Patent Application

App. No. 11/659,298

Abstract

Claims (23)

1 . A method for producing an elastic nonwoven fabric, comprising:

stretching a nonwoven web in the cross machine direction, machine direction, or both to reduce the basis weight, denier, or both of the nonwoven web to form the elastic nonwoven fabric,

wherein the nonwoven web comprises a plurality of multicomponent strands having first and second polymer components longitudinally coextensive along the length of the strands, said first component comprising an elastomeric polymer, and said second polymer component comprising a polymer less elastic than the first polymer component.

2 . The method according to claim 1 wherein the web is stretched in the cross and machine directions simultaneously.

3 . The method according to claim 1 , wherein the web is stretched in the cross direction using a tenter frame, is stretched in the machine direction using differential roller speeds, or both.

4 . The method according to claim 1 , wherein the nonwoven web is formed by:

melt spinning a plurality of multicomponent strands having first and second polymer components longitudinally coextensive along the length of the strands, said first component comprising an elastomeric polymer, and said second polymer component comprising a non-elastomeric polymer;

forming the multicomponent strands into a nonwoven web; and

bonding or intertwining the strands to form a coherent bonded nonwoven web.

5 . The method of claim 4 , wherein the nonwoven web is produced via spunbonding.

6 . The method of claim 1 , wherein the stretching occurs to at least 50% elongation in at least one direction to achieve at least a 20% reduction in basis weight.

7 . The method of claim 1 , wherein the stretching occurs to at least 50% elongation in only one direction to achieve at least a 20% increase in the ratio of the retractive forces at 50% extension (Rf(50)) for the stretched orientation over the orthogonal orientation, relative to the same ratio in the unstretched web.

8 . The method of claim 1 , wherein the nonwoven web has been thermo point bonded prior to stretching.

9 . The method of claim 1 , wherein the process occurs in the absence of an incremental stretching step.

10 . The method according to claim 8 , wherein the stretching occurs at a web temperature between 20 degrees Centigrade and the thermopoint bonding temperature of the spunbonded web.

11 . The method according to claim 4 , wherein the first polymer component comprises an elastomeric polyurethane, elastomeric polyethylene copolymers, elastomeric polypropylene copolymers, elastomeric styrenic block polymers, or blends thereof, and the second polymer component comprises a polyolefin that is less elastic than the elastomeric polymer.

12 . The method according to claim 11 wherein the second polymer component is polypropylene, polyethylene, or a blend thereof.

13 . The method according to claim 4 , wherein the melt spinning comprises arranging the first and second polymer components in the strand cross-section to form a sheath/core configuration.

14 . The method according to claim 4 , wherein the melt spinning comprises arranging the first and second polymer components in the strand cross-section to form polymer components in a tipped multilobal configuration.

15 . The method according to claim 1 , wherein at least a portion of the multicomponent strands has a sheath/core configuration.

16 . A nonwoven fabric made by the method of any of the preceding claims.

17 . A multilayer composite, comprising at least one layer formed by the method of claim 1 .

18 . An article produced at least in part with a material prepared according to claim 1 .

Assignments (8)