MXPA99001291A - Stable web having enhanced extensibility and method for making same - Google Patents

Abstract

The present invention provides a stable material having enhanced extensibility and a method for making the same. A tensioning force is applied to a neckable material to neck the material. The necked material is then subjected to mechanical stabilization to provide a stabilized extensible necked material. The stabilized extensible necked material is easily extended in a direction parallel to the direction necking.

Description

STABLE FRAME THAT HAS INCREASED EXTENSION CAPACITY AND METHOD TO MAKE THE SAME FIELD OF THE INVENTION The present invention relates to materials having increased spreading capacity and a mechanical post-processing method for making the same. High-spread materials, such as non-woven wefts and film wefts are particularly unsuitable for use in disposable absorbent articles, such as diapers, incontinence briefs, training pants, feminine hygiene garments and the like, since that these are capable of being used in parts of the article where the high extension capacity can help in the adjustment of the article to the body.

BACKGROUND OF THE INVENTION Non-woven wefts can be manufactured in products and product components so cheap that the product can be seen as disposable after only one or a few uses. Representatives of these products include diapers, training pants, towels, incontinence briefs, feminine hygiene garments and the like. The non-woven webs can be treated to provide the non-woven web with certain properties. For example, U.S. Patent 5,244,482 issued to Hassenboehier, Jr., et al. On September 14, 1993, discloses a method for treating a nonwoven web wherein the nonwoven web is heated to an elevated temperature and stretched. in a uniaxial way to consolidate and stabilize the nonwoven web. These nonwoven webs are noted to exhibit increased elasticity after processing.

Such an increase in elasticity is recognized as being made by the new "memory" infused by the heating of the nonwoven web. For applications that desire increased extension capacity rather than elasticity, such heating is therefore undesirable. Additionally, such stretching and adjustment of the nonwoven web by heating to an elevated temperature often causes the fiber to break and the non-woven web exhibits increased gloss. For many applications involving contact with the skin, for example, such as a diaper cover material, these attributes are contrary to the desired fabric-like properties of softness and non-plastic appearance (low gloss). Finally, the requirement to heat the non-woven web to consolidate and stabilize the wefts is added to the complexity and costs of the process. U.S. Patent 4,981, 747, issued to Morman on January 1, 1991, describes an "inversely acclimated" material. This teaches that non-stabilized padded material should be kept under high tension in a rewound roll until such time as the adjustment step with additional heat is performed to stabilize the material. This material again suffers from the deficiencies noted above with respect to preferred skin contact applications, and will increase the elastic properties of the material rather than the extensible behavior of the material. U.S. Patent 5,226,992 issued to Morirían on July 13, 1993, discloses a method for producing a composite, elastic bonded material. The tensioning force is applied to at least one actable material, such as a non-woven, contractible frame, for accelalaring or consolidating the material. Instead of heating the consolidated nonwoven web, this patent teaches overlaying the consolidated non-woven web, tensioned, over an elastic material and joining the consolidated non-woven web, not stressed to the elastic material, while the consolidated, tensioned non-woven web , it is in a stressed condition. By joining the consolidated nonwoven web tensioned to the elastic material while one is in an unstressed condition, the nonwoven web is constrained to its dimension acuellada. This method does not provide a means to produce a stabilized stretchable web without attaching the nonwoven web to an additional elastic layer. It is an object of the present invention to provide an extensible acueliada nonwoven web, stabilized able to be rolled up in a stable roll material or in the afghan form, suitable for subsequent conversion or combination operations. It is also an object of the present invention to provide a stretchable, stabilized, non-woven web, capable of extension at very high speed through a mechanical tensioning means. It is also an object of the present invention to provide a post-processing method for producing a stabilized extendable flattened nonwoven web. It is also an object of the present invention to provide a post-processing method for producing a non-woven, stretchable, stabilized non-woven web, which does not require heating the accullable material at elevated temperatures, to increase the extensible properties instead of the elastic properties , and to substantially preserve the original properties of the non-woven, compliant weft. As used herein the term "elastic" refers to any material that, during the application of a biasing force, is stretchable, i.e. stretchable, to at least about 60% (i.e., to a length deviated, stretched, which is at least approximately 160% of its relaxed non-deflected length), and which, will recover at least 55% of its elongation by releasing the elongation, stretching force. As used herein, the term "extensible" refers to any material which, upon application of a deflection force, is stretchable, ie stretchable, up to at least about 60% without suffering catastrophic failure (i.e. deviated, stretched length, which is at least approximately 160% of its relaxed undifferentiated length), but which does not recover more than 55% of its elongation by releasing the elongation, stretching force. As used herein, the term "highly extensible" refers to any material which, upon application of a deflection force, is stretchable, i.e. stretchable, up to at least about 100% without suffering catastrophic failure (i.e. , up to a deviated, stretched length, which is at least approximately 200% of its relaxed non-deflected length), but which does not recover more than 55% of its elongation upon release of the elongation, stretching force. As used herein, the term "stabilized" refers to a material of the present invention that is capable of being stored in a stable condition in any common and conventional raster storage without the need for additional heating or Adding or joining with other frames to stabilize the material. This storage medium included, for example, low voltage rolls or boxed material. As used herein the term "non-woven webs" refers to a web having a structure of individual fibers or threads which are inter-arranged, but not in any regular repeating manner. The non-woven webs have, in the past, been formed by a variety of processes such as, for example, melt and blow processes, glue spinning processes, and linked carded web processes. As used herein, the term "padded material" refers to any material that has been restricted in at least one direction by the application of a tension force in a direction that is perpendicular to the desired direction of the wrap.

As used herein, the term "castable material" refers to any material that can be padded. As used herein, the term "percent of compliance" refers to the ratio determined by the measurement of the difference between the uncapped dimension and the stabilized, tapered dimensions of the acceptable material in the direction of the course, and then dividing that difference between the uncapped dimension of the paddable material, then multiplying it by 100. As used herein, the term "composite elastic material" refers to a material comprising a bonded elastic member, a stabilized extensible, actable material. The elastic member can be attached to the extensible castable material, stabilized at intermediate points or can be continuously attached thereto. Bonding is achieved while the elastic member and the stabilized, extensible padding material is in a juxtaposed configuration. The composite elastic material is elastic in a direction generally parallel to the direction of the straightened, stabilized padding material, and can be stretched in that direction of the breaking point of the stabilized extensible tapered material. A composite elastic material may include more than two layers. As used herein, the term "polymer" generally includes, but is not limited to, such as polymers, copolymers, such as, for example, block, grafted, random and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. In addition, unless otherwise specifically limited, the term "polymer" must include all possible molecular geometric configurations of the material. These configurations include, but are not limited to, isotatic, syndiotactic and random symmetries.

BRIEF DESCRIPTION OF THE INVENTION In accordance with the present invention, a method is provided herein for producing a stabilized, extensible tapered material, comprising the steps of: providing a castable material; apply a tension force to the material to acclimate the material; and subjecting the padded material to mechanical stabilization to provide an extensible, stabilized padding material. The tapered, extensible, stabilized material is easily extended in a direction parallel to the direction of the winding. A preferred method for mechanically stabilizing the padded material comprises subjecting the padded material to increased stretch! in a direction generally perpendicular to the direction of padding. The method may also comprise the additional step of winding the extensible, stabilized padding material onto a squeezing roll or affixing the extensible, stabilized padding material within the box. The method may also comprise the additional step of attaching the stabilized, extensible, padded material to an elastic member to form a composite elastic material. If the material is stretchable, it can be stretched in a direction generally perpendicular to the desired direction of the winding. The compliant material can be any material that can be sufficiently padded at room temperature. These compliant materials include woven and loosely woven fabrics, linked carded nonwoven webs, spunbonded non-woven webs, or melt blown non-woven webs. The compliant material may also have multiple layers, such as, for example, multiple bonded spunlayers and / or multiple meltblown film layers or layers. The castable material can be made of polymers such as, for example, polyolefins. Exemplary polyolefins include polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and mixtures thereof. The actable material can be a non-elastic material, such as for example a non-elastic non-woven material. BRIEF DESCRIPTION OF THE DRAWINGS Although the description concludes with the claims pointing out in a particular way and claiming differently to the matter that is considered as formant of the present invention, it is believed that the invention will be better understood from the following description, which is taken in combination with the accompanying drawings, in which like designations are used to designate substantially identical elements, and in which: Figure 1 is a schematic illustration of an exemplary process for forming a padded material of the present invention; Figure 2 is an enlarged perspective illustration of the stabilizer roll arrangement; Figure 3 is a plan view of an exemplary castable material before tensioning and winding; Figure 4 is a plan view of an exemplary padded material; Figure 5 is a plan view of an exemplary composite elastic material, while being partially stretched; Figure 6 is a schematic illustration of another exemplary process for forming a cushion material of the present invention; Figure 7 is a plan view of a separate enhancement pattern, which are not suitable for fitting to the padded material; and Figure 9 is a plan view of another emboss pattern of the present invention that is suitable for adjusting the cushion material.

DETAILED DESCRIPTION OF THE INVENTION Referring to Figure 1, there is schematically shown in 20 in process to form a stabilized, extensible tapered material of the present invention. According to the present invention, a compliant material 22 is unwound from a supply roll 23 and travels in the direction indicated by the arrows associated with it as the supply roll 23 rotates in the direction indicated by the arrows associated therewith. The compliant material 22 passes through a gripping space 25 of the S-roll arrangement 26 formed by the stacked rolls 28 and 30. The compliant material 22 can be formed by known non-woven extrusion processes, such as by example, known meltblown processes or known spunbond processes, and passes directly through the gripping space 25 without first being stored in a supply roll. The compliant material 22 passes through the gripping space 25 of the S-roller arrangement 26, in a reverse S-path as indicated by the rotation direction arrows associated with the stacked rolls 28 and 30. As of FIG. the S-roll arrangement 26, the recoverable material 22 passes through the gripping space 32 formed by the incremental stretching rollers 34 and 36 of the mechanical stabilization arrangement 38. Because the peripheral linear speed of the rollers of the S-roll 26 is controlled to be less than the peripheral linear speed of the rollers of the mechanical stabilization arrangement 38, the paddable material 22 is tensioned between the S-roll arrangement 26 and the gripping space 32 of the rollers of incremental stretch 34 and 36 of the mechanical stabilization arrangement 38. By adjusting the difference in the speeds of the rollers, the material acquires 22 is tensioned in such a way that it cools to a desired amount and is maintained in such tensioned stressed condition. The mechanical stabilization arrangement 38 provides the stabilized pad material that can be attached to other materials. Other methods for tensioning the paddable material 22 can be used such as, for example, tenter arm arrangements or other stretching arrangements in the transverse direction of the machine that expand the paddable material 22 in other directions such as, for example, the transverse direction to the machine. The compliant material 22 may be an extensible, elastic or non-elastic non-woven material. The compliant material 22 can be a spunbonded web, a melt blown web or a carded bonded web. If the castable material is a web of extruded fibers by melting and blowing, this may include blown microfibers in the molten state. Acceptable material 22 can be made of fiber-forming polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers. In one embodiment of the present invention, the compliant material 22 can be a multi-layer material, having, for example, at least one layer of a spunbonded web attached by at least one at least one layer of an extruded web by melting and blowing, a carded bonded web or other suitable material. Alternatively, the material 22 can be a single layer of a material such as, for example, a spunbonded web, a meltblown web, or a carded bonded web.

The compliant material 22 can also be a composite material made of a mixture of two or more different fibers or a mixture of fibers and particles. These mixtures can be formed by the addition of fibers and / or particles to the gas stream in which the fibers made by melting and blowing are carried in such a way that the intimately wound mixture of the fibers made by melting and blowing and other materials, for example, wood pulp, short fibers and particles such as, for example, hydrocolloid particles (hydrogel), commonly referred to as superabsorbent material occur prior to the collection of the fibers made by melting and blowing on a collecting device to form a coherent web of fibers made by randomly dispersed melting and blowing and other materials. The non-woven fiber web must be bonded together to form a coherent web structure that is capable of resisting the bonding. Suitable bonding techniques include, but are not limited to, chemical bonding, thermo bonding such as point calendering, hydroentangling, and cooking. Figure 2 is an enlarged perspective illustration of a preferred embodiment of the mechanical stabilization arrangement 38 employing applicators or pressure stations having three-dimensional surfaces, which at least to one degree are complementary to one another. The mechanical stabilization arrangement 38 shown in Figure 2 comprises incremental stretching rollers 34 and 36. The compliant material 22 passes through the gripping space 32 formed by the incremental stretching rollers. 34 and 36 as the incremental stretching rollers rotate in the direction indicated by the arrows associated with them. The upper incremental stretching roller 34 comprises a plurality of teeth 40 and corresponding notches 41 that extend around the total circumference of roller 34. The lower incremental stretching roller 36 comprises a plurality of teeth 42 and corresponding notches 43 extending around of the total circumference of the roller 36. The teeth 40 in the roller 34 mesh with or link the notches 43 in the roller 36, while the teeth 42 in the roller 36, while the teeth 42 in the roller 36 mesh with or link the notches 41 in the roller 34. The teeth 40 and 42 in the rollers 34 and 36, respectively, extend in a direction substantially perpendicular to the travel direction of the weft 22 or in a direction substantially parallel to the width of the acceptable material 22. That is, the teeth 40 and 42 extend in a direction parallel to the direction transverse to the machine or direction CD . The incremental stretching rollers 34 and 36 incrementally stretch the weft pattern in a direction generally perpendicular to the padded direction by stabilizing the padded material 22 here in such a way that it remains in its cushioned condition after passing through the rollers. incremental stretch 34 and 36, and tension on the padded material is released. By stabilizing the padded material, the padded material substantially maintains a tapered width without returning to its broad precursor. After being stabilized by passing through the incremental stretching rolls 34 and 36, the stabilized pad material 22 includes a plurality of stabilizing embossments 44. The stabilizing embossments 44 extend in a substantially linear direction parallel to each other across the width total of the stabilized padded material 22. Stabilizing relays 44 are shown to be extending in a direction substantially parallel to the transverse direction of the CD machine. As seen in Figure 2, each stabilizing overhang extends through the stabilized pad material 22 from one bank to the other bank. This is very important since it places the fibers across the total width of the weft thus stabilizing the weft. If the stabilizing lugs 44 do not extend completely through a material that can be fitted 22, the part of the acuellable material that is not enhanced would return to its wide predecessor. For example, a pattern of separate enhancements, as shown in Figure 7, would not be placed or effectively established to the material. The portions of the material between the individual enhancements would not be placed or established, and therefore, would allow the material to return to its broad predecessor. The incremental stretching rollers 34 and 36 may include any number of teeth and notches to provide the desired stabilization in the non-woven web. In addition, the teeth and notches can be non-linear, such as, for example, curved, sinusoidal, zig-zag, etc. In addition, the teeth and notches may extend in a direction different from that perpendicular to the direction of travel of the acoustic frame. For example, the teeth and notches may extend at an angle with respect to the CD direction, but preferably not parallel to the machine or MD direction, since this type of incremental stretch would tend to expand the width of the frame, from this way canceling the purpose of the operation of acouellamiento. Referring now to Figure 1, after the acuellable material 22 passes through the mechanical stabilization arrangement 38, this is wound on a quencher roll 50. The stabilization of the accullable material in its acclimatized condition allows it to be wound on a quenching roll while in its in-box condition and then subsequently used for the desired end use. Once the material has been mechanically stabilized or fixed, it is suitable for handling in conventional high-speed diaper converting equipment without the need for special handling equipment. The stabilized padding material is easily extended in a direction parallel to the direction of airing. That is, the stabilized padded material is easily extended in the transverse direction of the machine. The stabilized, extensible, padded material is elongating by applying a deflection force to at least about 60 percent without suffering catastrophic failure (i.e., a deflected, stretched length of at least about 160 percent). its length not deviated relaxed). Preferably, the stabilized, extensible pad material is elongating upon the occurrence of the application of a deflection force to at least about 100 percent without suffering catastrophic failure, (i.e., at a deflected, stretched length, which is at least approximately 200 percent of its relaxed non-diverted length). Because the extensible, stabilized, stretched material is extensible and non-elastic, the extensible, stabilized padding material does not recover more than 55 percent of its elongation when the elongation, stretching force is released. The stabilized, extensible pad material is preferably elongate to at least 60 percent and more preferably to at least 100 percent or more, without suffering catastrophic failure upon application of a relatively low deflection force. Being elongate to at least 60% and more preferably to at least about 100% or more when a relatively low deflection force is applied, it makes the stabilized, extensible padding material particularly suitable for use in disposable absorbent articles such as as diapers, incontinence trusses, training pants, feminine hygiene garments, and the like, since these are capable of being used in parts of the article where the high extension capacity can help in the adjustment of the article to the body. The stabilized, extensible tapered material is preferably elongated to at least 60% and more preferably to at least 100% without suffering catastrophic failure upon application of a deflection force of less than about 100 grams, more preferably upon application of a force of deviation less than about 200 grams, and most preferably when a deviation force of less than about 300 grams is applied. Conventional drive means and other conventional devices that can be used in conjunction with the apparatus of Figure 1 are well known and, for purposes of clarity, have not been illustrated in the schematic view of Figure 1. In addition to the incremental stretch, there are other methods to mechanically stabilize the padded material. These methods include folding, and / or dragging rollers. Another suitable method includes passing the padded material through a gripping space of a pair of smooth rollers. The grip space pressure and / or the roller linkage of these stabilizing rollers are set to provide the desired degree of stabilization for the padded web. Figure 8 is a plan view of another suitable embossing pattern for stabilizing the sealable material. The pattern includes a plurality of linear enhancements 210 that extend continuously across the full width of the frame 205 in a direction generally parallel to the cross direction of the machine. The pattern also includes a plurality of linear embossments 212 extending continuously across the total width of the weft 205 at an angle to the machine's transverse direction and at an angle to the embossments 210. The frame 205 also includes a plurality of linear recesses 214 extending continuously through the total width of the weft 205 at an angle to the transverse direction of the machine and at an angle to the recesses 210 and 212. The recesses 212 and 214 may extend at any angle one with respect to the other and with respect to the embossments 210. Figure 9 is a plan view of another embossing pattern for stabilizing the cushioned material. The pattern includes a plurality of linear embossments 222 that extend continuously across the total width of the weft 220 at an angle to the transverse direction of the machine. The frame 220 also includes a plurality of linear embossments 224 extending continuously across the total width of the weft 220 at an angle to the transverse direction of the machine and at an angle to the embossments 222. The embossments 222 and 224 are aligned perpendicular to each other. Nevertheless, other angles may also be employed between the linear bores 222 and 224. The pattern of enhancement of Figures 8 and 9 is provided by feeding the padded material through a gripping space formed by a pair of pattern compression rolls. . Each roller comprising a series of raised surfaces, similar to the teeth 40 and 42 on the rollers 34 and 36, respectively. The raised surfaces on each of the rollers are complementary and they couple one or the other and compress the padded material, providing the pattern of enhancement shown in Figures 8 and 9. The compression provided by the compression rollers with fixed pattern to the individual fibers to stabilize the plot in its proper condition. Alternatively, the compression rolls with the pattern may comprise a patterned roll having a pattern of raised surfaces and an anvil roll having a smooth surface. The raised surfaces on the patterned roller compress the padded material against the anvil roller to provide the pattern of enhancement shown in FIGS. 8 and 9. The stabilized, extensible tapered material may subsequently be attached to an elastic member to form the material elastic composite. Preferably, the stabilized, extensible pad material is attached to the elastic member while the elastic member is in a substantially unstressed condition. The stretchable, stabilized padding material and the elastic member may be attached to each other, either intermittently or substantially continuously along at least a portion of their coextensive surfaces, while the elastic member is in contact with the elastic member. any of a stressed or unstressed condition. The stabilized, extensible pad material can be attached to an elastic member after it has been removed from the roll, such as the quench roll 50, or it can be attached to an elastic member after being subjected to mechanical stabilization. The elastic member can be made from any suitable elastic material. Generally, any of the suitable elastomeric fiber forming resins or mixtures containing them can be used for the non-woven webs of elastomeric fibers and any of the suitable elastomeric film-forming resins or mixtures containing the same, can be used for the elastomeric films of the invention. For example, the elastic member may be an elastomeric film made from block copolymers having the general formula AB-A ', where A and A' are each a terminal block of the thermoplastic polymer which contains a styrenic portion such as a poly (vinyl arene) and where B is an intermediate block of the elastomeric polymer, such as a conjugated diene or a lower alkene polymer. Other exemplary elastomeric films that can be used to form the elastic sheet include polyurethane elastomeric materials, such as, for example, those available under the TINS of B.F. Goodrich & Company, polyamide elastomeric materials, such as, for example, those available under the trademark PEBAX from Rilsan Company, and polyester elastomeric materials such as, for example, those available under the trade designation Hytrel from E.l. DuPont De Nemours & Company A polyolefin can also be mixed with the elastomeric polymer to improve the processability of the composition. The polyolefin must be one which, when mixed and subjected to an appropriate combination of high pressure and high temperature conditions, is extrudable, in the mixed form, with the elastomeric polymer. Useful blend polyolefin materials include, for example, polyethylene, polypropylene and polybutene, including ethylene copolymers, polypropylene copolymers and butene copolymers. The elastic member may also be a sheet of elastomeric pressure sensitive adhesive. For example, the elastic material itself can be tacky, or, alternatively, a compatible adhesion modifying resin that can be added with the extruded elastomeric compositions described above to provide an elastomeric sheet that can act as a pressure sensitive adhesive. , for example, to join the elastomeric sheet to a non-elastic, stressed, tensioned weft. The elastic sheet may also be a multilayer material which may include two or more individual coherent plies or films. Additionally, the elastomeric sheet can be a multi-layer material in which one or more of the layers contain a mixture of elastic or non-elastic fibers or particles. Other elastomeric materials suitable for use as the elastic member include "living" synthetic or natural rubber, including heat-shrinkable elastomeric films, formed elastomeric fabrics, elastomeric foams or the like. In an especially preferred embodiment, the elastic member comprises an elastomeric canvas available from Conwed Plastics. The relationship between the original dimensions of the actable material 22 to its dimensions after tensioning or accelalar determines the approximate limits of stretching of the composite elastic material. Because the castable material is able to stretch and return to its padded dimension in directions such as, for example, the machine direction, or the transverse direction of the machine the composite elastic material will be able to stretch in generally the same direction as the paddable material 22. For example, with reference to Figures 3, 4, and 5, if it is desired to prepare a composite elastic material capable of stretching up to 150% elongation, a width of the acceptable material shown schematically and not necessarily to scale in Figure 3, which has an "X" width such as, for example, 250cm, is tensioned in such a way that it accords to a "Y" width of approximately 100 cm. The padded material shown in Figure 4 is mechanically stabilized to provide an extensible, stabilized pad material. The stabilized, extensible tapered material is then attached to an elastic member having a width of approximately 10 cm, and which is at least stretchable to a width of 250 cm. The resulting composite elastic material shown schematically and not necessarily to scale in Figure 5, has a width "Y" of about 100 cm and is capable of stretching to at least the original width X of 250 cm of the actable material for an elongation of approximately 150%. As can be seen from the example, the elastic limit of the elastic member only needs to be as large as the minimum desired elastic limit of the composite elastic material. Referring now to Figure 6, there is schematically illustrated another process 100 for forming a cushion material of the present invention. A compliant material 122 is unwound from a supply roll 123 and travels in the direction indicated by the arrows associated with it as the supply roll 123 rotates in the direction indicated by the arrows associated therewith. The compliant material 122 passes through the gripping space 125 of the S-roll arrangement 126 formed by the stacked rolls 128 and 130. The corkable material 122 can be formed by non-woven extrusion processes, known, such as, for example, known melt processes and blow molding processes or known spinning processes, and passed directly through the gripping space 125 without first being stored in a supply roll. The compliant material 122 passes through the gripping space 125 of the S-roll arrangement 126 in an inverse S-path as indicated by the spin direction arrows associated with the stacked rolls 128 and 130. From the arrangement of the rollers at S 126, the compliant material 122 passes through the pressure gripping space 145 formed by the pressure roller arrangement 140 comprised of pressure rollers 142 and 144. Because the peripheral linear speed of the rollers of the roll arrangement at S 126 is controlled to be less than the peripheral linear speed of the rolls of the pressure roll arrangement 140, the paddable material 122 is tensioned between the roll arrangement at S 126 and the grip space by pressure of the pressure roller arrangement 140. By adjusting the difference in the speeds of the rollers, the aculellable material 122 is tensioned in such a way that it achieves a desired amount and is maintained in such a condition, stressed, stressed. From the pressure roll arrangement 140, the padded material 122 passes through the gripping space 151 formed by the mechanical stabilization arrangement 152 composed of incremental drawing rolls 153 and 154. Because the peripheral linear speed of the rolls of the arrangement of the pressure roller 140 is controlled to be less than or equal to the peripheral linear speed of the rollers of the mechanical stabilization arrangement 152, the material is maintained in its tensioned and / or clogged condition between the roller arrangement of pressure 140 and the mechanical stabilization arrangement 152. After leaving the mechanical stabilization and arrangement 152, the stabilized padding material 122 is wound on a quencher roll 160. Conventional driving means and other conventional devices can be used in conjunction with the device apparatus 6 which are well known and, for purposes of and clarity have not been illustrated in the schematic view of Figure 6. Although particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, attempts are made in the appended claims to protect all changes and modifications that are within the scope of this invention.

Claims (12)

1. - A method for producing an extensible, stabilized pad material, comprising the steps of: a) providing a castable material; b) apply a tensile force to the acuellable material to accelalar the material; and c) subjecting the padded material to mechanical stabilization to provide an extensible, stabilized padding material.

2. The method according to claim 1, wherein the actable material is a nonwoven web.

3. The method according to claim 2, wherein the castable material is a weft selected from the group consisting of a weft of carded bonded fibers, a weft of spunbonded fibers, a web of meltblown and blown fibers, and a multi-layer material including at least one of said frames.

4. The method according to any of the preceding claims, wherein step (c) comprises subjecting the padded material to incremental stretching.

5. The method according to claim 4, wherein the incremental stretching comprises feeding the padded material through a gripping space formed by a pair of incremental stretching rollers.

6. The method according to any of the preceding claims, wherein the mechanical stabilization comprises feeding the padded material through a grip space formed by a pair of patterned compression rolls.

7. The method according to any of the preceding claims, comprising the additional step of: d) winding the stabilized, extensible padding material on a quencher roll.

8. The method according to any of the preceding claims, comprising the additional step of: d) affixing the stabilized, extensible, padded material inside a box.

9. The method according to any of the preceding claims, further comprising the additional step of: d) joining the stabilized extendable, acylated material to an elastic member.

10. A nonwoven web made according to the method of claim 1.

11. A non-woven web comprising: a pattern of stabilizing enhancements as a result of being subjected to incremental stretching while the non-woven web is in a condition agreed.

12. A non-woven, stabilized, non-woven web, comprising: a pattern of stabilizing enhancements as a result of being subjected to incremental stretching while the non-woven web is in a corked condition, the non-woven web exhibiting an extension capacity of at least 100% at a force not greater than 100 grams.