Patent ID: 7803244

Claim:
A method of forming a nonwoven composite, the method comprising: Forming an elastic film from a polymer composition, Passing the film and a nonwoven web material through a nip formed by two rolls, at least one of which is patterned with raised bonding elements, wherein the film is under tension at a stretch ratio of from about 2.5 to about 7.0 at the nip, and wherein the nonwoven web material contains a polyolefin having a Vicat softening temperature of from about 130° C. to about 200° C. and further wherein at least one of the rolls is heated to a temperature of from about 50° C. to about 120° C. and At the nip, concurrently melt fusing the film to the nonwoven web material forming one or more discrete bond sites between the film and the nonwoven web material located proximate to a perimeter defined by at least one of the apertures and forming apertures in the film without substantially softening a polymer of the nonwoven web material, wherein at least one aperture has a length of from about 200 to about 5000 micrometers, and wherein the nonwoven web material remains generally unapertured after being melt fused to the film and the nonwoven web material remains substantially unbonded to the film except at the discrete bond sites.