Patent ID: 6994761

Claim:
A method of forming a breathable, stretchable section of a disposable absorbent garment, said method comprising the steps of: selecting a first material for a first material layer and a second material for a second material layer, whereby said first and second material layers are bondable by an ultrasonic bonding process; selecting an elastic material for a stretchable material layer; positioning the stretchable material layer between the first and second material layers to form a layer assembly; targeting one or more bond sites on the layer assembly for bonding one or more of the metered layers together; and securing the first, second, and stretchable layers together by ultrasonically bonding the first material layer with the second material layer at the one or more sites, whereby an aperture is formed through the stretchable material and whereby the first material layer and the second material layer substantially, completely bond through the aperture at the one or more bond sites, and such that the aperture provides a breathable passage therethrough.