Breathable laminate permanently conformable to the contours of a wearer

• Main Authors: Morman, Michael Tod, Hwang, Patricia Hsiaoyin, Ono, Audrie Tomoko, Welch, Howard Martin, Morell, Charles John
• Format: Patent
• Language: English
• Published: 14.10.2003

This invention relates to a breathable laminate (i.e., breathable to water vapor but substantially liquid-impermeable) which is permanently conformable to the contour of a wearer. The laminate stretches as needed to conform to the contour of the wearer and remains, essentially, in its extended or stretched state, even after a stretching force is removed. A breathable, substantially liquid impermeable laminate is provided that is permanently conformable to the contours of a wearer's body when used in a personal care absorbent article or a medical article. The laminate includes a breathable (preferably microporous) film and a fibrous nonwoven web. Both the film and the web are extendible in a cross direction to a width at least 25% greater than an original, unstretched width upon application of a stretching force. The web and the film, and the overall laminate, exhibit little or no retractive force once they have been stretched. A diaper or other garment can be constructed in undersized fashion using the laminate, permitting material savings. When the garment is worn, the laminate stretches only where needed to provide a substantially perfect fit on the wearer. The minimal retractive force avoids the skin marks, rashes, etc. that can result from elastic garments.