Patent ID: 7897078
Filing Date: 2011-03-01
Classification: A61F,B29C,B29L,Y10T

Abstract:
1. A method of manufacturing a stretched mechanical fastening web laminate comprising a thermoplastic web layer having two major surfaces, one of the major surfaces bearing a multitude of male fastening elements suitable for engagement with a corresponding female fastening material, and on its other major surface a fibrous web layer, said method comprising the steps of (i) providing the fibrous web layer having an initial basis weight, wherein the fibrous web layer comprises one or more nonwoven materials free of staple fibers, (ii) passing the fibrous web layer through a nip formed by two rolls, one of them having cavities that are negatives of a plurality of male fastening elements; introducing a molten thermoplastic resin into the cavities in excess of an amount that would fill the cavities which excess forms the thermoplastic web layer, wherein a surface of the fibrous web layer is in continuous contact with the thermoplastic web layer; allowing the resin to at least partially solidify; and stripping of a precursor web laminate thus formed comprising the fibrous web layer and the thermoplastic web layer bearing the multitude of male fastening elements from the roll having cavities, wherein the thermoplastic web layer has an initial thickness and an initial density of male fastening elements, (iii) stretching the precursor web laminate monoaxially or biaxially thereby decreasing the basis weight of the fibrous web layer and the thickness of the thermoplastic web layer from their respective initial values to provide a stretched mechanical fastening laminate having a basis weight of less than 100 g/m (iv) cutting through the stretched mechanical fastening web laminate in the cross-direction to form a portion of the stretched mechanical fastening web laminate, and (v) incorporating the portion into a component of a disposable absorbent article such that the male fastening elements are exposed and the fibrous web layer is not exposed.