houston, Texas. KRATON block copolymers are available in several different formulas, a number of which are identified in U.S. Patent Nos. 4,663,220 and 5,304,599, the complete contents of which are incorporated herein by reference.

Polymers composed of an elastomeric tetrablock A-B-A-B copolymer can also be used in the practice of this invention. Such polymers are discussed in U.S. Patent No. 5,332,613 issued to Tylor et al. In such polymers, A is a block of thermoplastic polymer and B is an isoprene monomer unit hydrogenated to essentially one unit of poly (ethylene-propylene) monomer. An example of such a tetrablock copolymer is an elastomeric block copolymer of styrene poly (ethylene-propylene) -styrene-poly (ethylene-propylene) or SEPSE available from Shell Chemical Company of Hosuton, Texas under the trade designation KRATON.

Other exemplary elastomeric materials which are believed to be suitable for use with the present invention include polyurethane elastomeric materials such as, for example, those available under the trademark TINY B. B. Goodrich & Company, or MORTHANE ™ 1"by Morton Thioko Corporation, elastomeric polyester materials such as, for example, those available under the HYTREL trade designation of EI DuPont De Nemours &Company, and those known as ARNITEL, formerly available from Akz Plastics from Arnhem, Holland and now available from DSM d Sittard, Holland.

In order to improve the thermal compatibility of the intermediate nonwoven fabric with those of the adjacent layers it may be desirable to add a glutinizer or a bonding aid to the elastic polymer composition. Examples of suitable glutinizing agents include, but are not limited to, those described in U.S. Patent No. 4,789,699 issued to Kieffer et al. Examples of commercially available glutinizing agents are REGALREZ 112 available from Hercules, Inc. of Wilmington, Delaware; ESCORE 5300 from Exxon Chemical Company and WINGTACK 95 from Goodyear Chemica Company of Akron, Ohio. The amount of glutinizer added will vary with respect to the particular elastic polymer employed in the intermediate elastic fiber layer and those polymers that comprise the adjacent layers. Although the amount of glutinizer added to the elastic intermediate layer will vary, a frequent addition of from about 5% to about 20% by weight of the polymer composition is desirable.

In a preferred embodiment, the elastic non-woven fabric comprises a matrix of fibers such as a meltblown fiber fabric, in a further aspect the fibrous elastic cap may comprise a layer of fibers bonded with spinning and / or of basic length fibers. of similar bas weights, desirably the non-woven fabric has a basis weight d between about 10 g / square meter and about 100 g / square meter, and more desirably a basis weight of between about 25 g / square meter and about 60 g / square meter. The selection of the basis weight will vary with respect to the basis weight of the overall laminate as well as the recovery properties of the film and / or the outer nonwoven layer. Where both the outer nonwoven layer and the film are stretchable but inelastic materials, an intermediate elastic fiber layer of higher basis weight will often be required to provide an overall laminate with the elastic properties. However, where the film and / or the outer non-woven layer is also elastic, the intermediate elastic fabric may comprise less than the basis weight of the overall laminate.

The stretchable film may comprise either a monolayer or a multilayer film. In addition, the non-porous and microporous films are believed to be suitable for use with the present invention. Desirably the film comprises a barrier layer and also exhibits a good drop; such films desirably have a basis weight of about 15 g / square meter and 100 g / square meter and, more desirably, between about 20 g / square meter and 60 g / square meter. The thermoplastic polymers used in the manufacture of the films of the present invention include, but are not limited to polyolefins including homopolymers, copolymers, terpolymers and mixtures thereof. In addition, flexible polyolefin films are also believed to be suitable for use in the present invention. Additional film-forming polymers which may be suitable for use with the present invention, alone or in combination with other polymers, include ethylene vinyl acetate (EVA), ethylene ethyl acrylate (EEA), ethylene acrylic acid (EAA) , ethylene methyl acrylate (EMA), normal ethylene butyl acrylate (EnBA), polyurethane (PU), poly (ether ester) and poly (amide ether) block copolymers. However, elastomeric polyolefin polymers are preferred such as, for example, ethylene and propylene polymers as well as copolymers, terpolymers and mixtures thereof.; examples include, but are not limited to, elastomeric polyolefin and ethylene-propylene copolymer blends.

In one aspect of the invention, the film may comprise a breathable barrier comprising such as, for example, microporous films having a water vapor transmission rate of at least 300 g / m2 / day and more. Desirably they have a water vapor transmission rate in excess of 800 g / square meter / day or 1,500 g / square meter / day. The microporous breathable film can be formed with any one of several methods known in the art. As an example, the breathable barrier film may comprise a filled and stretched film which includes a thermoplastic polymer and a filler. These (and other) components can be mixed together, heated and then extruded into a monolayer or multilayer film. The filled film can be made by any one of a variety of film-forming processes known in the art such as, for example, by the use of blow or melt film equipment. The thermoplastic polymer and filler can be stretched in at least one direction, thereby reducing the thickness or size of the film and creating a network of micropores of a size and frequency to achieve the desired level of breathability. Examples of barrier films capable of breathing suitable for use with the present invention are described in WO 95/16562 filed June 22, 1995 in the name of McCormack; WO 96/1934 filed June 27, 1996 in the name of McCormack and others, the patent applications of the United States of America will be numbers 08 / 722,726 filed on October 1, 1996 in the name of McCormack et al .; 08 / 883,164 filed June 26, 199 in the name of McCormack et al .; 08 / 882,712 filed on June 25, 1997 in the name of McCormack et al .; 08 / 843,14 filed on April 25, 1997 in the name of Gwaltney et al. 09 / 122,326 filed July 24, 1998 in the name of Shawve et al .; and express mail number RB 879664401US filed on September 1, 1997 in the name of Shawver and others; whose total content of the aforementioned references is incorporated herein by this mention. Such films, before stretching, desirably have a basis weight of less than about 10 g / square meter and even more desirably less than about 60 g / square meter. With stretching the multi-layer film desirably has a basis weight of less than 60 g / square meter and even more. desirably from between about 15 and 35 g / square meter. Suitable films may also include multilayer films such as, for example, those formed by coextrusion; see, for example, methods for forming multilayer films as described in U.S. Patent Nos. 4,522,203; 4,494,629 and 4,734,324, whose complete contents are incorporated herein by this mention.

The outer layer may comprise an extendable fibrous material capable of being laminated to the elastic intermediate fabric. The outer layer may comprise, as an example, the stretchable nonwoven materials, the mesh fabrics, the canvases, the loosely woven fabrics, the elastic composite materials and / or other similar materials Desirably, the fabric comprises one or more layers of fabric. thermoplastic fibers which are inherently stretchable or which have been treated as to become stretchable and / or elastic and which also have a fabric type drop and feel Examples of such suitable elastic and / or stretchable materials are described in US Pat. Patents of the United States of America Nos. 4,965,122 issued to Morman et al .; 5,114.78 granted to Morman et al .; 5,335,545 issued to Morman et al .; 4,720,415 granted to Vander Wielen and others; 4,789,699 issued by Kieffer and others; 5,332,613 granted to Taylor and others; 5,288.79 granted to Collier and others; 4,663,220 granted to Wisneski others; 5,540,976 issued to Shawver and others; European application No. 0,712,896 Al of Dj iaw et al .; patent application of the United States of America series No. 08 / 603,961 of Shawver and other and patent application of the United States of America series No. 08 / 674,365 granted by Levy et al., the complete contents of which are incorporated herein by reference. The composition of the thermoplastic polymer can be selected as desired to achieve a material having the desired properties, such as elasticity, feel, tensile strength, cost, etc. In addition, the outer nonwoven layer can be treated such as, for example, by etching, hydroentangling, mechanical smoothing, printing, anti-static treatment or otherwise treated in order to achieve the desired aesthetic and / or functional characteristics.

It is possible to engrave several attractive patterns within the elastic laminate of the present invention, eg, suitable patterns for the outer covers of an infant diaper. The bonding and / or engraving patterns of example can be seen with reference to Figures 4 and 5. Other bonding patterns can also be used in connection with the present invention such as, for example, those described in the patent application of the invention. The United States of America will be No. 08 / 754,419 filed December 17, 1996. In this regard, it has been found that the laminates of the present invention exhibit improved definition and a more spongy bonding. In addition, excellent patterns can be achieved while a laminate with excellent falling resistance to peeling is provided. The laminates of the present invention exhibit peel strengths in excess of 50 grams and even 1000 grams. Besides, apart from achieving the elastic laminates with peel resistance, these can be formed having a fall of between 1 and 7 centimeters. In one embodiment, the outer layer may comprise a fabric of 35 g / m 2 of fibers bonded with narrowed polypropylene yarn having a pattern printed and / or etched therein.

In addition, the polymer compositions comprising the fibers and / or the film may optionally include one or more stabilizers *, additives or other materials to achieve the desired attributes. Preferably, the compositions include an antioxidant such as, for example, an hindered phenol stabilizer. Commercially available antioxidants include, but are not limited to, IRGANO E 17 (α-tocopherol) and IRGANOX 1076 (octadecyl 3,5-di-tert-butyl 4-hydroxyhydrocinnamate) which are available from Cib Specialty Chemicals of Terrytown, New York . In addition, other stabilizers or additives which are compatible with the film forming process, stretch and any subsequent lamination steps which may be employed with the present invention may also be employed. For example, additional additives can be added to impart the desired characteristics to the film such as, for example, melt stabilizers, process stabilizers, heat stabilizers, light stabilizers, heat aging stabilizers and other additives known to those skilled in the art. Generally, phosphite stabilizers (e.g., IRGAFOS 168 available from Ciba Specialty Chemicals, of Terrytown, New York, and DOVERPHOS, available from Dover Chemica Corporation, of Dover, Ohio), are good melt stabilizers whereas amine stabilizers hampered (for example, CHIMASSORB 944 and 119 available from Ciba Specialty Chemicals, Terrytown, New York) are good light and heat stabilizers. Stabilizer packs comprise blends of one or more of the above mentioned stabilizers and are also commercially available such as, for example, B900 available from Ciba Specialty Chemicals.

In a further aspect of the invention and with reference to Figure 2, the sweeping laminate with breathable capability 21 may comprise a barrier film 22 with the opposite elastic melt blown fiber layers 24 and 24 each attached to one side of the film 22. The outer nonwoven layers 26a and 26b are bonded to the elastic melt blown fiber layers 24a and 24b; for example, the layers can be knitted together. The opposing layers 22a and 22b as well as the opposing layers 26a and 26b may comprise either the same or different materials.

Referring to Figure 3 is a schematic diagram of a process line for manufacturing a barrier laminate of the present invention. Referring to Figure 3, the film 105 can be formed of an extrusion film apparatus 100 such as a blow or blow unit as previously described above. Typically the apparatus 1 will include one or more polymer extruders 102. The stretched film 105 is extruded into a pair of pressure or chill point rolls 104 one of which may be patterned to impart an engraving pattern to the film recently. formed 105. The basis weight of the fluted film is desirably between about 50 g / m2 around 100 g / m2. NeverthelessIt will be appreciated by those skilled in the art that the basis weight of the stretched film will be based on the desired basis weight of the stretched film, the stretch ratio and other factors. As indicated above, the filler can be added to the extruded film in order to achieve a film capable of breathing with the stretch.

From the film extrusion apparatus 100 the stretched film 105 is directed to a film stretcher unit 106 such as a machine direction finder which is a device commercially available from vendors such as Marshall and Williams Company of Providence, Rhod Island . Such an apparatus 106 has a plurality of preheating and stretching rollers which are stretched thinning the unstretched film 105 in the machine direction of the film which is the direction of travel of the film 105 through the process. The film can be stretched in either one or multiple discrete stretch operators. With reference to Figure 3, the heated rollers 108a and 108b can act as preheating rollers. The slow roller 110 is also heated and moves at a slower circumferential speed than that of the rapid roller 112. The speed differences of the adjacent rollers act to stretch the film 105. After the film 115 is stretched, it can be left behind. slightly and / or being heated or tempered by one more heated rollers, such as by means of the heated quenching roller 114. After leaving the film stretching unit 106 the fluted film 115 desirably has a maximum basis weight of about 50 g / m2 and even more desirably has a basis weight of between about 15 to about 35 g / m2.

The fluted film 115 is bonded to the elastomeric amorphous polymer fiber fabric and to one or more outer nonwoven layers 22 to form a film / nonwoven laminate 125. Still referring to FIG. 3, the conventional nonwoven fabric forming apparatus 111, such as the meltblowing machines and the second conventional nonwoven fabric forming apparatus 110, such as the spinning knitting machines, can be used to form the elastomeric melt blowing layer 121 and the outer nonwoven layers Surfaces 122. The essentially continuous and long spun bonded fibers 112 are deposited on a forming wire 114 as an unbonded web 116 and can then be sent through a pair of compaction rollers and / or union 118 to add sufficient integrity to the fabric for additional processing. Spunbonded fibers may be bonded through air or knitted together, such as with a weave pattern S as shown in Figure 4. Once the film 115 has thinned as desired and the fiber weave d of amorphous elastomeric polymer 121 and outer layer 12 are formed, the layers can be put together and laminated to one another using a pair of bonding or rolling rolls 116. The binding rolls 116 are desirably heated and at least one of the rolls may have a pattern to create a desired bonding pattern with a prescribed surface area bound for the resulting laminate 125. The maximum point bonding area of the laminate 126 generally does not exceed about 50 percent of the total surface area desirably being between about 5% and about 30%. There are a number of bonding patterns which can be used. As an example, a pattern with baby objects is shown in the figure. a 5. Once the laminate 125 leaves the attached or rolling roller 116, it can be wound onto a furling roller 120. Alternatively, the laminate 15 can be continued in line for further processing and / or conversion.

The barrier laminates of the present invention can also be used to make and / or comprise a component of protective covers, infection control products, personal care products, garments and other items that desirably have barrier properties. conformability As examples thereof, the barrier laminates can be used as a bottom sheet or an outer cover in a diaper or in adult incontinence garments in a surgical suit.

Tests Hydrohead: A measure of the liquid barrier properties of a cloth is the hydro head test. The hydro head test determines the height of the water or the amount of water pressure (in millibars) that the fabric will hold before the liquid passes through it. A cloth with a higher hydrohead reading indicates that it has a greater barrier to liquid penetration than a cloth with a lower hydro head. The hydro head can be carried out according to Standard Federal Test Method 191A, 5514. The hydro head data cited here was obtained using a test similar to the aforementioned Federal Test Standard except as modified and indicated below. Hydrohead was determined using a hydrostatic head tester available from Mario Enterprises, Inc. of Concord, North Carolina. The sample was subjected to a standardized water pressure (as opposed to using a real water column), it was increased at a constant rate until runoff appears on the surface of the fabric in three separate areas. (Runoff on the edge adjacent staples are ignored). Unsupported fabrics such as a thin film can be supported to prevent premature rupture of the sample.

Melt index: The melt index is a measure of the viscosity of a polymer under a set of given conditions. The melt index is expressed as the weight of material flowing from a capillary vessel of known dimensions under a specific load or cut-off rate for a given period of time and was measured in grams / 10 minutes at 190 ° and at a load of 2160 grams according to the ASTM 1238 90b test.

Water Vapor Transmission Rate: The water vapor transmission rate (WVTR) for the sample materials was calculated in accordance with ASTM Standard E96-80. The circular samples measured 3 inches in diameter and were cut from each of the test materials and a control which was a piece of CELGARDMrca 2500 film from Hoechst Celanes Corporation of Sommerville, New Jersey. The film CELGARDMarc 2500 is a microporous polypropylene film. Three samples were prepared for each material. The test dish was a Vapometer tray number 60-1 distributed by the Thwing-Alber Instrument Company of Philadelphia, Pennsylvania. One hundred milliliters of water were poured into each Vapometer patent and individual samples of the test materials and control material were placed through the open upper parts of the individual trays. The bolted flanges were tightened to form a seal along the edges of the tray, leaving the associated test material or control material exposed to the ambient atmosphere over a circle diameter of 6.5 centimeters having an exposed area of about 33.17 square centimeters. The trays were placed in a forced air oven at 100 ° F (37 ° C) or 1 hour until equilibrium. The oven was a constant temperature oven with the external air circulating through it to prevent the accumulation of water vapor inside. The suitable forced air furnace is, for example, a Blue M. Power-O-Mati 60 furnace distributed by Blue M. Electric Company of Blue Island, Illinois. When the balance was complete, the trays were removed from the oven, weighed and immediately returned to the oven. After 24 hours the trays were removed from the horn and put on again. The preliminary test water vapor transfer rate values were calculated with l Equation (I) given below: (1) Test WVTR = (weight loss grams over 24 hours) X 315.5 g / m2 / 24 hours The relative humidity inside the oven was not specifically controlled.

Under the set of predetermined conditions d 37 ° C and relative humidity, the water vapor transmission rate for the control of CELGARD ** 1"2500 has been defined as being 5000 grams per square meter per 24 hours. Thus, the control sample was run with each test and the preliminary test values were corrected to establish the conditions using Equation (II) given below: (II) WVTR = (Test WVTR / WVTR control) x (5000 g / m2 / 24 hours) Peel Test: In the peel or delamination test a laminate is tested with respect to the amount of tension force that will pull the layers of laminate apart. The values for the peel strength are obtained using a specified fabric width, a grip jaw width and a constant extension rate. For samples that have a film side, the film side of the sample is covered with adhesive tape or some other suitable material in order to prevent the film from breaking apart during the test. The adhesive tape is only on one side of the laminate and does not contribute to the peel strength of the sample. This test uses two handles, each having two jaws, with each jaw having a face in contact with the sample, to hold the material in the same plane, usually vertically, separated by 2 inches to begin with. The sample size is 4 inches wide for as much length as necessary to delaminate enough sample length. The size of the jaw car is 1 inch in height by at least 4 inches wide, and the constant rate of extension is 30 millimeters / minute. The sample is delaminated by hand by a sufficient amount to allow it to be held in position and the handles move and separate at a specified rate of extension to pull the laminate and separate it. The specimen d is pulled and separated 180 ° apart between the layers and the peel strength is reported as an average d peak load in grams. Force measurement was started when 16 millimeters of laminate had been pulled and separated continued until a total of 170 millimeters had been delaminated. The Syntech 2 Tester, available from Sintec Corporation, 1001 Sheldon Drive, Cary, North Carolina 27513, the Instron Brand Model, available from Instro Corporation, 2500 Washington Street, Canton, Massachussett 02021, or the Thwing-Albert model INTELLECT II, available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, Pennsylvania 19154, may be used for this test. The results are reported as an average of three specimens and can be carried out with the specimen in the transverse direction (CD) or in the machine direction (MD).

Fall: The drop stiffness test determines the length of a fabric bending using the cantilever principle of the fabric under its own weight. A higher number indicates a more rigid fabric. The length of bending is a measure of the interaction between a fabric weight and the stiffness of the fabric. A strip of cloth of 1 inch (2.54 centimeters) by 8 inches (20.3 centimeters) is slid, at 4.75 inches per minute (1 centimeters) / minute) in a direction parallel to its long dimension so that the leading edge projects from the edge of a horizontal surface. The length of the overlap is measured when the tip of the sample is pressed under its own weight to the point where the line joining the tip of the fabric to the edge of the platform makes an angle of 41.5 ° with the horizontal. The drop rigidity is calculated as 0.5 x bending length A total of 5 samples of each fabric can be taken. This procedure conforms to the ASTM D-138 standard test except that the fabric length is different (longer). The test equipment used is a Cantilever Model 79-10 Obsolete Tester available from Testing Machines, Inc., 400 Bayview Avenue, Amityville, New York 11701. As with most tests, the sample must be conditioned to the conditions ASTM of 65 ± 2 percent relative humidity and 72 ° F (22 ± 1 ° C) or TAPPI conditions of 50 ± 2 percent relative humidity and 72 ± 1.8 ° F before the test.

Example 1 A film was extruded in a conventional film melt process from a compound having the following composition (percentages by weight): 47% calcium carbonate Supercoat (a mean particle size of 1 miera available from English China Clay of America, Sylacauga, AL), 53 of AFFINITY PL-1280 resin (an ethylene-1-octene copolymer 0.90 g / cm3 density, 5 MI, available from Dow Plastics, Freeport, Texas), 2000 parts per million B900 Stabilizing mix (available from Ciba-Geigy Corporation of Terrytown, New York). The extruded film was approximately 1.5 mil thick. This film was then stretched to make it breathable using a machine direction (MDO) orienter, such equipment which is available, for example, from the Marshall and Williams Company. The preheated and extruder rollers were at 160 ° F, the hardening rollers at room temperature and 180 ° F, the film inlet speed at 50 (feet per minute) (fpm) the exit velocity at 200 feet per minute for give a stretch ratio of 4X (an elongation of 300% of the original film length). The oriented film was then thermally laminated in line to a bond with narrowed yarn on which a blow cap with melting had previously been applied. The temperature controllers were set at 180 ° F on the anvil (smooth steel roll) and at 250 ° F for the roll with star-C pattern. E linked with yarn used was 17 g / m 2 of propylene homopolymer bonded with wire weave pattern, tapered 45 and overlaid with 17 g / m 2 of melt blown fiber fabric comprising a low density polyethylene elastomer available from Dow under the designation resin ENGAGE 52800.02 (3 MI, 0.870 g / cm3 density). At the joint pressure point the film was brought into contact with the anvil roller, meltblown was between the film and the coiled link, and the spin link was brought into contact with the patterned roller. The resulting laminate had a defined and attractive mu pattern. The peel strength was measured at 384. grams MD and 308.2 CD and the water vapor transmission rate was 790 g / m2 / 24 hours. The laminate also exhibited desirable elastic behavior: when it extended in the transverse direction to 150% of its starting length, in the first extension cycle the force to stretch it to 130% was 657 grams / 3 inches in width, and the Retraction force in the second cycle at 130% elongation was 130 grams / 3 inches wide.

Example 2 A three-layer elastic barrier laminate was made comprising a layer of elastic film, a blow-bond layer with fibrous elastomeric melt, and a nonwoven outer cap extending in the transverse direction. L elastic film 12 was a 1.0 mil non-porous film of type XMAX264.0 from Consolidated Thermoplastics Company of Chippewa Falls, Wisconsin. The elastomeric intermediate layer was a melt blown fabric of 30 g / m2 made of polyethylene elastomer, AFFINITY 58200.02. The resin had a melt index of 30 and a density of .87 grams / cm3. The extendable support layer in the non-woven transverse direction was comprised of a bonded and stretched bicomponent polypropylene / polyethylene side-by-side yarn with a basis weight of 33.9 g / m 2. The polypropylene fu ESCORENE ^ * "" * PD 3445 obtained from Exxon Chemical Company of Housto Texas, and the polyethylene was Dow 6831. The three layers were thermally bonded using an EHP binding pattern at a temperature of 135 ° F (57 ° C) and at a pressure point of about 30 pounds per square inch (206.9 kPa) at a speed d less than 3 meters / minute. A section width of 76.2 in the machine direction by 152.4 millimeters in the cross direction of the laminate was elongated to a length of 304.8 millimeters. With the release of the pressing force, the laminate returned to a final length of 109.5 millimeters. The laminate had a resistance to peeling in the direction of the machine / in the transverse direction of about 2000 grams and falling values in the range of 2 to 4 centimeters.

Although the invention has been described in detail with respect to specific embodiments thereof, it will be apparent to those skilled in the art that various alterations, modifications and other changes may be made to the invention without departing from the spirit and scope of said invention.

It is therefore intended that the claims cover such modifications, alterations and other changes encompassed by the appended claims.

Claims (20)

R E I V I N D I C A C I O N S

1. A film laminate comprising: an expandable polymeric barrier film; an outer non-woven layer of extendable thermoplastic polymer; Y an elastic intermediate nonwoven fabric comprising fibers of an amorphous polymer wherein said nonwoven fabric is bonded to both the barrier film and said nonwoven outer stretchable layer and further wherein said laminate is elastic.

2. The film laminate as claimed in clause 1, characterized in that said elastic fibrous fabric comprises a blown fiber fabric with elastic fusion having a basis weight of between about 8 g / m2 and 100 g / m2 and in wherein said film laminate has a peel strength in excess of 200 grams.

3. The film laminate as claimed in clause 2, characterized in that said extendable nonwoven outer layer comprises a narrow nonwoven fabric.

4. The film laminate as claimed in clause 2, characterized in that said extendable non-woven outer cap comprises a rsibly non-woven web.

5. The film laminate as claimed in clause 2, characterized in that the polymer comprising said extendable polymer barrier film is an elastic polymer and said film is elastic.

6. The film laminate as claimed in clause 2, characterized in that said extendable non-woven outer cap comprises an elastic non-woven fabric.

7. The film laminate as claimed in clause 4, characterized in that said blown fiber fabric with elastic fusion has a basis weight of less than about 34 g / m2.

8. The film laminate as claimed in clause 1, characterized in that said elastic intermediate nonwoven fabric comprises a polyethylene elastomer having a density between about 0.86 g / cm 3 and about 0.89 g / m 3.

9. The film laminate as claimed in clause 2, characterized in that said elastic intermediate woven fabric comprises a mixture of a polyethylene elastomer having a density of between about 0.8 g / cm3 and 0.89 g / cm3 and a second polyethylene having a density above 0.90 g / cm3.

10. The film laminate as claimed in clause 8, characterized in that said extendable non-woven outer cap comprises a non-woven web and said expanded polymeric barrier film comprises an elastic filled film having a water vapor transmission rate. greater than 300 g / m2 / hours.

11. The film laminate as claimed in clause 1, characterized in that said barrier film has a water vapor transmission rate in excess of 800 g / m2 / 24 hours.

12. The film laminate as claimed in clause 11, characterized in that said elastic intermediate nonwoven fabric comprises a polyolefin fiber fabric.

13. The film laminate as claimed in clause 12, characterized in that said elastic intermediate nonwoven fabric comprises a blown fiber fabric with melting.

14. The film laminate as claimed in clause 13, characterized in that said intermediate woven fabric has a basis weight of less than about 3 g / m2.

15. The film laminate as claimed in clause 13, characterized in that said barrier film comprises a microporous film.

16. The film laminate as claimed in clause 15, characterized in that said barrier film comprises a polyolefin polymer, said outer woven layer extendable comprises a polyolefin polymer and wherein said film laminate has a peel strength in Excess of 500 grams.

17. The film laminate as claimed in clause 16, characterized in that said barrier film comprises a polyethylene polymer and a replenishment and further wherein the recesses are located on one side of the filler.

18. The film laminate as claimed in clause 16, characterized in that said barrier film comprises a polypropylene polymer and a replenishment and further wherein the recesses are located on one side of the filler.

19. The film laminate as claimed in clause 16, characterized in that said elastic intermediate woven fabric comprises a polyethylene elastomer having a density of between about 0.86 g / cm 3 about 0.89 g / m 3.

20. The film laminate as claimed in clause 16, characterized in that said elastic intermediate woven fabric comprises a mixture of a polyethylene elastomer having a density of between about 0.8 g / cm3 and 0.89 g / cm3 and a second polyethylene having a density above 0.90 g / cm3. SUMMARY A laminate impervious to elastic liquid having an expandable barrier film is described; an elastomeric non-woven fabric from 8 g / m2 to 100 g / m2 comprising low density polyethylene fiber having a density of less than 0.89 g / cm3; and an outer layer of a stretchable cloth type, such as a non-woven fabric of fibers bonded with yarn. The barrier laminate can be laminated by means of thermal spot bonding to create patterns that have improved fluffiness, excellent feel and at the same time achieve peel strengths in excess of 1000 grams.