Three-dimensional highly elastic film/non-woven composite

• Main Authors: STEVE D. BRUCE, JAMES W. CREE, JEFFREY A. MIDDLESWORTH
• Format: Patent
• Language: English
• Published: 26.11.2001
• Edition: 7
• Subjects: BANDAGES, DRESSINGS OR ABSORBENT PADS; BRAIDING; COTTON-WOOL; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF,TUBULAR STRUCTURES OF THE BODY, E.G. STENTS; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS,NON-WOVEN FABRICS; FILTERS IMPLANTABLE INTO BLOOD VESSELS; FIRST-AID KITS; FOMENTATION; HUMAN NECESSITIES; HYGIENE; KNITTING; LACE-MAKING; LAYERED PRODUCTS; LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT ORNON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM; MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARYMATERIAL; MEDICAL OR VETERINARY SCIENCE; NON-WOVEN FABRICS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; PERFORMING OPERATIONS; PROSTHESES; TEXTILES; TRANSPORTING; TREATMENT OR PROTECTION OF EYES OR EARS; TRIMMINGS; WADDING

A three-dimensional highly elastic film/non-woven composite having a fluid and air impervious core layer and a first and second consolidated layer. The consolidated layers have unidirectional and non-unidirectional fibers. The composite is formed by laminating the air and fluid impermeable elastic core layer between the two layers of consolidated non-wovens. The resulting composite stretches only in the cross-machine direction due to the unidirectional properties of the consolidated non-woven material. The layers are then point bonded or welded together. Preferably the layers are welded by passing the composite between an ultrasonic horn and an ultrasonic bond roll having raised areas for effecting the weld points. A thin inelastic membrane is formed at each of the weld points. The welded composite may then be pre-stretched to rupture the membranes, thereby creating apertures, which makes the composite permeable.