Elastomeric, breathable laminate with enhanced breathability upon extension
View Patent ↗An elastomeric, breathable laminate having enhanced breathability is formed by bonding a breathable, microporous, extendible/elastic film to a nonwoven facing material. The facing material can be necked to impart cross-directional stretchability. Once the film and the facing material are bonded together, the resulting laminate is stretched in one or more areas to impart higher breathability to selected areas of the laminate. The breathable laminate with enhanced breathability is particularly useful as an outer cover for diapers and other personal care products.
1. A breathable laminate, comprising:
a breathable, microporous, elastic film; and
a nonwoven facing material bonded to the film;
wherein the laminate is selectively stretched to form at least one stretched zone thereof resulting in zones of differential breathability comprising at least one zone of higher breathability and at least one zone of moderate breathability;
wherein the at least one stretched zone of the laminate consists of the at least one zone of higher breathability; and
wherein each of the zones of differential breathability comprises a portion of the film and a portion of the nonwoven facing material.
2. The laminate of claim 1 , wherein the at least one zone of higher breathability has a water vapor transmission rate at least 10% higher than a water vapor transmission rate of the at least one zone of moderate breathability.
3. The laminate of claim 1 , wherein the at least one zone of higher breathability has a water vapor transmission rate at least 30% higher than a water vapor transmission rate of the at least one zone of moderate breathability.
4. The laminate of claim 1 , wherein the at least one zone of higher breathability has a water vapor transmission rate at least 50% higher than a water vapor transmission rate of the at least one zone of moderate breathability.
5. The laminate of claim 1 , wherein the water vapor transmission rate of the at least one zone of moderate breathability is at least about 500 grams/m 2 -24 hours.
6. The laminate of claim 1 , wherein the water vapor transmission rate of the at least one zone of moderate breathability is at least about 750 grams/m 2 -24 hours.
7. The laminate of claim 1 , wherein the water vapor transmission rate of the at least one zone of moderate breathability is at least about 1000 grams/m 2 -24 hours.
8. The laminate of claim 1 , wherein the laminate is elastomeric.
9. The laminate of claim 1 , wherein the facing material is necked.
10. The laminate of claim 1 , wherein the facing material is elastomeric.
11. The laminate of claim 1 , wherein the at least one selectively stretched zone is stretched at least twice.
12. The laminate of claim 1 , wherein the laminate can be stretched by about 50% to about 200% in a cross direction.
13. The laminate of claim 1 , wherein the laminate can be stretched by about 70% to about 170% in a cross direction.
14. The laminate of claim 1 , wherein the laminate can be stretched by about 100% to about 150% in a cross direction.
15. The laminate of claim 1 , wherein the laminate can be stretched by about 50% to about 200% in a machine direction.
16. The laminate of claim 1 , wherein the laminate can be stretched by about 70% to about 170% in a machine direction.
17. The laminate of claim 1 , wherein the laminate can be stretched by about 100% to about 150% in a cross direction.
18. An absorbent article outer cover comprising the laminate of claim 1 .
19. An outer cover for absorbent articles, comprising a breathable laminate;
the breathable laminate including a breathable, microporous, elastic film and a nonwoven facing material bonded to the film;
wherein the laminate is selectively stretched to form at least one stretched zone thereof resulting in zones of differential breathability comprising at least one zone of higher breathability and at least one zone of moderate breathability;
wherein the at least one stretched zone of the laminate consists of the at least one zone of higher breathability; and
wherein each of the zones of differential breathability comprises a portion of the film and a portion of the nonwoven facing material.
20. The outer cover of claim 19 , wherein the laminate is selectively stretched to form at least one stretched zone prior to incorporation in the absorbent article.
21. The outer cover of claim 19 , wherein the laminate is selectively stretched to form at least one stretched zone subsequent to incorporation in the absorbent article.
22. The outer cover of claim 19 , wherein the laminate is selectively stretched to form at least one stretched zone as the absorbent article is applied to a wearer.
23. The outer cover of claim 19 , wherein the laminate has a water vapor transmission rate of at least about 500 grams/m 2 -24 hours in the zone of moderate breathability.
24. The outer cover of claim 19 , wherein the laminate has a water vapor transmission rate of at least about 750 grams/m 2 -24 hours in the zone of moderate breathability.
25. The outer cover of claim 19 , wherein the laminate has a water vapor transmission rate of at least about 1000 grams/m 2 -24 hours in the zone of moderate breathability.
26. The outer cover of claim 19 , wherein the facing material is necked.
27. The outer cover of claim 19 , wherein the facing material is elastomeric.
28. The outer cover of claim 19 , wherein the at least one selectively stretched zone is stretched at least twice.
29. A method of making an outer cover for absorbent articles, comprising the steps of:
forming a breathable laminate by bonding a nonwoven facing material to a breathable, microporous, elastic film; and
selectively stretching the breathable laminate to form at least one stretched zone thereof resulting in zones of differential breathability comprising at least one zone of higher breathability and at least one zone of moderate breathability;
wherein the at least one stretched zone of the laminate consists of the at least one zone of higher breathability; and
wherein each of the zones of differential breathability comprises a portion of the film and a portion of the nonwoven facing material.
30. The method of claim 29 , further comprising the step of selectively stretching the laminate to format at least one stretched zone prior to incorporation of the laminate in the absorbent article.
31. The method of claim 29 , further comprising the step of selectively stretching the laminate to form at least one stretched zone subsequent to incorporation of the laminate in the absorbent article.
32. The method of claim 29 , further comprising the step of selectively stretching the laminate to form at least one stretched zone as the absorbent article is applied to a wearer.