Three-dimensional highly elastic film/non-woven composite

B - Operations – Transporting – 32 – B

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B32B 7/04 (2006.01) A61F 13/15 (2006.01) B32B 5/02 (2006.01)

Patent

CA 2407120

A three-dimensional highly elastic film/non-woven composite (10) having a fluid and air impervious core layer (16) and a first and second consolidated layer (12, 14). The consolidated layers (12, 14) have unidirectional and non- unidirectional fibers. The composite (10) is formed by laminating the air and fluid impermeable elastic core layer (16) between the two layers of consolidated non-wovens (12, 14). The resulting composite (10) 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 (10) may then be pre-stretched to rupture the membranes, thereby creating apertures, which makes the composite permeable.

L'invention concerne un composite (10) tridimensionnel film/non-tissé hautement élastique constitué d'une couche centrale (16) imperméable aux fluides et à l'air et d'une première et d'une seconde couche consolidées (12, 14). Lesdites couches consolidées (12, 14) renferment des fibres unidirectionnelles et non unidirectionnelles. Pour former ce composite (10), on dispose la couche centrale (16) imperméable à l'air et aux fluides entre deux couches de non-tissés consolidés (12, 14). Du fait des propriétés unidirectionnelles du matériau non-tissé consolidé, le composite (10) ainsi obtenu ne s'étire qu'en sens travers. Les couches sont ensuite liées par points ou soudées les unes aux autres. De préférence, pour souder lesdites couches, on fait passer le composite entre un émetteur ultrasonore et un rouleau de liage ultrasonore dont des zones surélevées permettant la réalisation des points de soudage. Une fine membrane non élastique est formée au niveau de chacun des points de soudage. Le composite soudé (10) peut alors être pré-étiré de manière à rompre les membranes, créant ainsi des ouvertures qui rendent le composite perméable.

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