MXPA01006564A - Composite material having stretch and recovery including a layer of an elastic material and a transversely extensible and retractable necked laminate of non-elastic sheet layers - Google Patents

Abstract

The present invention is directed to a composite material and a process for making the material. The composite material may be breathable and is formed from at least one layer of an elastic material and a necked laminate of sheet layers. The sheet layers include at least one non-elastic neckable material laminated to at least one non-elastic film defining a longitudinal and transverse dimension wherein the laminate is extensible and retractable in at least one dimension without significantly reducing the breathability and/or liquid barrier properties of the film layer. This laminate extensibility and retractability is the result of striated rugosities in, for instance, the longitudinal dimension of the film layer which enables the necked laminate to have an amount of extensibility and retractability in the transverse dimension. A breathable laminate may be made by first partially stretching a filled non-elastic film layer, attaching a non-elastic neckable layer to form a laminate and then stretching the laminate to neck the laminate and lengthen the film to its desired fully stretched configuration. Attachment of at least one layer of an elastic material to the necked laminate further provides stretch and recovery in at least one dimension.

Description

COMPOSITE MATERIAL THAT HAS STRETCHING AND RECOVERY INCLUDING A LAYER OF AN ELASTIC MATERIAL AND AN EXTENDED AND RETRACTABLE STRIPED LAMINATE TRANSVERSELY OF NON-ELASTIC SHEET LAYERS Field of the Invention The present invention is directed to a composite material and to a process for making the composite material. The composite material may be capable of breathing and is formed of at least one layer of non-elastic film, at least one non-elastic, non-stretchable material, and at least one layer of an elastic material. The sheet layers of at least one non-elastic shrinkable material laminated to at least one non-elastic film are combined to form a tapered laminate defining longitudinal and transverse dimensions wherein the tapered laminate is extensible and retractable in at least one dimension without significantly reduce the ability to breathe and / or the liquid barrier properties of the film layer. The shrinkage and extensibility of the tapered laminate is the result of fluted roughness in, for example, the longitudinal dimension of the film layer which allows the tapered laminate to have an amount of extensibility and retractability in the transverse dimension. The addition of at least one layer of an elastic material to the tapered laminate to form a composite material provides a stretch and recovery which is not present in the tapered laminate while still maintaining barrier and breathability properties.

Background of the Invention Multilayer and multi-ply composite materials, for example layers of non-woven fabric and film, are known to be useful in such articles as diapers, training pants, incontinence garments, mattress pads, wipes, products for the care of women such as sanitary napkins, in medical applications such as surgical drapes, gowns and face masks, articles of clothing or parts of the mass including work clothes and lab coats, and the like.

These composite materials are made so that the article can be produced at a relatively low cost and therefore be disposable only after one use or a few uses. Much research and development continues, however, to achieve visual and tactile qualities of "type of fabric" in these articles without sacrificing the ability to breathe and low cost, while also providing an article that is impervious to liquid. In particular, a disadvantage of such articles is that the material used to make the article not "sede", for example, as a cotton fabric does, which is due to its fiber and yarn structure having a natural ability to extend and retract. These properties are necessary to allow the article to conform to the body of the user, feeling and therefore looking more like a type of fabric. Even when the article "gives of itself", it can quickly lose its shape if it does not exhibit stretching and recovery. A known solution for this problem has been the use of an elastomeric or elastic material to form, for example, the film layer of a film / nonwoven laminate. Without the ability to breathe is achieved by stretching a filled elastic film to form micropores, there are problems associated with maintaining the ability to breathe filled elastic films since the recovery of the elastic material after stretching generally closes or partially closes the micropores which have been created for the ability to breathe.

The layers of the non-woven fabric have been narrowed (as defined below) before applying an elastomeric sheet and made using an elastomeric polymer as described in, for example, commonly assigned U.S. Patent No. 5,336,545 issued to Morman The narrowing of the non-woven fabric allows it to extend in the transverse direction, but will not allow it to recover without holding the elastic sheet.

The prior art laminates made of non-elastic materials which were used as, for example, an outer diaper cover will not stretch in all directions and yet be of a capacity to breathe through a non-elastic microporous film. In addition, the prior art laminates of the non-elastic materials that have been used in the waistband components in articles such as diapers have been made to be more conformable by first stretching an elastic waistband, then attaching the laminate to the waistband stretched so that when the waistband retracts, it pulls the laminate. A problem for this design is that the laminate is difficult to fold or bulge and that the resulting product has minimal extension and retraction. Such bulky laminates are very difficult to manufacture, have a current appearance and are not comfortable when in contact with the body.

The present invention avoids these and other difficulties by providing a cheap composite material of a non-elastic narrowed laminate and an elastic material which achieves stretching and recovery without compromising other properties such as the ability to breathe, barrier to liquid properties and of resistance.

Synthesis of the Invention The present invention is directed to a composite material and to a process for making the material. The composite material can be breathable and is formed of at least one layer of an elastic material and a narrow laminate of sheet layers. The sheet layers include at least one non-elastic shrinkable material laminated to at least one non-elastic film defining a longitudinal and transverse dimension wherein the laminate is extensible retractable into at least one dimension without significantly reducing the ability to breathe and / or the liquid barrier properties of the film layer. This extensibility of the laminate and the retraction is the result of fluted roughnesses in, for example, the longitudinal dimension of the film layer which allows the narrowed laminate to have an amount of extension and retraction in the transverse dimension. A breathable laminate can be made by first partially stretching a filled non-elastic film layer, clamping a non-elastic, narrowable layer to form a laminate and then stretching the laminate to narrow the laminate and lengthening the film to its desired fully stretched configuration . The clamping of at least one layer of an elastic material to the tapered laminate further provides stretch and recovery in at least one dimension.

Brief Description of the Drawings Figure 1 is a schematic representation of an example process for forming a composite material of the present invention.

Figure 2 is a top plan view of the laminate forming the composite material of the present invention as it is narrowed showing the grooved ridges in the longitudinal dimension.

Figure 3 is a perspective view of the process of Figure 1 showing the stretching of the elastic film layer, the clamping of the non-elastic shrinkable material, the narrowing of the laminate, and the clamping of the elastic material to form the composite material of the present invention.

Figure 4 is a top plan view partly in section of an absorbent article for personal care of example, in this case a diaper, which can use the composite material according to the present invention.

Figure 5 is a plan view of an exemplary medical article, in this case a mask for the face which may use the composite material according to the present invention.

Figure 6 is a top plan view of an optical photomicrograph (high resolution digital image) of the side of the non-elastic film layer of the tapered laminate forming the composite material of the present invention showing the narrowed roughness.

Figure 6a is a top plane view of an optical photomicrograph of the amplified section of Figure 6 showing variation and chance of striated roughness.

Figures 7, 8 and 9 are optical photomicrographs in cross section of a laminate forming the composite material of the present invention showing the trapezoidal, folded and crenellated striae, respectively.

Figure 10 is an oblique view of an optical photomicrograph of the previous art laminate.

Figures a, b and c, and 12a, b, and c graphically illustrate the load against extension curves for several samples.

Figure 13 is a schematic representation of an exemplary process for forming the composite material of the present invention having a stretched layer of elastomeric filaments.

Figures 14-15 graphically illustrate the amplified curves of the load against extension for several samples.

Figures 16-18 graphically illustrate the results of cycling tests done on several samples.

Figures 19a and b show the sine wave and point joining patterns respectively, used to join the tapered laminate to the elastic material to form a composite material of the present invention.

Figure 20 is a top plan view of an image of the non-resilient, narrowable material side of the tapered laminate constituting the composite material of the present invention.

Figure 21 is the opposite side of Figure 20, showing the layer of elastomeric filaments which were stretched on the LD while being attached to the longitudinal dimension of the non-elastic film side of the tapered laminate.

Figure 22 is a top plan view of an image of the non-elastic narrowed material side of the tapered laminate constituting the composite material of the present invention, showing the layer of elastomeric filaments which were fastened longitudinally to TD of the side of the non-elastic film of the tapered laminate.

Figure 23 is an optical cross-section photomicrograph of the composite material, in this case using a blown non-stretched non-woven fabric to form the layer of elastic material according to the present invention.

Figure 24 is an optical cross-section photomicrograph of the composite material in this case using a blown nonwoven nonwoven fabric to form the layer of elastic material according to the present invention.

Figure 25 is an optical cross-section photomicrograph of the composite material in this case using a stretch-blown non-woven fabric stretched to form the layer of elastic material according to the present invention.

Figures 26-28 graphically illustrate the results of the LD stress test load against the extension curves for several samples.

Figures 29-31 graphically illustrate the results of the TD voltage test load against the extension curves for several samples.

Figures 32-34 graphically illustrate the results of the LD cycling test done on several samples.

Figures 35-37 graphically illustrate the results of the TD cycling test performed on several samples.

Detailed description of the invention The present invention is directed to a composite material which can be breathable and is formed of at least one layer of non-elastic film, at least one non-elastic, non-stretchable material, and an elastic material. The sheet layers of at least one non-elastic shrinkable material laminated to at least one inelastic film are combined to form a tapered laminate, wherein the laminates define the longitudinal and transverse dimensions so that the laminate is extensible and retractable in the laminate. at least one dimension without significantly reducing the ability to breathe and / or liquid barrier of the film layer. This extension and retractability of the laminate is the result of the ridges striated in, for example, the longitudinal dimension ("LD" as defined below) of the film layer which allows the narrow laminate to have an amount of extensibility and retractability in the transverse dimension ("TD" as defined below). At least one layer of the elastic material is attached to the tapered laminate to form a composite material which is both stretchable and recoverable.

As contemplated herein, the elastic material may be present in the composite material in various ways. For example, the elastic material may be in the form of a non-resilient elastic material (such as a layer of a non-woven fabric blown with elastic fusion), elastomeric filaments, (such as essentially continuous long fibers as found in commonly assigned U.S. Patent No. 5,385,775 to Wright), and the like.

If the elastic material is present in the composite material of the present invention as a layer of elastomeric filaments, these filaments may or may not be stretched in the longitudinal direction before being fastened to a tapered laminate having extension and retractability in the transverse direction. When the elastomeric filaments are stretched and held longitudinally while being stretched to the tapered laminate along the longitudinal dimension of the tapered laminate, the composite exhibits stretching and recovery in the longitudinal dimension and extension and retraction in the transverse dimension. In addition, the elastomeric filament layer can be held longitudinally in the transverse dimension of the tapered laminate, thereby providing stretch and recovery in the transverse dimension.

If the elastic material is present as an elastic, unstretched material, the resulting composite will exhibit a stretch and recovery in the transverse dimension. Stretching in the transverse dimension is however limited by the extension of the tapered laminate because the inelastic film part of the tapered laminate is not actually stretched-instead of this the fluted roughness is temporarily removed essentially when a pressing force is applied on the laminate. the transverse direction. If these fluted roughnesses are not permanently removed, for example, by over-extending the laminate in the transverse direction or by heating the extended laminate to impart a "new" memory then the laminate will tend to return to or retract close to its original dimension.

If the elastic material is present as an elastic non-narrowing material, it can be stretched and while being stretched, it has been fastened to the tapered laminate to form a composite material which is both stretchable and recoverable in the multiple directions. The non-stretchable and elastic material can, for example, be stretched in the longitudinal direction and then be attached to the tapered laminate having extension and retraction in the transverse dimension. By the addition of the longitudinally stretched non-stretchable elastic material, stretching and recovery in the longitudinal dimension can be achieved which will complement the stretching and the recovery in the transverse dimension found in the tapered laminate and in the non-stretchable elastic and non-stretched material. The composite material will not only stretch and recover in the longitudinal dimension and in the transverse dimension, but instead it will have some stretching and recovery in all directions.

The tapered laminate is made, for example, by first partially stretching the non-elastic film layer, by attaching a non-elastic, narrowable layer to the film layer to form a laminate, and then stretching the laminate to narrow the laminate and to complete the laminate. Stretching / orienting the film layer to its desired fully stretched configuration. A layer of elastomeric filaments can then be attached to the tapered laminate to form the composite material. Alternatively, an elastic material may be stretched in the longitudinal direction and then be fastened to the tapered laminate to form the composite material. As another alternate embodiment, an elastic material is fastened, without first stretching, to the tapered laminate to form the composite material. When a laminate is "fully stretched" it exhibits completely sufficient properties for the intended use, for example, ability to breathe and resistance to stress. As used herein, the term "partially stretched" means that the film and / or the laminate are not fully stretched.

As used herein the term "constricting" or "stretching with interlock" interchangeably means that the laminate is pulled so that it is stretched under conditions that reduce its width or its transverse dimension by pulling and lengthening to increase the length of the fabric. . The controlled pulling can take place under cold temperatures, room temperature or higher temperatures and be limited to an increase in the overall dimension in the direction that is being pulled to the elongation required to break the laminate, which in many cases is around 1.2 to 1.5 times. When relaxed, the laminate does not retract to its original longitudinal dimension or extend to its original transverse dimension, but instead essentially maintains its narrowed dimension. The tapering process typically involves unwinding a sheet from a supply roll and passing it through a brake pressure point roller assembly at a given linear speed. A pressure point or take-up roller operates at a linear speed higher than that of the brake pressure point roller, pulls the fabric and generates the tension necessary to lengthen and narrow the fabric. U.S. Patent No. 4,965,122 issued to Morman, and commonly assigned to the assignee of the present invention discloses a reversibly tapered nonwoven material which can be formed by squeezing the material, then heating the tapered material, followed by the cooling and is incorporated herein by reference in its entirety. The heating of the constricted material causes an additional crystallization of the polymer giving it a partial heat setting and some shrinkage.

As used herein, the term "constrictive material or layer" means any material which can be narrowed such as a nonwoven, woven or woven material. As used herein the term "narrowed material" refers to any material which has been pulled in at least one direction, (for example in the longitudinal direction) reducing the opposite dimension (for example the width) so that when the force Pulling is removed, the material can be pulled back to its original width. It should be understood that the term "narrowable" describes the attribute of the material as being capable of being constricted and does not require that the material be actually narrowed. The narrowed material has a higher basis weight per unit area than that of the non-narrowed material. When the constricted material is pulled back to its original non-constricted width, it should be around the same base step as the non-constricted material. This differs from the narrowing / orientation of the film layer during which the film is thinned and the basis weight is reduced.

The term "laminate" as used herein means a combination made of at least two layers of sheets wherein at least one layer of sheet is a layer of non-elastic film and at least one layer of sheet is a layer of an Narrow non-elastic material. Also, the term "longitudinal direction or LD" means the length of the material in the direction in which the material is moving when it is produced. The "longitudinal dimension" is therefore the dimension of the longitudinal direction. The term "transverse direction or TD" means the width of the material, for example the direction generally perpendicular to the longitudinal direction. Similarly, the "transverse dimension" is therefore the dimension of the transverse direction.

Referring to Figure 1, there is schematically shown an example process 10 for forming a composite material 8 according to the present invention. For all figures, the same reference numbers represent the same element or an equivalent element or structure. A non-elastic film layer 12 is unwound from a first supply roll 16 and fed to a stretching means 20 using the guide rollers 26. Once in the stretching means 20, the non-elastic film layer 12 is partially stretched in a longitudinal direction by the stretching rollers 24 which stretch and thin the film layer 12. Such stretching usually occurs with very little or no narrowing of the film layer. If the distance between the rollers is very large, irreversible narrowing of the film layer can occur. After partially stretching the film layer 12 and before lamination to the narrowable material 14, the tension of the film layer 12 is only that which is sufficient to maintain the layer preventing it from being torn off or recovered. In other words, it is not necessary to continue stretching the film layer 12 between the stretching means 20 and the rolling means 30.

A non-resilient, narrowable material 14, similarly, is unwound from the second supply roll 18 which rotates in the direction of the arrows associated therewith. In an embodiment where the partial film stretch is controlled to avoid film narrowing, marrying the film width with the width of the narrowable material is facilitated. It should be understood that the non-elastic shrinkable material and / or the film layer can be just formed in line rather than being pre-formed and unrolled.

The adhesive spray 34 applies adhesive to the surface of the narrowable material 14 which is then laminated to the film layer 12 using the rolling means 30 (for example the pressure tip rollers) to form the tapered laminate. The laminate can also be formed by thermal point, sonic welded or point junction or the like. The laminate thus formed 2 is then narrowed by a narrowing means 22 for example pick-up roll) which can be achieved as shown in Figure 1 wherein the surface velocity V0 of the rolling means 30 is less than the speed of surface Vj of the narrowing means 22. As used here, to say that the laminate has been pulled IX means that the surface velocity V0 is equal to the surface velocity V,. The "close pull" therefore is the surface velocity V, divided by the surface velocity V0. Furthermore, the distance x between the rolling means 30 and the narrowing means 22 must be sufficient to allow the narrowing of the laminate so that the transverse dimension of the laminate is smaller than that of the non-narrowed laminate. As a general rule, the distance x must be at least twice the transverse (width) dimension of the laminate. Such narrowing provides ridged ridges in the film and / or laminate resulting in a transverse extension and retraction to the tapered laminate 2 and a more "fabric type" aesthetic (for example, the tapered laminate is softer than prior art laminates). and it looks more like a woven material due to fluted roughness.

Additionally, an elastic material forming apparatus 48, such as an apparatus conventionally used to form a blown nonwoven fabric with elastic fusion, such as that found in commonly assigned United States of America Patent No. 4,663,220 issued to Wisneski and others which is incorporated herein by reference in its entirety is used to form the elastic material 50. The meltblown fibers are deposited on the tapered laminate 2 and can be sent through a pair of bonding rollers 52 and 52 '. for attaching the layer of the elastic material 50 to the tapered laminate 2. Alternatively, a layer of essentially continuous and long elastomeric filaments 51 (which can be seen in Figure 4) can be similarly fastened to the tapered laminate 2. As discussed previously, the elastic material can be held in any stretched or unstretched state depending on the properties attempted.

As shown in Figure 1, the connecting rollers 50 and 52 'rotate at speeds sufficient to perform the narrowing function as described above so that they have a dual function of joining and narrowing in this illustration. Further, the composite material 8, is shown here as being wound on the roll 52. Since the elastic material 50 can be tacky and therefore can not be easily unwound, the composite material 8 can just as easily be converted into an article in line. Figure 3 is essentially the same as Figure 1 except that this is a perspective view and the upper tie roll 52 'has been removed since the tie roll may not be necessary to join the layer of elastic material 50 to the laminate narrowed 2. In other words, the layer of the elastic material 50 can be essentially fused onto the tapered laminate 2.

Referring to Figure 13, an elastic material forming apparatus 48 in this case is used to form the essentially parallel rows of elastomeric filaments 51. The essentially continuous and long elastomeric filaments are deposited on the forming wire 56. The layer of elastomeric filaments 51 it is stretched while joining the tapered laminate 2 by the same means as described above for the narrowing means. The surface velocity V0 of the bonding rolls 52 is less than the surface speed Vj of the rolling means 30 so that the layer of the elastomeric filaments 51 is being stretched while being laminated to the narrowed material 2. The tension of the narrowed elastomeric filaments 51 is, therefore, maintained while being laminated to the tapered laminate 2. In this embodiment, the composite thus formed 8 exhibits stretching and recovery in the longitudinal direction and extensibility and retractibility in the transverse direction.

Now referring to Figure 20, a top plan view is shown of an image of the non-resilient, narrowable material 14 'on the side of the tapered laminate 2 which constitutes the composite material 8 of the present invention. The fluted roughnesses can be seen in the longitudinal direction at the point 28. Figure 21 is the opposite side of Figure 20, showing the layer of elastomeric filaments 51 which were stretched in the longitudinal direction while being fastened to the longitudinal dimension on the side of the non-elastic film 12 'of the tapered laminate 2. FIG. 22 is a top plan view of an image of the non-resilient, narrowable material 14' of the tapered laminate 2 which constitutes the composite material of the present invention, showing the layer of elastomeric filaments 51 which were fastened longitudinally to the transverse dimension of the side of the non-elastic film 12 'of the tapered laminate 2.

It is known that stretching and orientation of a filled film layer causes micropores to form in the film, but longitudinally fluted roughnesses are typically not formed in the film layer when stretched. The film layer will instead become physically thinner and may narrow slightly. However, in the attempt to elongate the filled film layer oriented in the transverse direction it may result in tearing when very little force is applied, which is possibly due to tearing along the micro-grooves in the transverse direction which they have formed from the stretching and orientation of the filled film layer. The polymer used to make the film, the amount of filler and how much the film was pulled completely affects how far the film can be extended in the transverse dimension before it is divided. By narrowing the laminate, the non-elastic shrinkable material, which is fastened to the non-elastic film layer, will narrow and bring the non-elastic film layer therewith, thus forming the longitudinal fluted ridges in the film that allow the the film layer extending and retracting in the transverse dimension without adversely affecting the ability to breathe and the barrier properties of the film. In Figure 2, the fluted roughness 28 is shown figuratively in the longitudinal direction LD of the laminate 2 which was tapered in the transverse direction TD. The non-constricted transverse dimension 32 is the dimension that the laminate will have except for the narrowing. The double-sided arrows indicate the extension and retraction of the laminate in the transverse direction. As used herein, the term "fluted roughness" refers to thin wrinkles, narrow or grooved grooves in the non-elastic film layer 12 of the tapered laminate 2. Referring to Figure 6, the fluted roughnesses can be shown generally at point 28 on the surface of the film layer 12 'of the sample 6 (in the examples that follow). Figure 6A is an enlarged view of Figure 6. As can be seen in these figures, the fluted roughness has a variable and random pattern. Figure 7-9 are amplified cross-section end views of the laminate 2 of Figure 6 at different points along the section showing the variable grooves in the film layer 12 'which is attached to the narrowable material 14'. . Figure 7 generally shows a trapezoidal flute 40. Figure 8 generally shows the folds 42; even when Figure 9 generally shows crenellated grooves 44. As used herein, the term "crenelated" is used as a crenellated cast, which according to the Third New Edition of Webster International Dictionary, copyright 1986, is "a molding of .1 .. [a] indented pattern common in medieval buildings ". Fluted roughness currently occurs predominantly in the non-elastic film layer, but can be seen through the tapered material and give the entire laminate a more fabric-like appearance. If one were to delaminate the film layer of the shrinkable material after the constriction, the film layer would visually retain the fluted roughness while the constrictable material would not. The separate film would extend and retract in the transverse direction much like an accordion. One theory that can be described for this phenomenon is that the film actually crystallizes and / or plastically deforms to some degree when the fluted roughness is formed, thereby setting a "memory" in the film which works to retract the laminate once it has spread.

By the term "non-elastic", what is meant is that the sheet layers are made of polymers that are generally considered to be inelastic. In other words, the use of such inelastic polymers to form the sheet layers will result in layers of sheets which are not elastic. As used herein, the term "elastic" means any material which, with the application of a pressing force, is stretchable, this is elongate, at least about 60 percent (at a pressed and stretched length which is of at least about 160 percent of its unstressed and relaxed length) and which will recover immediately to at least 55 percent of its elongation with the release of the stretching elongation force. By "immediately", what is meant is that the elastic material will behave, for example, as a rubber band to recover as soon as the lengthening force is removed. A hypothetical example would be that of a one-inch material sample which is elongated to at least 4.06 centimeters and which when lengthened to 4.06 centimeters and being released immediately, for example, within less than a second, will recover to a length of no more than 3.23 centimeters. Many elastic materials can be elongated by much more than 60 percent, for example, 100 percent or more, and many of these will recover to essentially their initial relaxed length, for example, within 105 percent of their initial relaxed length with the release of the stretching force.

The terms "extensible and retractable" have been chosen to describe what the laminate does of the non-elastic sheet layers of the present invention does with the application and removal of a pressing force. For the novel narrowed laminates described herein, the materials used to form the sheet layers are not elastic and in this way the terminology chosen to describe the phenomenon exhibited by the laminate with the application and removal of a pressing force is "extensible and retractable" . Those with an ability in the art of elastic materials have conventionally used the phrase "stretch and recovery" to describe what an elastic material does with the application and removal of the pressing force as described above. As used herein, the terms "recover" and "recovery" refer to the immediate contraction of the stretched elastic material with the termination of the pressing force after stretching of the material by the application of the pressing force.

As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and mixtures and modifications of the same. Such mixtures include blends include blends of inelastic polymers with elastic polymers provided said elastic polymers are used in such amount and composition that the use of these does not render the elastic polymer. Unless otherwise specified or limited, the term "polymer" shall include all possible geometric configurations of the molecule. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

The non-elastic film layer 12 can be made from either blown or set film equipment, can be co-extruded and can be recorded if desired. The film layer may be made of any suitable non-elastic polymer composition.

Such polymers include but are not limited to non-elastic, extrudable polymers such as polyolefin or a mixture of polyolefins, nylon, polyester and ethylene vinyl alcohol. More particularly, useful polyolefins include polypropylene and polyethylene. Other useful polymers include those described in U.S. Patent No. 4,777,073 issued to Sheth, assigned to Exxon Chemical Patents Inc., such as a polypropylene copolymer and a low density polyethylene or linear low density polyethylene.

Other useful polymers include those mentioned as the single site catalyzed polymers such as the "metallocene" polymers produced according to a metallocene process and which have limited elastic properties. The term "metallocene catalyzed polymers" as used herein, includes those polymer materials that are produced by the polymerization of at least ethylene using metallocene or constrained geometry catalysts, a class of organometallic complexes, as catalysts. For example, a common metallocene is ferrocene, a metal complex between two cyclopentadienyl ligands (Cp). Metallocene process catalysts include bis (n-butylcylopentadienyl) titanium dichloride, bis (n-butylcyclopentadienyl) zirconium dichloride, bis (cyclopentadienyl) scandium chloride, bis (indenyl) zirconium dichloride, bis (methylcyclopentadienyl) titanium dichloride, bis (methylcyclopentadienyl) zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl (cyclopentadienyl-1-fluorophenyl) zirconium dichloride, dichloride olibdoceno, nickelocene dichloride, niobocene, ruthenocene, titanocene dichloride, hydride chloride of zirconocene, zirconocene dichloride, among others. A more exhaustive list of such compounds is included in U.S. Patent No. 5,374,696 issued to Rosen et al. And assigned to the Dow Chemical Company. Such compounds are also discussed in U.S. Patent No. 5,064,802 issued to Stevens et al. And also assigned to Dow.

Such metallocene polymers are available from Exxon Chemical Company of Baytown, Texas, under the trade name EXXPOL® of polymers based on polypropylene and EXACT® for polymers based on polyethylene. Dow Chemical Company of Midland, Michigan, has polymers commercially available under the name ENGAGE®. Preferably, the metallocene polymers are selected from the copolymers of ethylene and 1-butene, copolymers of ethylene and 1-hexene, copolymers of ethylene and 1-octene and combinations thereof. For a more detailed description of the metallocene polymers and the processes for producing them which are useful in the present invention, see commonly-assigned US patent applications Nos. 774,852 and 854,658 filed first on 27 December 1996 in the name of Gwaltney and others, each of which is hereby incorporated by reference in its entirety. In general, the metallocene-derived ethylene-based polymers of the present invention have a density of at least 0.900 grams per cubic centimeter.

The non-elastic film layer may be a multilayer film layer which may include a core layer or a "B" layer and one or more layers of skin or "A" layers on either side or both sides of the layer of core. When more than one layer of skin is present, it is not a requirement that the layers of skin are the same. There may be a capital A and a layer A '. Any of the polymers discussed above are suitable for use as a core layer of a multilayer film. Any of the fillers discussed here are suitable for use in any film layer.

The skin layer will typically include extrudable thermoplastic polymers and / or additives which provide specialized properties to the non-elastic film layer. Therefore, the skin layer can be made of polymers which provide such properties as antimicrobial, barrier, water vapor transmission, adhesion and / or antiblock properties. The polymers are therefore chosen for the particular attributes desired. Examples of possible polymers that can be used alone or in combination include homopolymers, copolymers and blends of polyolefins as well as ethylene vinyl acetate (EVA), ethylene ethyl acrylate (EEA), ethylene acrylic acid (EAA), ethylene methyl acrylate (EMA), ethylene butyl acrylate (EBA), polyester (PET), nylon (PA), ethylene vinyl alcohol (EVOH) ), polystyrene (PS), polyurethane (PU), and olefinic thermoplastic elastomers which are multi-step reactor products in which a random copolymer of amorphous ethylene propylene is molecularly dispersed in a continuous matrix of low ethylene monomer predominantly semicrystalline propylene monomer. The skin layer may be formed of any semicrystalline or amorphous polymer including one that is elastic. However, the skin layer is generally a polyolefin such as polyethylene, polypropylene, polybutylene or an ethylene-propylene copolymer, but may also be completely or partially polyamide, such as nylon, polyester, such as polyethylene terephthalate, polyvinylidene fluoride. , polyacrylate, such as poly (methyl methacrylate) (only in mixtures) and the like and mixtures thereof.

The non-elastic film layers in the laminate of the present invention can be made of breathable or non-breathable materials and can be perforated. The non-elastic film layer may contain such fillers as fillers that develop micropores, for example, calcium carbonate; opacifying agents, for example, titanium dioxide; and antibloque additives, for example, diatomaceous earth.

The fillers can be incorporated to develop micropores during orientation of the non-elastic film layer resulting in films capable of breathing. Once the film filled with particles has been formed, it is then either stretched or crushed to create paths through the film layer. Generally, to qualify as being "breathable" for the present invention, the resulting laminate must have a water vapor transmission rate (WVTR) of at least about 250 grams per square meter per 24 hours as It can be measured by a test method as described below. Preferably, the laminate will have a water vapor transmission rate of at least about 1000 grams per square meter per 24 hours.

As used herein, a "micropore filler and developer" is intended to include particles and other forms of materials which can be added to the polymer and which will not chemically interfere with or adversely affect the extruded film but will be able to be dispersed evenly through the film layer. Generally the micropore development fillers will be in the form of particles and will usually have something of a spherical shape with the average particle sizes in the range of about 0.5 to about 8 microns. The non-elastic film layer will usually contain at least about 20 volume percent, preferably about 20 to 40 volume percent of micropores developing filler based on the total volume of the film layer. Both fillers that develop organic and inorganic micropores are contemplated as being within the scope of the present invention as long as they do not interfere with the process of film formation, the ability to breathe of the resulting non-elastic film layer, the barrier properties to the liquid of the film layer or its ability to bind to another sheet layer.

Examples of fillers that develop micropores include calcium carbonate (CaC03), various kinds of clay, silica (Si02), alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, sulfate aluminum, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivative, polymer particles, chitin and chitin derivatives. The filler particles that develop micropores can optionally be coated with a fatty acid, such as stearic acid, or a chain fatty acid larger than starch such as behenic acid which can facilitate the free flow of the particles (a bulk) and its ease of dispersion in the polymer matrix. Fillers containing silica may also be present in an effective amount to provide antiblock properties.

It is also contemplated here the fastening of a non-elastic additional narrowing material which is not narrowed and which would be more benignly fastened to the non-constricted elastic material, opposite the tapered laminate. Such an additional layer will provide a more pleasant sensation and appearance to the other side of the composite material.

At least one layer of the non-elastic shrinkable material is added to the composite material of the present invention. The non-resilient, narrowable material 14 (see, for example, Figure 1) includes non-woven fabrics, woven materials and knitted materials which are permeable to air.

As used herein, the term "nonwoven fabric or fabric" means a fabric having a structure of individual fibers or threads which are interleaved but not in an identifiable manner as in a woven fabric. Fabrics or non-woven fabrics have been formed from many processes such as, for example, carded and bonded tissue processes, meltblowing processes and spinning processes. The basis weight of non-woven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and useful fiber diameters are usually expressed in microns. (Note that to convert from ounces per square yard to grams per square meter multiply ounces per square yard by 33.91). The narrowable material of the present invention has a basis weight of 5 to 90 grams per square meter, preferably 10 to 90 grams per square meter, more preferably 20 to 60 grams per square meter.

Suitable fibers for forming the non-elastic shrinkable material include natural and synthetic fibers as well as bicomponent, multi-component and shaped polymer fibers. A plurality of non-elastic narrowable materials can also be used according to the present invention. Examples of such materials may include, for example, spunbond / meltblown composites and spunbond / meltblown / spunbondedbond compounds as taught in Brock et al., Patent of the United States of America No. 4,041,203, which is incorporated herein by reference in its entirety. Narrow non-elastic materials may also be formed from "Coform" as described in commonly assigned United States of America Patent No. 4,100,324 issued to Anderson et al.

As used herein, the term "spunbonded fibers" refers to fibers of small diameter which are formed by extruding through one or more extruders, attached to one or more banks made of at least transfer tubing and spinning plates for producing molten thermoplastic material as filaments from a plurality of fine, usually circular, capillary vessels, in a spinning organ with the diameter of the extruded filaments then being rapidly reduced as, for example, indicated in the Patents of the United States. United of America No. 4,340,563 granted to Appel and others; the Matsuki Patent and others 3,802,817; that of Dorschner and others; 3,692,618; Kinney Patents 3,338,992 and 3,341,394; Hartman's Patent 3,502,763; and Dobo 3,542,615. Yarn spun fibers are generally non-sticky when they are deposited on a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns, more often between about 10 and 40 microns. The resulting fiber mat is then bonded to form a strong, narrow fabric. This connection can be carried out by ultrasonic bonding, chemical bonding, adhesive bonding, thermal bonding, needle bonding, hydroentanglement and the like.

As used herein, the term "meltblown fibers" means fibers formed by extruding a molten thermoplastic material through a plurality of thin, usually circular, capillary vessels such as strands or filaments fused into gas streams (eg. air), usually hot and at high speed which attenuate the filaments of the molten thermoplastic material to reduce its diameter which can be to a microfiber diameter. Then, the melt blown fibers are carried by the gas stream at high speed and are deposited on a collecting surface to form a fabric of meltblown fibers dispersed at orange blossom. Such a process is described, for example, in U.S. Patent No. 4,849,241, issued to Butin et al. The melt blown fibers are microfibers which may be continuous or discontinuous, and are generally smaller than 20 microns in average diameter.

As used herein the term "microfibers" means small diameter fibers having an average diameter no greater than about 75 microns; for example, having an average diameter of from about 0.5 microns to about 50 microns, more particularly from about 2 microns to about 40 microns. Another frequently used expression of fiber diameter is denier, which is defined as grams per 9,000 meters of a fiber and can be calculated as the fiber diameter (in microns) squared, multiplied by the polymer density in grams / cm2 , multiplied by 0.00707. For the same polymer, a lower denier indicates a finer fiber and a higher denier indicates a thicker or heavier fiber. For example, the diameter of polypropylene fiber given as 15 microns can be converted to one denier per square, multiplying the result by 0.89 grs / cm3 and multiplying by 0.00707. Therefore, a fiber of 15 microns of polypropylene has a denier of about 1.42 (152 x 0.89 x 0.00707 = 1.415). Outside the United States of America, the unit of measurements is more commonly the "tex" which is defined as grams per kilometer of fiber. Tex can be calculated as denier / 9.

The non-elastic shrinkable material is preferably formed from at least one member selected from fibers and filaments made from non-elastic polymers such as polyesters, for example, polyethylene terephthalate, polyolefins, for example, polyethylene and polypropylene, polyamides, eg, nylon 6 and nylon 66. These fibers or filaments are used alone or in a mixture of 2 or more thereof.

Many polyolefins are available for fiber production according to the present invention, for example, fiber-forming polypropylenes include Escorene® Polypropylene PD 3445 from Exxon Chemical Company and PF-304 from Himont Chemical Company. Polyethylenes such as the linear low density polyethylene ASPUN®6811A from Dow Chemical, 2553 LLDPE 25355 and 12350 are also suitable polymers. Polyethylenes have melt flow rates of around 26, 40, 25 and 12 respectively. Many other polyolefins are commercially available.

If at least one layer of elastomeric filaments 51 is added to the composite material these filaments can be formed by the method of forming essentially parallel courses of elastomeric filaments found in commonly assigned United States of America Patent No. 5,385,775 issued to Wright. which is incorporated herein by reference in its entirety. The elastomeric filaments may have an average diameter of at least about 40 microns (μm), preferably, varying from at least about 40 to about 750 microns.

The elastomeric filament layer and / or the elastic material are preferably formed from at least one selected member of fibers and filaments made of elastic (or elastomeric) polymers which can be formed as described above for non-elastic shrinkable materials, by example, in a non-woven fabric of elastic fibers, for example, melt blown elastic fibers. A useful layer of an elastic material can have a basis weight ranging from about 5 g / m2 to about 300 g / m2, for example, from about 5 g / m2 to about 150 g / m2. The elastomeric thermoplastic polymers useful in the practice of this invention may be made from block copolymers such as polyurethanes, copolyester esters, block copolymers of polyether polyamide, ethylene vinyl acetates (EVA), block copolymers having the general formula ABA 'or AB as copoly (styrene-ethylene-butylene), styrene-poly (ethylenepropylene) -styrene, styrene-poly (ethylene-butylene) -styrene, (polystyrene / poly) (ethylene-butylene) / polystyrene, poly (styrene / ethylene-butylene) / styrene) and the like.

Useful elastomeric resins include block copolymers having the general formula A-B-A 'or A-B, wherein 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 polymer of lower alkene. Block copolymers of type A-B-A 'may have different or the 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 regard, the radial block copolymers can be designated (AB) mX, wherein X is a polyfunctional atom or molecule and in which each of (AB) m-radiates from X in a way that A is a block of extreme. In the radial block copolymer, X can be a molecule or a polyfunctional organic or inorganic atom and m is an integer having the same value as the functional group originally present in X.

This is usually at least 3, and this is often 4 or 5, but it is not limited to this. Therefore, in the present invention, the term "block copolymer", and particularly block copolymer "ABA" and "AB" is intended to encompass all block copolymers having rubberized blocks and thermoplastic blocks as discussed above which they can be extruded (for example by meltblowing) and without limitation as to the number of blocks. The elastomeric nonwoven fabric can be formed of, for example, elastomeric block copolymers of (polystyrene / poly (ethylene-butylene) / polystyrene). Commercial examples of such elastomeric copolymers are, for example, those materials known as KRATON® which are available from Shell Chemical Company of Houston Texas. KRATON® block copolymers are available in several different formulas, a number of which are identified as copolymers and are available in several different formulas, a number of which are identified in United States of America patents No. 4,663,220 and 5,304,599, incorporated herein by reference.

Polymers composed of an elastomeric tetrablock copolymer A-B-A-B can also be used in the practice of this invention. Such polymers are discussed in U.S. Patent No. 5,332,613 issued to Taylor et al. In such polymers, A is a block of thermoplastic polymer and B is a unit of isoprene monomer hydrogenated to a monomer unit of poly (ethylene-propylene). An example of such a tetrablock copolymer is an elastomeric block copolymer of styrene-poly (ethylene-propylene) -styrene-poly (ethylene-propylene) or SEPSEP available from Shell Chemical Company of Houston Texas under the trade designation KRATON® G- 1657 Other example elastomeric materials which may be used include polyurethane elastomeric materials such as for example those available under the trademark ESTAÑE® from B.F. Goodrich & Co. or MORTHANE® by Morton Thiokol Corporation, elastomeric polyether ester materials such as, for example, those available under the trade designation HYTREL® of E.l. du Pont de Nemours and Company and those known as ARNITEL®, formerly available from Akzo Plastics of Arnhem, the Netherlands and now available from DSM of Sittard, The Netherlands.

Another suitable material is a polyether block amide copolymer having the formula: OO HO- [- C - PA - C - O - PE - 0] n - H where n is a positive integer, PA represents a segment of polyamide polymer and PE represents a segment of polyether polymer . In particular, the polyether block amide copolymer has a melting point of from about 150 ° C to about 170 ° C, as measured in accordance with ASTM D-789; a melt index of around 6 g / 10 min. at around 25 grams / 10 min. , as measured in accordance with ASTM D-1238, condition Q (235 C / lKg load); a flexural modulus of flexure from about 20Mpa to about 200 Mpa, as measured in accordance with ASTM D-790; a tensile strength at break from about 29 Mpa to about 33 Mpa as measured in accordance with ASTM D-638 and a final elongation at break from about 500 percent to about 700 percent as measured by the ASTM D-638 standard. A particular incorporation of the polyether amide block copolymer has a melting point of about 152 ° C as measured according to ASTM D-789; a fusion index of around 7 grs / 10 min. as measured in accordance with ASTM D-1238, condition Q (235 c / lkG load); a modulus of elasticity in flexion of about 29.50 MPa, as measured in accordance with ASTM D-790; a tensile strength at breaking of about 29 MPa, a measure in accordance with ASTM D-639; and an elongation at break of about 650 percent as measured in accordance with AST D-638. Such materials are available in various grades under the PEBAX® trade designation of Atochem Inc. Polymers Division (RILSAN®), of Glen Rock, New Jersey. Examples of the use of such polymers can be found in the Patents of the States United States No. 4,724,184, 4,820,576 and 4,923,742 incorporated herein by reference to Killian and others and assigned to the same assignee of this invention.

The elastomeric polymers also include copolymers of ethylene and at least one vinyl monomer such as, for example, the vinyl acetates, the unsaturated aliphatic monocarboxylic acids and the esters of such monocarboxylic acids. The elastomeric copolymers and the formation of the elastomeric non-woven fabrics of these elastomeric copolymers are described in, for example, U.S. Patent No. 4,803,117.

The thermoplastic copolyester elastomers include the copolyether esters having the general formula: 0 0 0 0 H- ([0-G-0-C-C6H4-C] b- [0- (CH2) a-0-C-C6H4-C] m) n-0- (CH2) a-0H Where "G" is selected from the group consisting of poly (oxyetho 1 not) - alpha, omega-diol, poly (oxypropylene) -alpha, omega-diol, poly (oxytetramethylene) -alpha, omega -diol and "a" and "b" are positive integers including 2, 4 and 6, "m" and "n" are positive integers including 1-20. Such materials generally have an elongation at break of from about 600 percent to 750 percent when measured in accordance with ASTM D-638 and a melting point of from about 350 ° F to about 400 ° F (176 to 205 ° F). C) when measured in accordance with ASTM D-2117.

Commercial examples of such copolyester materials are, for example, those known as ARNITEL®, formerly available from Akzo Plastics of Arnhem, The Netherlands and now available from DSM of Sittard, The Netherlands, or those known as HYTREL® which are available from E.l. du Pont de Nemours and Company, Inc., of Wilmington, Delaware. The formation of an elastomeric non-woven fabric of polyester elastomeric materials is described in, for example, U.S. Patent No. 4,741,949 issued to Morman et al. And U.S. Patent No. 4,707,398 issued to Boggs and incorporated here by reference.

A non-woven fabric layer can be joined to impart a discrete bonding pattern with a prescribed bonding surface area. This is known as the thermal point union. The "thermal point union" involves passing a fabric of fibers that are to be joined between a pattern roller or heated calender and an anvil roller. The calendering roller is patterned so that the entire constrictable material is not bonded through its entire surface. In fact, this feature is very important to narrow the narrow materials as described here. If too much joint area is present on the narrowable material, it will break before it narrows. If there is not a sufficient joint area, then the narrow material will separate. Typically, the percent binding area useful in the present invention ranges from about 5 percent to about 40 percent of the area of the narrowable material. Many patterns for calendering rolls have been developed as will be understood by those skilled in the art, the percentages of joint area are, of necessity, described in approximations or ranges since the joint bolts are normally tapered and wear out over time. . Those skilled in the art will also recognize, the references to "bolts / inch2" and "joints / inch2" that are somewhat interchangeable since the bolts will create joints in the substrate in essentially the same sizes and surface ratios as the bolts on the roll . There are a number of discrete union patterns which can be used. See, for example, Brock et al., U.S. Patent No. 4,041,203. An example of a pattern that has dots and is the Hansen Pennings pattern or "H &P" with about 200 joints / inch2 as taught in U.S. Patent No. 3,855,046 issued to Hansen &; Pennings. The "H &P" pattern has bolt or square dot joining areas where each bolt can have a side dimension of 0.965 millimeters, for example, resulting in a pattern having a joined area of about 30 percent. Another typical point binding pattern is the Hansen & Pennings or "EHP" which produces a joint area of about 15 percent to 18 percent which can have a square bolt that has a side dimension of 0.94 millimeters, for example, and a bolt density of about 100 bolts / inch2 . Another typical point union pattern designated "714" has the square bolt joint areas where each bolt can have a side dimension of 0.023 inches for example, for a joint area of 15 percent to 20 percent and about 270 bolts per inch2 Other common patterns include the "Ramisch" diamond pattern with repetitive diamonds that have a bound area of 8 percent to 14 percent and 52 bolts per square inch, an HDD pattern which includes the point joints that have about 460 bolts per inch2 for a united area of about 15 percent to about 23%, as well as a pattern of woven wire that looks like its name suggests, for example, as a window grid and that has a 15 percent bound area to 20% and 302 joints per inch2. Another bonding pattern for the spunbonded face fabric is an "S" woven pattern as described in the commonly assigned United States of America Patent No. 5,964,742 issued to McCormack et al., Which is incorporated herein by reference. In its whole.

The lamination of the non-elastic film layer to the non-elastic shrinkable material to form the tapered laminate can occur by typical methods known in the art including adhesive bonding, knit bonding, thermal bonding and sonic welding. The use of inelastic and / or elastic adhesives for adhesive bonding is also contemplated here. As discussed in more detail below, the use of an elastic adhesive has not been found to significantly impact the ease of extension. When the film layer and the shrinkable material are joined together through the use of heat and / or pressure, the rolling means 30 (Figure 1) such as rolling rolls can be used.

The rolling rolls can be heated and the point connection can be used. The temperature at which the rolling rolls are heated will depend on the properties of the film and / or the shrinkable material but will usually be in the range of 200-275 ° F (93-135 ° C). The rolling rolls can each have a pattern or a roller can be smooth while the other roller has a pattern. If one of the rollers has a pattern this will create a discrete bond pattern with a prescribed bonding area for the resulting narrow laminate 2.

As previously stated, the composite material that has stretch and recovery can be used in a wide variety of applications, including absorbent articles for personal care such as diapers, underpants, incontinence devices and products for the hygiene of women such as sanitary napkins. An example article 80, a diaper is shown in Fig. 4. Referring to Fig. 4, most personal care absorbent articles include a liquid-permeable liner or sheet 82, an outer cover or back sheet 84 and an absorbent core 86 positioned between and contained by upper sheet 82 and lower sheet 84. Articles 80 such as diapers can also include some type of fastening means 88 such as adhesive fastening tapes or type fasteners. of mechanical hook and loop to keep the garment in place on the user.

The composite material can be used to form various parts of the article including, but not limited to, the upper sheet 82 and the lower sheet 84. If the composite material is to be used as the upper sheet 82, it is more likely to be perforated or otherwise. way it will become permeable to liquid. When the composite material is used as the bottom sheet 84, it is usually advantageous to place the nonwoven side, if only one side has a nonwoven, facing away from the wearer. Furthermore, in such embodiments it may be possible to use the non-woven part of the composite material as the part of the curls of the combination of hooks and curls of the fastening means 88.

As the composite material has stretch and recovery, the elastic waistband 90 can be fastened / incorporated in an unstretched configuration during the production of the diaper, significantly simplifying the conversion process. The resulting waistband will stretch, recover, and seal around the baby's waist much better. The composites of the present invention are equally useful in articles used in medical applications. Referring to Figure 5, the composite material has been used to form an example article useful in medical applications, in this case a mask for the face 60. The composite material is attached to the fastening means 88 'for tying the mask from the face 60 to the head of a user. In this application, the non-elastic film layer will more easily be perforated so that the user can breathe comfortably. Such perforations 62 will be sized and located so that breathing is not impeded but they will not be very large or numerous so that the function of the mask for the face (for example protecting the user) is impeded. One such embodiment may have the openings in the edges in the transverse dimension of the face mask (not shown).

Yet another example article is a protective garment such as a lab coat or footwear. A particularly troublesome aspect of the use of the non-elastic laminate of the prior art is the lack of "give" as discussed above. This can be better understood in the context of folding an elbow of a laminated dress. If the laminate of the prior art was used to create the garment when the elbow is bent, the material is tightened around the elbow which can cause the material to tear or at least cause discomfort to the user. If the garment were to be made of the composite material of the present invention, however, the material would "yield" when the elbow was bent and then tend to return to its previous form.

An advantage of using a composite material in such applications is that the articles will be more "cloth-like" in both appearance and feel. Additionally, stretching and recovery will allow the item to conform more closely to the user's body.

The composite material of the present invention is capable of maintaining properties such as strength, hydro head and breathability while improvements in "fabric type" characteristics such as formability and stretch and recovery are obtained. The advantages and other features of the present invention are best illustrated by the following examples.

Examples Samples of the present invention were prepared as described below. The samples were then subjected to the following tests: Stress Test: The stress test measured the strength and elongation or stress of a fabric when subjected to a unidirectional stress according to the Standard ASTM D 5034-95 test, as well as the Federal Test Methods Standard No. 191A Method 5102-78. This test measured the resistance of the pounds and the percentage of stretching while the sample was lengthened until it broke. The upper numbers indicate a stronger and / or more stretchable fabric respectively. The term "peak load" means the force or maximum load, expressed in pounds, required to lengthen a sample at break in a stress test. The terms "elongation", "tension" or "stretch percentage" means the increase in length of a sample during the stress test expressed as a percentage. The values for peak load and peak load tension were obtained using a cloth width of 76 x 152 millimeters, a clamp width of 76 millimeters, a gauge length of 76 millimeters, and a constant rate of extension of 305 millimeters per minute, where the full sample width was caught in the handles. The specimen was grasped for example in an Instron 1130 apparatus available from Instron Corporation or in an INTELLECT II apparatus from Thwing Albert available from Thwing Albert Instrument Company, 10960 Dutton Road, Philadelphia Pennsylvania 19154 and the unit was zeroed, rocked and It was calibrated according to the standard procedure.

Cycle Test: Samples were also cycled in the Instron tester with Microcon II using a 50 kilogram load cell. The sample sizes and the tester were put as described above except that the gauge length was 5.08 centimeters. Scheme and cruzeta speeds were set at 50.8 centimeters per minute. The maximum extension limit for the length of the cycle was set at a certain distance by calculating 50 percent of the "elongation at break" of the stress test. Samples were cycled to the specific cycle length 2 times and then taken to break over the third cycle. The test equipment was set to measure the peak load in grams force for each cycle. Over a third cycle (cycle to break) the peak elongation and the peak load were measured.

% Permanent Settlement: The permanent settlement test measures the degree of retraction of a material after it has been stretched to a specific length. Usually, the greater the value placed permanent, the less retractable is the sample. After the laminate was produced and wound onto a roll, the indelible ink was used to mark a strip 5.0 cm wide of the material in the transverse dimension. After the laminate was unrolled, a sample area of 7.62 centimeters in the longitudinal direction x 11.43 centimeters in the transverse direction was cut from the laminate to include the marked area. Each sample was placed between two jaws 7.62 centimeters wide. The jaws were separated at a distance of 5.08 centimeters apart and the jaws were caught on the marks that had been previously made on the material. The marks were then lengthened to a specified amount (for example 90% or 4.57 centimeters) and allowed to retract. The elongation was recorded when the force during the retraction reached 25 grams. The permanent settlement was calculated as follows: Permanent settlement% = 100 x (distance x between the jaws when the rolling resistance drops to 25 grams under force during the retraction cycle - initial length H- total stretched length = [x (inch) -2 (inch)] 1.8 = [x (cm) -5.08 (centimeter)] - * - 4.57.

Three repetitions were carried out and the average value is represented in the examples that follow.

Breathability Test: The water vapor transmission rate (WVTR) for the sample materials was generally calculated according to the following test method in order to measure the breathing capacity of the samples. The test procedure establishes a means for determining the normalized rate of water vapor transmission through solid and porous films, non-woven materials, and other materials while under steady-state conditions. The material that will be evaluated and sealed to the top of a cup of water and placed in a temperature controlled environment. The evaporation of water in the cup results in a higher vapor pressure inside the cup than the vapor pressure in the environment outside the cup. This difference in vapor pressure causes the steam from the cup to flow through the test material to the outside of the cup. The rate of this flow will depend on the permeability of the sealed test material to the top of the cup. The difference between start and stop cup weights is used to calculate the water vapor transmission rate.

In particular, circular samples measuring 3 inches in diameter were cut from each of the test materials and a control which was a piece of a CELGARD® 2500 film from Hoechs, Celanese Corporation. The CELGARD® 2500 film is a microporous polypropylene film. the test disc was a cup of Vapometer 68-1 distributed by the Thwing Albert Instrument Company of Philadelphia Pennsylvania. 100 milliliters of water were poured into each cup Vapometer and individual samples of test materials and control material were placed through the open top parts of the individual cups. A rubber gasket and a metal ring (fitted to the cup) were placed on the sample and grasped using the metal handles. The sample test material and the control material were exposed to room temperature over a diameter circle of 6.5 centimeters, having an exposed area of approximately 33.17 square centimeters. The cups were placed in an oven at a temperature of about 38 ° C, for a sufficient time for the cups to achieve thermal equilibrium. The cups were removed from the oven, weighed and put back in the oven. The oven was a constant temperature oven with an external air circulating through it to prevent the accumulation of water vapor inside. A suitable forced air furnace is, for example, a Blue M Power-O-Matic 60 furnace distributed by Blue M. electric Company of Blue speak, Illinois. After 24 hours, the cups were removed from the oven and weighed again. The values of water vapor transmission rate of preliminary test were calculated with equation (1) given below: APP MVT = (weight loss grams over 24 hours) x 7571/24 expressed in grams / m2 / 24 hours.

The approximate moisture vapor transfer is designated by "APP MVT". Under the predetermined conditions of around 38 ° C and ambient relative humidity, the water vapor transmission rate for the CELGARD® 2500 control has been defined as being 5000 grs / m2 x 24 hours. Therefore, the control sample was run with each test and the preliminary test values were corrected to established conditions using equation (II) given below: (II) Water Vapor Transmission Rate = (water vapor transmission rate test / control water vapor transmission rate) x (5000 grs / m2 / 24 hrs.) Hydrohead: A measure of the liquid barrier properties of a cloth is the hydro head test. The hydro head test determines the height of water (in centimeters) which the fabric will support before a predetermined amount of liquid passes through it, usually three drops. A fabric with a higher hydro head reading has a greater barrier to liquid penetration than a fabric with a lower hydro head. The hydrohead test was carried out according to federal testing standard 191A, Method 5514 using a Textest FX-3000 Hydrostatic Head Tester available from Mario Industries Inc. of P.O. Box 1071, Concord, North Carolina. A circular head having an inner circumference of 26 centimeters was used to grip the sample.

Theoretical extension%: The theoretical extension% is the amount of extension and retraction that can be expected for the narrowed laminates of the present invention based on how much the original width is reduced and assuming that the original laminate has no inherent extension. In the following equations, the original width is the untwisted width (transversal dimension) of laminate, while the narrowed width is the width of laminate after narrowing. The theoretical extension percentage can be determined as follows: % theoretical extension = 100 [(original width-narrowed width) -r narrowed width] which can be rewritten as: % theoretical extension = 100 x [(original width - = - narrowed width) -1].

The% of the original width that the laminate is narrowed can be represented by the following equation: % original width = 100 x (narrow width - ^ original width) which can be rewritten as: (original width -I- narrowed width) = 100 -s-% original width.

Substituting the equation in% of theoretical extension above: % theoretical extension = 100 x [(100 -H% original width) -1] In this way, for each sample below, the original width was measured, as was the narrowed width and the theoretical extension percentage was calculated as shown below in Table 3.

Example 1 This example explains the process used to prepare the tapered laminate which was then used as part of the composite materials given below. The tapered laminate was prepared from a non-elastic film layer and a non-elastic nonwoven fabric layer. A 1.5 mil layer of meltblown film made of 48% by weight (25 volume percent) of SUPERCOAT calcium carbonate as manufactured by English China Clay America, Inc. from Sylacauga, Alabama, 47% by weight (68% by volume) of linear low density polyethylene (LLDPE) available under the trade designation DOWLEX NG 3347A as manufactured by the Dow Chemical Company ("Dow"), 5% by weight (7% by volume of low density polyethylene (LDPE) available under the trade designation 6401 as manufactured by Dow and 2000 per million antioxidant stabilizer available under the trade designation B900 as manufactured by Ciba Specialties Company of Tarrytown, New The film layer, made of the compound as described above, was made and rolled into a roll.To make this layer of highly breathable film, it should be stretched about 4X (4 times its original length) by example up to 5X or more.The film layer was then unrolled from a film unwinding unit in an orienter in the direction of the conventional machine manufactured by The Marshall and Williams Comp. any where this was partially stretched as shown in table 1 given below (pulled with stretching) in the direction of the machine to form a film layer with a partially stretched breathing capacity. Similarly, a standard polypropylene spunbonded material of 0.4 oz. Per square yard of basis weight having a wire weave pattern as is done by Kimberly Clark Corporation of Dallas Texas, was unrolled from an adhesive of 3 grs / m2 weight (at the point of application) available as H2525A from Ato-Findley of Wauwatosa, Wl was applied to a surface of the non-woven fabric layer using a spray device aided with air such as as a blown device with fusion as described in Butin et al., above. Such devices are generally described in, for example, U.S. Patent No. 4,949,668 issued to Heindel et al.; U.S. Patent No. 4,983,109 issued to Miller et al., Assigned to Nordson Corporation; and U.S. Patent No. 5,728,219 issued to Alien et al. assigned to J &M Laboratories Inc.

The adhesive side of the non-woven fabric layer was then laminated to the partially stretched film layer using rolling rolls at a pressure of 5.4 kilograms per linear centimeter of an elastic anvil roll (rubber coated) smooth on one side and a roller of unheated steel smooth to form a laminate.

The laminate was then stretched in the longitudinal dimension and narrowed in the transverse direction by passing it through a stretch clamping point at a speed greater than the speed of the rolling rolls. (see table 1 given below, pulling of rolled narrowing).

Pulling with constriction caused contraction (constriction) of the laminate in the transverse direction. The rolling rolls were spaced by about 2.4 centimeters from the stretch pressure point. The "total pull" in table 1 is the pull-in-fold multiplied by pulling with stretch and was sufficient to ensure sufficient orientation or stretch to make the film layer highly breathable. The transversely extensible retractable and thus retractable laminate thus formed was then wound onto a roll. Samples were cut from the tapered laminate and tested, the results of which are reported below in Table 1. Samples Cl and C2 are comparative examples (baseline) where the film layer was stretched as indicated , but the laminate was not narrowed. Figure 10 shows an oblique image of the prior art laminate of the sample Cl, wherein the film layer 12 was fully stretched before lamination the narrowable material 14 to form the laminate which was not subsequently tapered. Sample 8 was a repetition of sample 7. The "maximum voltage" is the voltage at a "maximum load".

Table 1 Sample 6 had the maximum stress in the highest transverse dimension. In this laminate, the film layer had been pulled to a total of 5.0X, which is the typical pull for such items. The laminate had been further narrowed by a 1.4X pull. The film layer of the Cl sample had also been pulled by a total of 5.0X, but the laminate was not narrowed at all. Even though the film layers had been pulled by the same amount, the example of the present invention, sample 6 had a peak tension in the transverse dimension much greater than that of the comparative example, which is an indication of the extension improvement and transverse retraction of the present invention. FIGS. 1 a, b and c and 12 a, b and c graphically illustrate load curves against extension for samples Cl and 6, while FIGS. 14 and 15 graphically illustrate the amplified curves of the spread against the load for these samples. FIGS. 1 a, b and c relate to three duplicates of the delaminated film layer of the sample Cl, while FIGS. 12 a, b and c relate to three duplicates of the delaminated film layer of the sample 6, having the fluted ridges.

Table 3 given below represents the narrowed width in inches (centimeters) as a function of the percent stretch and shows how easily the tapered laminate elongates in the transverse direction for each of the samples in Table 1. From the strength test to the tension given above, the force in pounds (kilograms) was recorded below in table 2 for each sample at 30%, 60%, 90%, 120%, 150%, and 180%. The laminates which have been narrowed to a narrower width (sample 5, 6, 8, table 3"narrowed laminated width" column) elongated to a much smaller force at the same percent elongation as the control and to a much larger extent before of the break. If the sample broke before or after the percentage of change of step, it was designated as "-".

Table Table 3 additionally showed the calculated percent of the theoretical extent as described above for each of the samples in Table 1.

Table The ability to breathe was measured by the water vapor transmission rate for the tapered laminate when it was in the extended configuration in the transverse direction, since this is the configuration it would have when in use such as in a diaper. Other replicates of sample 6 were extended to 100% and 166% and tested for the water vapor transmission rate. The results were as follows in table 4. Note that the laminate extended in the transverse direction had a much higher water vapor transmission rate than any of the comparative examples.

Table 4 To better describe the extension in the transverse direction of the film layer, for samples Cl and 6 above, the film layer was delaminated from the spunbonded layer for further testing. Prior to delamination, a length of 7.62 centimeters was marked on the side of the laminate film through the transverse direction. The delamination was carried out by completely submerging and soaking the laminate in denatured ethyl alcohol (ethanol) which softened and partially dissolved the bonding adhesive between the film layer and the spun bonded layer, so that the fluted ridges of the film layer were not removed, damaged or otherwise distorted. Once delaminated, the film layer was tested in a tension tester as described above and the force was measured when the film layer had extended by 0.762 centimeters (10% tension). The force required to extend the Cl sample (the average of three repetitions) was approximately 1000 grams per thousandth of an inch of the film layer thickness. The force required to extend sample 6 (the average of three repetitions) on the other side was approximately 60 grams per thousandth of an inch of the film layer thickness, which was the thickness determined with the flattened fluted roughness.

Example 2 The additional laminates were prepared as described above, except that the non-elastic adhesive was used in some samples and because some samples were heated after being tapered. The modifications were made to evaluate the impact of: 1) the use of the non-elastic adhesive compared to the semi-elastic adhesive used above, and 2) the heating of the laminate after the narrowing process. For each sample, the non-elastic film layer was stretched to a length of 4X before lamination to the spunbonded layer. The laminates were narrowed as indicated in Table 5 and tested for permanent settlement as described above. The non-elastic adhesive used was Rextac® 2730, available from Huntsman Polymers in Odessa, Texas. In addition, the samples that were heated after the constriction were put in contact with the heated rollers maintained at a temperature above about 76 ° C.

A sample of 10 centimeters by 10 centimeters was measured while the laminate was still rolled on a roller. Since the materials were wound under tension and some degree of relaxation tends to occur over time, the samples were measured again after being cut from the roll. The C9 and CIO samples are comparative materials (base line) where the film was stretched but the laminate was not narrowed.

Table 5 The heat set materials, samples 14 and 15, maintained their original dimensions better than the materials that were narrowed and not seated by heat, based on the comparison between the sample size before and after the roll cut. In addition, all materials, regardless of the use of elastic and inelastic adhesive, exhibited the same degree of permanent settlement. There was very little difference between the permanent settlement of the laminates made with the semi-elastic adhesive and those made with the inelastic adhesive indicating that the small amount of elastic adhesive used does not affect the overall extent and retraction of the non-woven fabric laminate.

The samples were further tested for the tensile properties in the transverse dimension (TD) and the water vapor transmission rate according to the test methods described above. The results are summarized in table 6.

Table When the samples were 50% elongated, the control materials (not narrowed), the C9 and CIO samples, exhibited a significantly higher load than the narrowed materials, samples 11-16, indicating that a much greater force was necessary to extend the control samples in the transverse dimension.

Example 3 The strands of the elastomeric filaments in the form of rubber bands were fastened longitudinally to the longitudinal dimension of the film side of the tapered laminate of the sample 6 from Example 1 above, using a spray of 3M "Super 77" adhesive. " The entire film surface was sprayed with the adhesive. The stretched rubber bands were pressed against the adhesive and kept there for about 15 seconds. Even though the rubber bands were still under tension, the drinking powder (as available from Johnson &Johnson) was sprayed onto the adhesive-coated sample to eliminate the adhesive effect at locations other than the belt attachment locations. of rubber. With the release of the pressing force, the elastomeric filaments were retrieved, pulling the rolled laminate together with these. The composite thus formed exhibited a stretch and recovery in the longitudinal direction and an extension and retraction in the transverse direction. Figures 20 and 21 show images of the composite material thus formed.

Example 4 The composite was made as described essentially above for Example 3, except that the elastomeric filaments were not stretched and were attached perpendicular to the longitudinal dimension and fluted roughness. In other words, the elastomeric filaments were clamped in the transverse dimension of the tapered laminate as can be seen in Figure 22. The composite material thus formed exhibited stretching and recovery in the transverse direction.

Example 5 A "SBL" bonded and bonded laminate of 73 grams per square meter of elastic material as an inner elastic material, which has standard polypropylene spunbonded coatings such as those made by Kimberly-Clark Corporation of Dallas, Texas, subject to both sides of the inner elastic material, was carefully delaminated from one of the layers joined with spinning. The "stretched joint" conventionally refers to an elastic member that is being joined to another member while the elastic member is extended at least about 25% of its relaxed length. The "bonded and stretched laminate" refers to a material having at least two layers in which one layer is a foldable layer and the other layer is an elastic layer. The layers are joined together when the elastic layer is in an extended condition so that with the relaxation of the layers, the recoverable layer is folded. Such material can be stretched to the extent that the non-elastic material collected between the joined places allows the elastic material to elongate. A type of bonded and stretched laminate is described, for example, by commonly assigned United States of America 4,720,415 to Vander Wielen and others in which multiple layers of the same polymer produced from the multiple banks of extruders are used. .

The elastic material with a spin-bonded coating was attached to the laminates of Example 1 given above. For the elastic material of the delaminated SBL material used here, the elastic material was formed by meltblowing a 70% by weight mixture of a block copolymer * A-B-A 'having end blocks "A" and "A" of polystyrene and a middle block "B" of poly (ethylene-butylene) (obtained from Shell Chemical Company under the trade designation KRATON® GX 1657) and 30% by weight of a polyethylene (obtained from U.S. I. Chemical Company under the trade designation PE Na601).

The melting blow of the elastic material was achieved by extruding the mixture of materials through an extruder and through the meltblown matrix as described in commonly assigned U.S. Patent No. 4,663,220 to Wisneski et al.

The elastic material and the spunbonded layer were then laminated to the narrowed laminates of Example 1 above to form composite materials as follows in Table 7. The side of elastic material was bonded directly to the side of the laminate film narrowed through of the use of a junction plate with sine wave pattern and a Carver press (Model number 1528, series number 2518-66). The attached pattern used is shown in Figure 19a. A press temperature of 150 ° F (65.56 ° C) was used, and the binding period was 15 seconds. The force used was 20,000 pounds (88,960 newtons) as indicated by the meter on the Carver press. The sample size was around 22.86 x 25.4 cm).

Samples 1-8 of Example 1 given above were used to form the tapered laminate for the composite materials of samples 9-16 respectively. The samples were elongated to the break and the peak load and the elongation to the breaking load were recorded as follows in table 7 given below. By having the bonded layer with additional spinning (of the SBL material), the peak tension in the transverse direction increases for all the samples 9-16 to about 150 to 160%. This was because the peak load is now increased by the layer bonded with SBL yarn as shown by high peak transverse direction charges. The only exception is that the sample 14 (which was sample 6 with the elastic layer bonded and the layer bonded with additional spinning) had a tension of 189.657% compared to the sample tension 6 'of 197.79% due to which sample 6 had itself had a high elongation. Figure 25 is an optical photomicrograph in cross section of a composite material in which the elastic material was not stretched showing the multiple layers of the sample 14.

Table In Table 8, samples 1-8 of Example 1 given above are compared to samples 9-16, respectively for the cycling test carried out as described above. Each of the samples was cycled to different lengths depending on the "elongation at maximum load" of the voltage tests given above. As can be deduced from these data, the elastic materials helped to maintain the extension and retraction force after the initial stretch, for example the samples 1-8 were extended without tearing but did not retract much, or at least very quickly. Samples 9-16 on the other hand, were stretched and recovered in the direction of the transverse dimension as can be seen by the lowest permanent settlement and maintenance of the extension force and retraction force at 50% of the distance of lengthening. Figure 16 shows the cycling for sample 6 while figure 17 shows cycling for sample 1. Figure 6 has a permanent high settlement compared to sample 14.

Table 8 Example 6 A stretched and bonded laminate (SBL) having 73 grams per square meter of elastic material was formed as described above for Example 5 except that the spunbonded coatings were removed from samples 18-22. The inner elastic material, the KRATON® elastic meltblown material, was then combined without stretching with the narrowed laminates of Example 1 given above as follows: Sample 16 was made of the Cl sample; sample 19 was made from sample C2; and samples 20 and 21 were made from sample 6. Also at this time, a press temperature of 48.89 ° C and a binding period of 30 seconds were used. The sample sizes were 20.32 x 25.4 cm. The sinusoidal wave join pattern of Figure 19a was used for samples 18-20, while the dot-junction pattern of Figure 19b was used for sample 21. These samples were cycle tested as described above for Example 2 and the results are reported below in Table 9. Again, the permanent settlement was greatly reduced when the elastic material was used to make the composite material. Extensive and retractable forces were significantly increased. Figure 16 showed the cycling for sample 6, while figure 18 showed cycling for sample 20.

Table 9 Table 10 gave the results of the water vapor transmission rate and the hydro head test for all the samples described above, including the sample 22 which was made by stretching the sample 20 100% in the transverse direction.

Table 10 Table 11 below summarizes the water vapor transmission rate data for samples Cl, C2, and 6, corresponding to their counterparts above in example 5 (samples 9, 10 and 14) and examples 6 ( 18, 19 and 20) respectively. The composite materials which have the elastic material which was not stretched, therefore, have not been adversely affected with respect to the ability to breathe by the addition of the elastic material.

Table 11 Example 7 The sample 17 was made by adding the elastic material (nonwoven fabric blown with KRATON® fusion) of the inner elastic material described in example 6 given above to sample 6 of example 1 given above. The elastic material was first stretched in the longitudinal dimension and joined in the stretched state to the side of the film of the sample 6. The joint was achieved using the Carver press as described above for example 5. The binding pattern used was the sinusoidal wave union pattern shown in Figure 19a. A press temperature of 43.33 ° C was used and the binding period was 15 seconds. The strength used was 88,960 newtons. The sample size was around 15.24 by 15.24 centimeters. The samples were tested and the results were reported in Table 12 given below. The example tension test curves are shown in Figures 26-31 for both the test in the longitudinal direction and in the transverse direction. Figure 25 is an optical cross-section photomicrograph of the composite material of the present invention showing the multiple layers of the sample 17. Some of the samples were drawn as indicated and retested for the water vapor transmission rate for imitate the ability to breathe when the composite material was stretched as would feasibly occur in actual use. Sample 17 was both stretched and recovered in the longitudinal direction and in the transverse direction, as well as in all directions, which is not specifically indicated by these data. This sample also had excellent liquid barrier properties (water), an ability to breathe and had a good appearance and feel.

Table 12 Supported by a light weight layer (approximately 0.4 ounces per square yard) of a yarn bonded material as it is elastic and would otherwise break under the weight of the water.

These samples were cycle tested as described above for Example 5 and the results are reported below in Tables 13 and 14. The samples in Table 13 were tested for cycle in the longitudinal direction which is illustrated graphically in figures 32 -3. 4. The samples in Table 14 were tested for cycle in the longitudinal direction which is illustrated graphically in Figures 35-37.

Table 13 Table 14 Having thus described the invention in detail it should be evident that various modifications can be made to the present invention without departing from the spirit and scope of the following claims.

Claims (33)

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

1. A composite material comprising: a) at least one first layer of a non-elastic shrinkable material; b) at least a second layer of a non-elastic film fastened to at least a first layer to form a laminate; wherein said laminate is constricted in a first dimension to form a tapered laminate and wherein said second layer of film has ridged ridges in a dimension perpendicular to said first dimension; Y c) at least one layer of an elastic material bonded to said tapered laminate.

2. The composite material as claimed in clause 1, characterized in that said material exhibits extension and retraction in at least one dimension and stretching and recovery in at least one dimension.

3. The composite material as claimed in clause 2, characterized in that the scored ridges comprise trapezoidal, crenellated or folded grooves.

4. The composite material as claimed in clause 2, characterized in that said fastening means comprise a point joint, a thermal point joint, an adhesive joint or a sonic weld.

5. The composite material as claimed in clause 4, characterized in that the adhesive bond is used to hold the layers.

6. The composite material as claimed in clause 2, characterized in that said first dimension is defined by a transverse dimension and said perpendicular dimension is defined by a longitudinal dimension.

7. The composite material as claimed in clause 2, characterized in that said material has the capacity to breathe.

8. The composite material as claimed in clause 2, characterized in that said non-elastic shrinkable material has a basis weight of from about 10 grams per square meter to about 90 grams per square meter.

9. The composite material as claimed in clause 2, characterized in that said non-elastic shrinkable material or said non-elastic film comprises a polyolefin.

10. The composite material as claimed in clauses 2 or 9, characterized in that said narrowable material comprises a nonwoven material bonded with spinning.

11. A conformable composite material for use in a garment comprising: a) at least one first layer of a non-elastic shrinkable material; b) at least a second layer of a non-elastic film fastened to at least a first layer to form a laminate; wherein the laminate is constricted in a first dimension to form a tapered laminate and wherein said second layer of film has ridged ridges in a dimension perpendicular to said first dimension; Y c) at least one layer of an elastic material fastened to said tapered laminate; wherein a pressing force applied to said first dimension of said material will cause said material to extend, stretch and conform around the body of the user.

12. The conformable composite material as claimed in clause 11, characterized in that said grooved ridges comprise trapezoidal, crenelated or folded grooves.

13. The conformable composite material as claimed in clause 11, characterized in that said clamping means comprise the thermal point joint, the point joint, the adhesive bond or the sonic weld.

14. The conformable composite material as claimed in clause 13, characterized in that the adhesive bond is used to hold the layers.

15. The conformable composite material as claimed in clause 11, characterized in that said first dimension is defined by a transverse dimension and said perpendicular dimension is defined by a longitudinal dimension.

16. The conformable composite material as claimed in clause 11, characterized in that said non-elastic shrinkable material has a basis weight of from about 10 grams per square meter to 90 grams per square meter.

17. The conformable composite material as claimed in clause 11, characterized in that said composite material is capable of breathing.

18. The conformable composite material as claimed in clause 11, characterized in that said laminate forms at least a part of the absorbent article for personal care.

19. The conformable composite material as claimed in clauses 11, 17, or 18, characterized in that said laminate forms at least a portion of an outer covering for an absorbent article for personal care.

20. The conformable composite material as claimed in clause 11, characterized in that said composite material contains openings.

21. The conformable composite material as claimed in clause 20, characterized in that said composite material forms at least a part of a liner for an absorbent article for personal care.

22. The conformable composite material as claimed in clause 11, characterized in that said laminate forms at least a part of a protective garment.

23. The conformable composite material as claimed in clauses 11 or 20, characterized in that said laminate forms at least a part of a mask for the face.

24. A method for making a composite material comprising: a) providing at least a first layer of a non-elastic shrinkable material; b) providing at least a second layer of a non-elastic film layer; c) fastening said non-elastic, non-elastic material to said inelastic film to form a laminate; d) stretching said laminate in a first dimension to narrow said laminate in a dimension perpendicular to said first dimension to form a tapered laminate so that the fluted roughnesses are formed in the non-elastic film layer in said perpendicular dimension; Y e) in addition to clamping at least a third layer of an elastic material to said narrowed laminate.

25. The method as claimed in clause 24, further characterized in that it comprises partially stretching said non-elastic film layer prior to forming the laminate to make the film layer in the laminate breathable.

26. The method as claimed in clause 25, characterized in that said non-elastic film layer contains from about 20 percent to about 45 percent by volume of filler.

27. The method as claimed in clause 25, characterized in that said laminate has a water vapor transmission rate of at least about 1000 grams per square meter per 24 hours.

28. The method as claimed in clause 24, further characterized in that it comprises heating said laminate.

29. The method as claimed in clause 24, characterized in that said clamping step comprises the adhesive connection, the thermal point connection, the point connection or the sonic welding.

30. The method as claimed in clause 29, characterized in that the adhesive bond is used to hold the layers.

31. The composite material as claimed in clause 24, characterized in that said laminate is stretched to about 1.2 to about 1.6 times its original length.

32. A conformable and conformable breathable material for use in a garment comprising: a) at least one first layer of a material bonded with non-stretchable and non-elastic yarn having a basis weight of from about 10 grams per square meter to about 24 grams per square meter; b) at least a second layer of a non-elastic film containing from about 20% to about 45% by volume of filler, said second layer of film bonded to said spin-bonded material is non-elastic narrowable to form a laminate; wherein said laminate is tapered in a first dimension to about 30% to about 80% of its original width to form a tapered laminate, and wherein said film layer has ridged ridges in a dimension perpendicular to said first dimension, of so that a pressing force applied to said first dimension of said laminate will cause the tapered laminate to extend and conform around the wearer's body; Y c) at least one layer of a stretched elastic material attached to said tapered laminate so that the composite exhibits stretch and recovery in at least one dimension.

33. The conformable and breathable composite material as claimed in clause 32, characterized in that said composite material exhibits stretching and recovery in multiple dimensions. SUMMARY The present invention is directed to a composite material and to a process for making the material. The composite material can be breathable and is formed of at least one layer of an elastic material and a narrow laminate of layers of sheets. The sheet layers include at least one non-elastic shrinkable material laminated to at least one non-elastic film defining a longitudinal and transverse dimension wherein the laminate is extensible and retractable in at least one dimension without significantly reducing the ability to breathe. and the liquid barrier properties of the film layer. The extension and retraction of the laminate is the result of the ridges roughened in, for example, the longitudinal dimension of the film layer which allows the constricted laminate to have an amount of extension and retraction in the transverse dimension. A breathable laminate can be made by first partially stretching a filled non-elastic film layer, clamping a non-elastic, narrowable layer to form a laminate and then stretching the laminate to narrow the laminate and lengthening the film to its desired fully stretched configuration. The fastening of at least one layer of an elastic material to the tapered laminate further provides stretch and recovery in at least one dimension.