Flexible Composite Sheet For Disposable Garment

January 7, 2003

Patented is a flexible composite sheet for use in a disposable garment. The sheet contains a thermoplastic synthetic film with an upper and a lower surface and longitudinal and transverse directions. The thermoplastic synthetic film is approximately 0.001-0.05mm thick and includes numerous flat portions that are 0.03-1mm wide. The flat portions extend parallel to one another in the longitudinal direction. The thermoplastic synthetic film also features several intermittent apertures extending in longitudinal direction between the flat portions to form aperture rows extending parallel to one another in the longitudinal direction. Pairs of the flat portions have the aperture rows interconnected by several bridge portions, which extend between and across the aperture rows. The bridge portions extend across the respective aperture rows and are formed intermittently in the transverse direction. There are two types of bridge portions: those that extend upward or downward from the upper surfaces of the flat portions to the upper surfaces of the respective adjacent flat portions to form arcs and bridge portions that are flush with the flat portions. The intermittent apertures are defined by edges of the flat portions that extend in the longitudinal direction and edges of the bridge portions extend in the transverse direction. The flat portions are formed along the edges that extend in the longitudinal direction with pointed tooth-shaped portions that extend upward from the upper surfaces. A nonwoven fibrous layer with a lower surface and a substantially uniform basis weight is bonded to the lower surface of the thermoplastic synthetic resin film. Several discrete depressed areas are formed by depressing discrete areas of the composite sheet downward from the upper surface of the thermoplastic synthetic resin film toward the lower surface of the nonwoven fibrous layer by a depth of 0.1 mm. The depressed areas have bottoms and intermittent apertures. The nonwoven fibrous layer contains thermoplastic synthetic fibers in an amount of 30% by weight and have a density that is higher in the first regions immediately underlying the discrete depressed areas than in regions immediately surrounding the first regions.
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