Laminates with bonded webs

• US 8,728,051 B2
• Filed: 01/12/2011
• Issued: 05/20/2014
• Est. Priority Date: 01/12/2010
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Lu, Jonathan Aaron, Turner, Robert Haines, Burkhart, Thomas, Hartl, Helmut, Kong, Deying, Newkirk, David D., Reynolds, Lisa Marie
• Primary Examiner(s): Stephens, Jacqueline F.
• Application Number:
  US13/005,237
• Publication Number:
  US 20110282313A1
• Time in Patent Office: 1,224 Days
• Field of Search: 604/378, 604/385.16, 604/385.22, 604/385.24, 604/385.27, 604/385.28, 442/363, 442/394, 442/365, 428/196
• US Class Current: 604/385.22
• CPC Class Codes: A61F 13/5148 having an impervious inner layer and a cloth-like outer layer
• CPC Class Codes: A61F 13/53 characterised by the absorbing medium A61F13/20 takes precedence
• CPC Class Codes: A61F 2013/51023 being polymeric fibres
• CPC Class Codes: A61F 2013/51026 being in thermoplastic material
• CPC Class Codes: A61F 2013/51045 with thermoplastic binder
• CPC Class Codes: A61F 2013/51052 having different diameters
• CPC Class Codes: A61F 2013/51054 having different densities
• CPC Class Codes: A61F 2013/530226 with polymeric fibres
• CPC Class Codes: A61F 2013/530481 having superabsorbent materials, i.e. highly absorbent polymer gel materials
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• 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: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D04H 3/14 with bonds between thermoplastic yarns or filaments produced by welding
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 442/64 Islands-in-sea multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/641 Sheath-core multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/642 Strand or fiber material is a blend of polymeric material and a filler material
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet

Abstract

Laminates with a layer of bonded nonwoven material attached to a layer of film.

Claims

1. A laminate comprising a layer of nonwoven material attached to a layer of film, wherein:

the layer of nonwoven material comprises filaments of a first polymer and a second polymer;

the first polymer has a first melt temperature, and the second polymer has a second melt temperature, wherein the second melt temperature is higher than the first melt temperature, and wherein the first polymer and the second polymer form a bicomponent filament;

the layer of nonwoven material is thermally bonded;

the layer of nonwoven material has a machine direction and a cross direction;

the layer of nonwoven material has;

a basis weight that is less than or equal to 25 gsm;

a neckdown modulus in the cross direction that is greater than or equal to 1000 N/m and less than or equal to 3000 N/m;

a tensile strength in the cross direction that is less than or equal to 4 N/cm; and

an extensibility in the cross direction that is greater than or equal to 80% and less than or equal to 300%.

2. The laminate of claim 1, wherein the basis weight is less than or equal to 22 gsm.

3. The laminate of claim 1, wherein the basis weight is less than or equal to 20 gsm.

4. The laminate of claim 1, wherein the basis weight is less than or equal to 18 gsm.

5. The laminate of claim 1, wherein the basis weight is less than or equal to 16 gsm.

6. The laminate of claim 1, wherein the neckdown modulus in the cross direction is greater than or equal to 1200 N/m.

7. The laminate of claim 1, wherein the neckdown modulus in the cross direction is greater than or equal to 1400 N/m.

8. The laminate of claim 1, wherein the neckdown modulus in the cross direction is greater than or equal to 1600 N/m.

9. The laminate of claim 1, wherein the neckdown modulus in the cross direction is greater than or equal to 2000 N/m.

10. The laminate of claim 1, wherein the tensile strength in the cross direction is less than or equal to 3.5 N/cm.

11. The laminate of claim 1, wherein the tensile strength in the cross direction is less than or equal to 3.0 N/cm.

12. The laminate of claim 1, wherein the tensile strength in the cross direction is less than or equal to 2.5 N/cm.

13. The laminate of claim 1, wherein the tensile strength in the cross direction is less than or equal to 2.0 N/cm.

14. The laminate of claim 1, wherein the extensibility in the cross direction is greater than or equal to 100%.

15. The laminate of claim 1, wherein the extensibility in the cross direction is greater than or equal to 120%.

16. The laminate of claim 1, wherein the extensibility in the cross direction is greater than or equal to 150%.

17. The laminate of claim 1, wherein the extensibility in the cross direction is greater than or equal to 200%.

18. The laminate of claim 1, wherein when the laminate is subjected to the Sutherland Ink Rub test, the nonwoven material has a weight loss that is less than or equal to 0.15 mg/cm².

19. The laminate of claim 1, wherein when the laminate is subjected to the Sutherland Ink Rub test, the nonwoven material has a weight loss that is less than or equal to 0.12 mg/cm².

20. The laminate of claim 1, wherein when the laminate is subjected to the Sutherland Ink Rub test, the nonwoven material has a weight loss that is less than or equal to 0.10 mg/cm².

21. The laminate of claim 1, wherein when the laminate is subjected to the Sutherland Ink Rub test, the nonwoven material has a weight loss that is less than or equal to 0.08 mg/cm².

22. The laminate of claim 1, wherein the film is an elastic film.

23. The laminate of claim 22, wherein the laminate is incrementally stretched in the cross direction.

24. The laminate of claim 23, wherein the laminate is incrementally stretched in the machine direction.

25. A disposable wearable absorbent article comprising the laminate of claim 23.

26. The article of claim 25 wherein the article is a front fastenable disposable wearable absorbent article and the laminate is included in a side ear of the article.

27. The article of claim 25 wherein the article is a pant-type disposable wearable absorbent article and the laminate is included in a side panel of the article.