Stretchable laminates of nonwoven web(s) and elastic film

• US 8,231,595 B2
• Filed: 04/08/2010
• Issued: 07/31/2012
• Est. Priority Date: 04/08/2009
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Turner, Robert Haines, Zgoda, Donald, Daniels, Walter Douglas, Bader, Jim Thomas, Galvis, Erika Fabiola
• Primary Examiner(s): Stephens, Jacqueline F.
• Application Number:
  US12/756,226
• Publication Number:
  US 20100262105A1
• Time in Patent Office: 845 Days
• Field of Search: 604/385.22, 604/385.24, 604/385.25, 604/385.26, 604/385.27, 604/366, 604/361, 604/365, 604/367, 604/368, 156160-167, 442/361, 442/328, 442/327
• US Class Current: 604/385.22
• CPC Class Codes: A61F 13/4902 characterised by the elastic material
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/14 comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/285 comprising polyethers
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/327 comprising polyolefins obtained by a metallocene or single-site catalyst
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/04 : characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/147 : by treatment of the layer
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/601 : Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/637 : Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material

Abstract

A stretchable laminate, a process of making a stretchable laminate and a disposable absorbent article that includes a stretchable laminate are disclosed. The stretchable laminate includes a nonwoven web and a web of elastomeric material. The nonwoven web includes two layers of spunbond multi-component fibers and one layer of meltblown fibers. The multi-component fibers include a first polymer and a second polymer having different melt temperatures. Thermo-bonds are formed at least partially through the nonwoven web. Some of the thermo-bonds can be elongated in the cross-machine direction of the nonwoven web.

Claims

1. A stretchable laminate comprising:

a. a first nonwoven web, said first nonwoven web comprising;

a first layer of fibers comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a top and a bottom surface, a machine direction and a cross-machine direction;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein said the top surface of said second layer faces said bottom surface of said first layer; and

a third layer of fibers comprising spunbond fibers layer, said third layer having a top and a bottom surface, a machine direction and a cross-machine direction, wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the top surface of said third layer faces said bottom surface of said second layer such that said second layer is positioned between said first and third layers;

wherein said first nonwoven web comprises a plurality of thermo-bonds extending at least partially through said first nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds such that at least some of said thermo-bonds are elongatable in said cross-machine direction;

and

b. a web of an elastomeric material having top and bottom surfaces,

wherein the bottom surface of said third layer comprising spunbond fibers of said first nonwoven web is bonded to said top surface of said elastomeric web to form a laminate.

2. The stretchable laminate of claim 1 wherein the melt temperature of said second polymer forming said sheath is less than about 150°

.

3. The stretchable laminate of claim 1 further comprising:

c. a second nonwoven web bonded to the bottom surface of said elastomeric web comprising;

a first layer comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a inner and an outer surface;

a second layer of fibers comprising meltblown fibers said second layer having a top and a bottom surface wherein the bottom surface of said second layer faces the top surface of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the bottom surface of said third layer faces said top surface of said second layer such that said second layer is positioned between said first and third layers of said second nonwoven web;

wherein said second nonwoven web comprises a plurality of thermo-bonds extending at least partially through said second nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds,

wherein the top surface of said third layer comprising spunbond fibers of said second nonwoven web is bonded to said bottom surface of said elastomeric web.

4. The stretchable laminate of claim 1 wherein said elastomeric web is a film comprising an elastomeric polyolefin.

5. The stretchable laminate of claim 1 wherein said first nonwoven web is adhesively bonded to said elastomeric web with a hotmelt adhesive having a melt temperature.

6. The stretchable laminate of claim 5 wherein the melt temperature of said hotmelt adhesive is greater than the melt temperature of said second polymer.

7. The stretchable laminate of claim 6 wherein the melt temperature of said hotmelt adhesive is lower than the melt temperature of said first polymer.

8. The stretchable material of claim 1 wherein at least a portion of said laminate is mechanically activated.

9. A process of making a stretchable laminate comprising:

obtaining a first nonwoven web, said first nonwoven web comprising;

a first layer of fibers comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a top and a bottom surface, a machine direction and za cross-machine direction;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein said the top surface of said second layer faces said bottom surface of said first layer; and

a third layer of fibers comprising spunbond fibers layer, said third layer having a top and a bottom surface, a machine direction and a cross-machine direction, wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the top surface of said third layer faces said bottom surface of said second layer such that said second layer is positioned between said first and third layers;

wherein said first nonwoven web comprises a plurality of thereto-bonds extending at least partially through said first nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds such that at least some of said thermo-bonds are elongatable in said cross-machine direction;

obtaining a web of an elastomeric material having top and bottom surfaces; and

bonding the bottom surface of one of said third layer comprising spunbond fibers of said first nonwoven web to said top surface of said elastomeric web.

10. The process of claim 9 wherein the melt temperature of said second polymer forming said sheath is less than about 150°

.

11. The process of claim 9 further comprising:

bonding a second nonwoven web to the bottom surface of said elastomeric web.

12. The process of claim 11 wherein said second nonwoven web comprises:

a first layer comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a inner and an outer surface;

a second layer of fibers comprising meltblown fibers said second layer having a top and a bottom surface wherein the bottom surface of said second layer faces the top surface of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the bottom surface of said third layer faces said top surface of said second layer such that said second layer is positioned between said first and third layers of said second nonwoven web;

wherein said second nonwoven web comprises a plurality of thermo-bonds extending at least partially through said second nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds,

wherein the top surface of one of third layer comprising spunbond fibers of said second nonwoven web is bonded to said bottom surface of said elastomeric web.

13. The process of claim 9 wherein said elastomeric web is a film of an elastomeric material comprising an elastomeric polyolefin.

14. The process of claim 9 wherein said first nonwoven web is adhesively bonded to said elastomeric web with a hotmelt adhesive having a melt temperature that is greater than the melt temperature of said second polymer.

15. The process of claim 9 wherein said first nonwoven web is adhesively bonded to said elastomeric web with a hotmelt adhesive having a melt temperature that is greater than the melt temperature of said second polymer.

16. A disposable absorbent article comprising:

a chassis having opposing first and second longitudinal side edges, said chassis comprising a liquid pervious topsheet, a liquid impervious backsheet and an absorbent core disposed between said topsheet and said backsheet; and

a pair of stretchable ears or side panels connected to each longitudinal side edge of said chassis, each of said ears or side panels comprising a stretchable laminate comprising;

a. a first nonwoven web, said first nonwoven web comprising;

a first layer of fibers comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a top and a bottom surface, a machine direction and a cross-machine direction;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein said the top surface of said second layer faces said bottom surface of said first layer; and

a third layer of fibers comprising spunbond fibers layer, said third layer having a top and a bottom surface, a machine direction and a cross-machine direction, wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the top surface of said third layer faces said bottom surface of said second layer such that said second layer is positioned between said first and third layers;

wherein said first nonwoven web comprises a plurality of thermo-bonds extending at least partially through said first nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds such that at least some of said thermo-bonds are elongatable in said cross-machine direction;

and;

b. a web of an elastomeric material having top and bottom surfaces,

wherein the bottom surface of said third layer comprising spunbond fibers of said first nonwoven web is bonded to said top surface of said elastomeric web to form a laminate.

17. The absorbent article of claim 16 wherein the melt temperature of said second polymer forming said sheath is less than about 150°

.

18. The absorbent article of claim 16 further comprising:

c. a second nonwoven web bonded to the bottom surface of said elastomeric web wherein said second nonwoven web comprises;

a first layer comprising spunbond fibers wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, said first layer having a inner and an outer surface;

a second layer of fibers comprising meltblown fibers said second layer having a top and a bottom surface wherein the bottom surface of said second layer faces the top surface of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface wherein said spunbond fibers are multi-component fibers having a core comprising a first polymer having a first melt temperature and a sheath comprising a second polymer having a second melt temperature wherein said second melt temperature is lower than said first melt temperature, wherein the bottom surface of said third layer faces said top surface of said second layer such that said second layer is positioned between said first and third layers of said second nonwoven web;

wherein said second nonwoven web comprises a plurality of thermo-bonds extending at least partially through said second nonwoven web, wherein the first polymer forming the core of said multi-component fibers has not melted within said thermo-bonds and the second polymer forming the sheath of said multi-component fibers has melted within said thermo-bonds,

wherein the top surface of said third layer comprising spunbond fibers of said second nonwoven web is bonded to said bottom surface of said elastomeric web.

19. The disposable absorbent article of claim 16 wherein said elastomeric web is a film comprising an elastomeric polyolefin.

20. The disposable absorbent article of claim 16 wherein at least a portion of said stretchable laminate is mechanically activated.