HYDROENTANGLED ELASTIC FILM-BASED, STRETCH-BONDED COMPOSITES AND METHODS OF MAKING SAME
A stretch-bonded elastic nonwoven composite includes a machine-direction elastic apertured film-based, stretch-bonded laminate layer that has been hydroentangled throughout all of its laminate layers with a hydrophilic fibrous layer. The elastic apertured film-based, stretch-bonded laminate layer includes a middle elastic film layer positioned between one or two inelastic layers, each of which layers includes hydrophilic fibers from the hydrophilic fibrous layer.
1 . A process for making a stretch-bonded elastic nonwoven composite includes the steps of:
a) providing a machine-direction elastic, apertured film-based, stretch-bonded nonwoven laminate layer, itself having an apertured elastic film layer and at least one inelastic layer;
b) stretching the stretch-bonded laminate layer in the machine direction such that the at least one inelastic layer is in a generally flattened configuration, and no rupture of the inelastic layer occurs;
c) providing a hydrophilic fibrous layer on the stretched, apertured film-based, stretch-bonded nonwoven laminate layer, the fibrous layer including either staple fibers, substantially continuous fibers, pulp fibers or a combination thereof;
d) hydroentangling the fibers of the hydrophilic fibrous layer into the elastic stretched, apertured film-based, stretch-bonded nonwoven laminate layer to produce a hydroentangled stretch-bonded elastic nonwoven composite that is absorbent to both aqueous and oil-based liquids;
e) allowing the hydroentangled stretch-bonded elastic nonwoven composite to dry and relax;
f) storing said hydroentangled stretch-bonded elastic nonwoven composite or moving said composite to a further product manufacturing process.
2 . The process of claim 1 , wherein said machine direction elastic apertured film-based, stretch-bonded laminate includes an elastic apertured mono-layered or multi-layered film.
3 . The process of claim 2 , wherein said elastic apertured monolayered or multilayered film includes apertures configured in multiple directions along said film dimensions.
4 . The process of claim 2 , wherein said elastic apertured monolayered or multi-layered film includes apertures having a longer dimension primarily along the cross-machine direction.
5 . The process of claim 1 , wherein said machine direction elastic apertured film-based, stretch bonded laminate includes two inelastic layers, one of each inelastic layer bonded to a separate side of a middle elastic apertured film layer.
6 . The process of claim 1 , wherein the stretching step is accomplished by a series of progressively faster moving rolls.
7 . The process of claim 6 , wherein the stretching step is accomplished by a pair of rolls in an S-wrap arrangement in which the ratio of speeds between the second roll farthest from the laminate source and the first roll closer to the laminate source is between about 1.1:1 and 5:1.
8 . The process of claim 7 , wherein the ratio of speeds is between about 1.5:1 and 3:1.
9 . The process of claim 1 , wherein the hydrophilic fibrous layer is cellulosic based.
10 . The process of claim 9 , wherein the hydrophilic fibrous layer is present initially in a basis weight range of between about 2 and 200 gsm.
11 . The process of claim 1 , wherein the pressure of fluid utilized in the hydroentanglement step is between about 500 and 5000 psi, alternatively between about 1400 and 3000 psi.
12 . The process of claim 1 , wherein the hydroentangled webs are moved passed a hydroentanglement manifold at a distance of between about 0.25 inch and 2 inches.
13 . The process of claim 1 , wherein the elastic apertured film layer of the elastic apertured film-based, stretch-bonded laminate has an open aperture area in the film layer of between about 2 and 40 percent before hydroentanglement.
14 . The process of claim 13 , wherein the open aperture area in the film layer is between about 10 and 30 percent.
15 . A stretch-bonded elastic nonwoven composite including a machine-direction elastic apertured film-based, stretch-bonded laminate layer that has been hydroentangled throughout all of its laminate layers with a hydrophilic fibrous layer.
16 . The stretch-bonded elastic nonwoven composite of claim 15 , wherein said apertured film-based, stretch-bonded laminate layer is comprised of a middle apertured, machine-direction elastic film that has been laminated between two inelastic nonwoven layers.
17 . The stretch-bonded elastic nonwoven composite of claim 16 , wherein said two inelastic nonwoven layers are selected from the group consisting of spunbond, meltblown, and bonded carded webs.
18 . The stretch-bonded elastic nonwoven composite of claim 17 , wherein said hydrophilic fibrous layer has a basis weight of between about 2 and 200 gsm and includes cellulosic fibers.
19 . A stretch-bonded elastic nonwoven composite that is absorbent to both aqueous and oil-based liquids made from the method of claim 1 .
20 . A wipe, medical product or personal care product made from the stretch-bonded elastic nonwoven composite of claim 19 .