阅读说明：本技术 具有柔软非卷曲纺粘纤维网的弹性体层合体 (Elastomeric laminate with soft non-crimped spunbond web ) 是由 U.P.达拉尔 T.D.伦瑟 L.N.菲利普斯 C.A.梅特纳 M.A.卡巴莱罗 T.L. 于 2019-03-26 设计创作，主要内容包括：吸收制品包括第一腰区、第二腰区、和设置在所述第一腰区与第二腰区之间的裆区。所述制品也包括基础结构,所述基础结构具有顶片、底片、和设置在所述顶片与底片之间的吸收芯；以及接合到所述基础结构的耳片。所述耳片包括由第一非织造材料和第二非织造材料以及夹置在所述第一非织造材料和第二非织造材料之间的弹性体材料形成的层合体。所述层合体还包括多个超声波粘结部；并且所述第一非织造材料包括具有5db V2rms或更小的平均TS750值的外表面。(An absorbent article includes a first waist region, a second waist region, and a crotch region disposed between the first and second waist regions. The article also includes a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and backsheet; and an ear joined to the chassis. The ear comprises a laminate formed of first and second nonwoven materials and an elastomeric material sandwiched between the first and second nonwoven materials. The laminate further comprises a plurality of ultrasonic bonds; and the first nonwoven comprises an outer surface having an average TS750 value of 5db V2rms or less.)

1. An absorbent article comprising:

a first waist region, a second waist region, a crotch region disposed between the first and second waist regions;

a chassis comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and backsheet; and

an ear joined to the chassis, and the ear comprising:

a laminate comprising a first spunbond nonwoven material and an elastomeric material, wherein the laminate further comprises a plurality of ultrasonic bonds; and is

The first spunbond nonwoven has an average bond area of 12% or less and at least 0.160 (N/cm)/(g/m)²) Average normalized peak force of.

2. The absorbent article of claim 1, wherein the first spunbond nonwoven material is free of crimped fibers.

3. The absorbent article of claim 1 or 2, wherein the first spunbond nonwoven has an average bonded major dimension of at least 1.25 mm.

4. The absorbent article of any of the preceding claims, wherein the first spunbond nonwoven material comprises a nonwoven having a V of 5db²rms or less mean TS750 value.

5. The absorbent article of any of the preceding claims, wherein the laminate has an average load-at-break of 25N or greater.

6. The absorbent article of any of the preceding claims wherein the first spunbond nonwoven has an average strain% at peak force of 60% or less.

7. The absorbent article of any of the preceding claims, wherein the first spunbond nonwoven has 0.5mm²Or a larger bond site area.

8. The absorbent article according to any of the preceding claims, comprising a second nonwoven material, wherein the elastomeric material is sandwiched between the first spunbond nonwoven material and the second nonwoven material.

9. The absorbent article of claim 8, wherein the second nonwoven material comprises a nonwoven materialHas 5db V²rms or less mean TS750 value.

10. The absorbent article of claim 8 or 9, wherein the second nonwoven material comprises a non-crimped fiber nonwoven material.

11. The absorbent article of any of claims 8-10, wherein the second nonwoven material comprises a spunbond nonwoven material.

12. The absorbent article of any of the preceding claims wherein the laminate comprises a first inelastic region and an elastic region wherein the first inelastic region is free of the elastomeric material.

13. The absorbent article of claim 12 wherein the outer surface of the first spunbond nonwoven in the elastic region has a 12db V²rms or less mean TS7 value.

14. The absorbent article of claim 12 or 13, wherein the outer surface of the first spunbond nonwoven in the elastic region has 100db V²rms or less mean TS750 value.

15. The absorbent article of any of claims 12-14, wherein the outer surface of the first spunbond nonwoven in the first inelastic zone has 10db V²rms or less mean TS750 value.

Technical Field

The disclosure herein relates to spunbond fibrous nonwoven webs and articles incorporating them, and in particular absorbent articles incorporating the spunbond webs.

Background

Elastomeric laminates are used in a variety of products, including absorbent articles (e.g., diapers, incontinence articles, feminine hygiene pads). Such laminates typically include an elastomeric layer that provides extensibility to the laminate and an outer layer that is less stretchable but is suitable for providing durability and desirable tactile properties. In this way, the laminate allows the components of the article to closely and comfortably contact the wearer while providing the desired appearance qualities.

Elastomeric laminates can be prepared by a variety of methods. For example, the laminate may be in the form of a gathered laminate, wherein the cover layer forms gathers when the elastic layer is relaxed. The gathered laminate may be formed by stretching the elastic layer material to a greater extent than the outer layer material when the lamination is performed. Alternatively, the outer layer material may be corrugated and the elastic material may be in its relaxed state when laminated. In either case, after lamination, the cover gathers or gathers and wrinkles are formed when the laminate is in a relaxed state.

Another type of elastomeric laminate is a zero strain laminate. During lamination, the outer layer and the elastic layer are joined at about zero relative strain (i.e., the two layers are relaxed under about zero strain conditions). Zero strain laminates are activated by a mechanical strain process that creates a separation or deformation in the outer layer material, thus making the laminate elastic.

Nonwoven webs are typically used as the outer layers in such laminates. Nonwoven materials may be formed by various techniques, many of which may have disadvantages with respect to forming laminates. For example, nonwoven webs made from carded staple fibers are generally softer and easily extensible with little resistance during mechanical activation, but are expensive and have lower tensile strength at break. Spunbond nonwovens, on the other hand, are relatively inexpensive, but tend to be relatively coarse in texture and therefore less popular with consumers. The use of softer nonwovens to improve the feel often results in poorer performance of the laminate. In fact, there is often an inverse relationship between the strength of the laminate and its softness. While crimped spunbond fiber nonwovens have been proposed to enhance softness while maintaining strength, crimped fibers involve additional steps and cost.

Accordingly, there is a need for a laminate comprising a nonwoven material having the desired softness and texture while maintaining suitable strength. There is also a need to reduce costs and increase the efficiency of forming elastomeric laminates.

Disclosure of Invention

The absorbent article includes a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region. The article also includes a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and an ear joined to the chassis. The ear may comprise a laminate formed of a first nonwoven and a second nonwoven and an elastomeric material sandwiched between the first nonwoven and the second nonwoven. The laminate may further comprise a plurality of ultrasonic bonds; and the first nonwoven material may comprise a non-crimped spunbond nonwoven web.

In other aspects, the first nonwoven can comprise an outer surface having an average TS750 value of 5db V2rms or less. Additionally or alternatively, the web can have an average bond area of 12% or less and/or at least 0.160 (N/cm)/(g/m)²) Average Normalized Peak Force (Average Normalized Peak Force).

These and other features are described in more detail below.

Drawings

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention will be more readily understood from the following description taken in conjunction with the accompanying drawings, wherein:

FIG. 1A is a photograph showing crimped fibers;

FIG. 1B is a photograph showing straight fibers;

fig. 1C is a schematic view of a nonwoven laminate of the present disclosure, shown in cross-sectional view of the nonwoven laminate;

FIG. 2 is a photograph of an exemplary nonwoven material and bond pattern;

FIG. 3 is a photograph of an exemplary nonwoven material and bond pattern;

FIG. 4 is a photograph of an exemplary nonwoven material and bond pattern;

FIG. 5 is an exploded schematic view of an exemplary elastomeric laminate according to the present disclosure;

fig. 6 is a schematic plan view of an exemplary ear shape in accordance with one non-limiting embodiment of the present invention;

figure 6A is a schematic cross-sectional view of the ear of figure 6 taken along the lateral centerline of the ear;

FIG. 6B is a schematic plan view of an exemplary ultrasonic bonding pattern;

FIG. 7 is a graph illustrating the tensile properties of an exemplary nonwoven web;

FIG. 8 is a graph illustrating the stretch properties of an exemplary laminate;

FIG. 9 is a schematic plan view of an exemplary absorbent article according to one non-limiting embodiment of the present invention. The absorbent article is shown in a flat, uncontracted state;

fig. 10 is a schematic perspective view of a package according to an embodiment of the invention;

FIG. 11 is a schematic perspective view of a clamp suitable for use in the tensile testing method herein; and

fig. 12 is a schematic side elevation view of a clamp suitable for use in the tensile testing methods herein.

Detailed Description

"activation" is the mechanical deformation of a plastically extensible material that results in a permanent elongation of the extensible material or a portion of the extensible material in the direction of activation in the X-Y plane of the material. For example, activation occurs when a web or portion of a web is subjected to a stress that causes the material to strain beyond the onset of plasticity, which may or may not include complete mechanical failure of the material or portion of the material. The activation process may be applied to a single substrate or laminate comprising multiple layers. Activation processes are disclosed in, for example, U.S. patent publication 2013/0082418, U.S. patent 5,167,897, and U.S. patent 5,993,432. "activated" refers to a material that has been subjected to activation.

"roll-around" or "roll-around activated" assemblies have been activated by roll-around systems such as those described in U.S. Pat. Nos. 5,156,793 or 5,167,897 or by High Speed Research Presses (HSRP) such as those described in U.S. Pat. Nos. 7,062,983 and 6,843,134 to Anderson et al.

"bicomponent fibers" refers to fibers that have been formed from at least two different polymers extruded from separate extruders but spun bonded together to form one fiber. Bicomponent fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers. For example, the configuration of such bicomponent fibers may be a sheath/core arrangement in which one polymer is surrounded by another; or may be in a side-by-side arrangement, a pie arrangement, or a "sea-island" arrangement.

"biconstituent fibers" refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Biconstituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber, and the various polymers are usually not continuous along the entire length of the fiber, but rather usually form fibrils which start and end at random. Biconstituent fibers are sometimes referred to as multiconstituent fibers. In other examples, the bicomponent fiber may comprise a multicomponent component.

"elastic," "elastomeric," and "elastically extensible" mean that a material is capable of being stretched at least 100% under a given load without cracking or breaking, and that the elastic material or component exhibits at least 80% recovery (i.e., has a set of less than 20%) in one of the directions of the hysteresis test as described herein when the load is released. Tensile, sometimes referred to as strain, percent strain, engineering strain, tensile ratio, or elongation, along with recovery and set, can each be determined according to the "hysteresis test" described in more detail below. Inelastic materials are referred to as inelastic.

"extensible" refers to the ability to stretch or elongate (without breaking or breaking) by at least 50% according to step 5(a) of the hysteresis test herein (replacing the specified 100% strain with 50% strain).

By "laminate" is meant two or more materials bonded to each other by any suitable means known in the art, such as adhesive bonding, thermal bonding, ultrasonic bonding, or high pressure bonding using unheated or heated patterned rolls.

By "longitudinal" is meant the direction in the assembly along the length such that the longitudinal direction extends parallel to the maximum linear dimension in the x-y plane of the assembly. In the absorbent article as described herein, the longitudinal direction extends substantially perpendicularly from the waist end edge to the opposite waist end edge when the absorbent article is in a flat, uncontracted state, or from the waist end edge to the bottom of the crotch in a bi-folded article.

"lateral" means a direction generally perpendicular to the longitudinal direction. In the absorbent articles described herein, the lateral directions extend substantially parallel from a side edge to an opposite side edge.

"machine direction" or "MD" is the direction parallel to the direction of travel of the web during manufacture. The longitudinal direction is generally the longitudinal direction of the ears of a component, such as an absorbent article. The "cross direction" or "CD" is the direction substantially perpendicular to the MD and in the plane generally defined by the web.

"nonwoven web" refers to a web having a structure of individual fibers or threads which are interlaid, but not in a repeating pattern as in a woven or knitted fabric (which typically do not have randomly oriented fibers). The basis weight of nonwoven fabrics is typically expressed in grams per square meter (gsm). The basis weight of the nonwoven web is the total basis weight of the component layers and any other added components. Fiber diameter is typically expressed in microns; fiber size, which may also be expressed in denier, is the unit of weight per fiber length.

"spunbond fibers" refers to small diameter fibers formed by the process of: the molten thermoplastic material is extruded as filaments from a plurality of fine, usually circular capillaries of a spinneret, and the extruded filaments are then rapidly reduced in diameter. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from at least 10 samples) greater than 7 microns, more particularly between about 8 and 40 microns.

The spunbond web may include crimped fibers or may be free of crimped fibers.

"crimped fibers" or "crimped spunbond fibers" refer to bicomponent spunbond fibers having crimps, which may be configured in a side-by-side, core-eccentric sheath, or other suitable configuration. Selection of a suitable resin combination and bicomponent fiber configuration can result in the generation of helical crimp or twist in the fiber. "crimp" refers to the undulations, curls or waves in the fiber. Fig. 1A is a photograph of a crimped spunbond fiber, while fig. 1B is a photograph of a straight, uncrimped fiber. The crimping may occur spontaneously upon itself after web formation during the spinning or laying process. In some cases, crimp may be induced mechanically or chemically during fiber preparation or processing. The curl may be helical, planar, or a combination of both. The purpose of crimped fibers is to increase the volume of each fiber, which in turn helps to improve the softness of substrates made with crimped fibers. The fibers are typically evaluated for crimp using microscopic or SEM analysis.

"uncrimped" refers to a web that is substantially free of crimped spunbond fibers.

Fiber web

The present invention relates to spunbond nonwoven webs 100 suitable for use in absorbent articles, such as disposable absorbent articles. Although shown as rectangular in fig. 1C, it should be understood that the web is fibrous rather than smooth, but generally planar. The web may comprise a non-crimped spunbond nonwoven web. The non-crimped spunbond web 101 comprises one or more layers 102 of non-crimped spunbond fibers 103. In some non-limiting examples, a majority of the layers in the uncrimped spunbond web comprise uncrimped spunbond layers. In some embodiments, the nonwoven web 100 is simply a non-crimped spunbond layer.

In other aspects, the web 100 can include multiple layers 102, such as one or more layers having non-crimped spunbond layers and one or more layers formed by other methods (e.g., meltblown, carded, through air bonded, or hydroentangled fiber layers). The nonwoven layer 102 may include a spunbond layer (S), a nanofiber layer (N), and/or a meltblown layer (M), and the web may have any suitable configuration, including but not limited to: SMS, SSS, SSMMS, SSMS, and SSMNMS. The web 100 can be free of a carded fibrous layer and/or free of a crimped spunbond fibrous layer.

The fibrous layers of the web may be joined by any suitable method, including calender bonding. The layers may be joined by a plurality of bonds 104, as shown in FIG. 2. In some embodiments, the web has an Average Bond Area Percentage (Average Bond Area percent) of about 14% or less, or about 12% or less, or about 11.5% or less, or about 5% to about 15%, or about 7% to about 14%, or about 8% to about 12%, wherein increments of every 1% are listed for each range, as determined by the Bond Dimensions Test Method herein.

The bond 104 may have any suitable shape. In non-limiting examples, the bonds are circular, elliptical, oval, ring-shaped, rod-shaped, and combinations thereof. The bond may include one or more curvilinear portions. The plurality of bonds may have the same shape or different shapes. Also, the bonds may be of the same size or of different sizes. In some embodiments, the web may include a bond pattern 106 that includes one or more repeat units 108, as shown, for example, in fig. 2-4. The repeating unit is a portion of a pattern that can be replicated to form the entire pattern.

The bond may have a bond height (N2) that is the distance between the ends of the bond in the longitudinal direction. In non-limiting examples such as those of fig. 3 and 4, the bond height may be at least 0.35mm, or at least 0.75mm, or at least 1mm, or at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 3mm, or from about 0.45mm to about 10mm, or from about 1mm to about 8mm, with increments of every 0.1mm listed for each range. Additionally or alternatively, the nonwoven material may have an Average Bond Height (N2) of at least 0.35mm, or at least 0.75mm, or at least 1mm, or at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 3mm, or from about 0.45mm to about 10mm, or from about 1mm to about 8mm_av) For each range is listed increments of every 0.1 mm. The bond also has a bond width (N1) that is the distance in the lateral direction between the ends of the bond. The bond width may be greater or less than the bond height of a given bond. Alternatively, the bond width may be about the same as the bond height. In non-limiting examples, the bond width may be at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 2.15 mm. Additionally or alternatively, the nonwoven material may have an Average Bond Width (N1) of at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 2.15mm_av)). In some embodiments as shown in fig. 3 and 4, the bond may have a major dimension (i.e., the largest dimension in any direction) of at least 1.25mm, or at least 1.5mm, or at least 1.75mm, or at least 2mm, or at least 2.15mm, or at least 3mm, or from about 1.25mm to about 8mm, with increments of every 0.1mm listed for the ranges. The major dimension may be a height or a width,or may extend in a direction disposed at an angle relative to the longitudinal and lateral directions. Additionally or alternatively, the web may have an average bonded major dimension of at least 1.25mm, or at least 1.5mm, or at least 1.75 mm.

The bond also has a bond thickness (N3) that is the maximum lateral thickness of the bond. In some non-limiting examples, the bond height is the same as the bond thickness, which can be seen, for example, in fig. 4. However, in other examples, the thickness of the bond is different than the bond height as shown in fig. 3. The Bond thickness (N3) may be at least 0.5, or at least 0.75mm, or at least 1mm, or at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 2.15mm, or an Average Bond Height (N3av)) of from about 0.5mm to about 3mm, or from about 0.75mm to about 2.25mm, with increments of each 0.1mm being listed for each range. The web may have an Average Bond Thickness (N3)_av) At least 0.5, or at least.75 mm, or at least 1mm, or at least 1.25mm, or at least 1.5mm, or at least 2mm, or at least 2.15mm, or from about 0.5mm to about 3mm, or from about.75 mm to about 2.25mm, wherein increments of 0.1mm are listed for each range.

Each bond also includes a bond site area (N8), which is the two-dimensional area of the bond. In certain embodiments, the bond site area is at least about 0.5mm²Or at least about 0.6mm²Or at least about 0.75mm²Or about 0.5mm²To about 2mm²Wherein each 0.1mm is listed for the range²The increment of (c). The nonwoven web may have at least about 0.5mm²Or at least about 0.6mm²Or at least about 0.75mm²Or about 0.5mm²To about 2mm²Average bonding site Area of (2) (Average bond site Area (N8))_av) For which every 0.1mm is listed²The increment of (c). Bond height, Bond width, Bond thickness, Bond site area and percent Bond site area, as well as their respective averages, can be determined by the Bond Dimensions Test Method herein.

The spacing between bonds may be in phaseThe same or may vary at different regions of the web. The web may include overlapping bonds and/or a staggered bond pattern. The bonds may be arranged such that one or more rows and/or one or more columns of bonds are formed, as may be seen, for example, in fig. 2-4. The columns may be longitudinally extending and the rows may be laterally extending. Two laterally adjacent non-overlapping bonds may have a Minimum Lateral Bond Distance (N4) of at least about 2.25mm, or at least about 2.5mm, or at least about 3mm, or at least about 3.5mm, or from about 2.25mm to about 5mm, or from about 2.5mm to about 4mm, or from about 3mm to about 3.75mm, with increments therein of every 0.5mm being listed for each range, as measured by the Bond Dimensions Test Method herein. As shown in fig. 3, adjacent, non-overlapping means that when any overlapping bonds (such as 104c) are ignored, the bonds are in the measuring direction with no bonds 104a,104b between them. The web may have an Average Minimum Lateral Bond Distance (N4) of at least about 2.25mm, or at least about 2.5mm, or at least about 3mm, or at least about 3.5mm, or from about 2.25mm to about 5mm, or from about 2.5mm to about 4mm, or from about 3mm to about 3.75mm_av) For each range, increments of 0.1mm are listed therein, as measured by the Bond Dimensions test method herein.

Two adjacent columns may have a Minimum Lateral Column Offset (N6) of at least about 0.3mm, or at least about 0.5mm, or at least about 1mm, or from about 0.3mm to about 2mm, or from about 0.5mm to about 1.5mm, where increments of every 0.1mm are listed for each range. Additionally or alternatively, the web may have an Average Minimum Lateral Column Offset (N6) of at least about 0.3mm, or at least about 0.5mm, or at least about 1mm, or from about 0.3mm to about 2mm, or from about 0.5mm to about 1.5mm_av) For each range is listed increments of every 0.1 mm.

Two longitudinally adjacent non-overlapping bonds may have at least about 1.5mm, or at least about 2mm, or at least about 3mm, or at least about 3.5mm, or from about 1.4mm to about 6mm, or from about 2mm to about 5mm, or from about 3mm to about 6mmA Minimum Longitudinal Bond Distance (N5) of about 4.75mm is listed for each range, with increments of every 0.1 mm. Additionally or alternatively, the web may have a Minimum machine direction Bond Distance (N5) of at least about 1.5mm, or at least about 2mm, or at least about 3mm, or at least about 3.5mm, or from about 1.4mm to about 6mm, or from about 2mm to about 5mm, or from about 3mm to about 4.75mm_av) For each range is listed increments of every 0.1 mm.

Two adjacent rows may have a Minimum Longitudinal Row Offset (N7) of at least about 1.05mm, or at least about 1.1mm, or from about 1mm to about 2mm, or from about 1.1mm to about 1.6mm, with increments of every 0.5mm listed for each range. Additionally or alternatively, the web may have an Average minimum longitudinal Row Offset (N7) of at least about 1.05mm, or at least about 1.1mm, or from about 1mm to about 2mm, or from about 1.1mm to about 1.6mm_av) For each range is listed increments of every 0.5 mm.

For the avoidance of doubt, the bond distance and row or column pitch may be taken from different adjacent bonds. In other words, the nearest adjacent non-overlapping bonds may not be in the nearest row or column. In the case of the staggered pattern as shown in fig. 3, a Minimum Lateral Bond Distance (N4) is taken between the first Bond 104a and the closest but non-overlapping Bond 104b, while a Minimum Lateral Column Offset (N6) is taken between the first Bond 104a and its closest adjacent Bond in the Lateral direction 104 c.

Further, because multiple bonds may include overlapping portions, the distance may be measured "forward" within the scope of the present invention, as shown, for example, at N7 in fig. 4, from the right edge of a first bond 104d to the left edge of a bond in an adjacent column 104e, or "backward" as shown, for example, at N7 in fig. 3, from the right edge of a first bond 104d to the left edge of a bond in an adjacent column 104e (where the bonds overlap). A positive number will be used to indicate a measurement regardless of whether the bond overlaps or not.

According to the drawingTensile Test Method, a suitable non-crimped spunbond nonwoven web may have an Average Strain at Peak Force (Average% Strain at Peak Force) of about 70% or less, or from about 40% to about 60%, with increments of every 1% listed for each range. Additionally or alternatively, the nonwoven web can have a caliper of at least about 0.150 (N/cm)/(g/m)²) Or at least about 0.160 (N/cm)/(g/m)²) Or about 0.160 (N/cm)/(g/m)²) To 0.230 (N/cm)/(g/m)²) Average Normalized peak force (Average Normalized peak force).

As shown in fig. 5, the web 100 may include opposing surfaces 314, 316, which are further disclosed below. In certain embodiments, the fiber web may include one or more surfaces having about 11dB V2rms or less, or about 10dB V²rms or less, or about 5dB V²rms or less, or about 1dB V²rms to about 11dB V²rms, or about 1.5dB V²rms to about 6dBV²rms, or about 2dB V²rms to about 4dB V²The mean TS750 value for rms, listed for each range, where each 0.1dBV²Increment of rms. Additionally or alternatively, the web includes one or more surfaces having about 7dB V according to the softness test method herein²rms or less, or about 6.5dB V²rms or less, or about 6.4 or less, or about 1dB V²rms to about 7dB V²rms, or about 4dB V²rms to about 6.5dB V²The mean TS7 value for rms, listed for each range, where every 0.1dB V²Increment of rms. Lower TS7 values and TS750 values indicate higher softness, which is highly desirable in absorbent articles. Consumers may find absorbent articles with high TS7 and TS750 values uncomfortable and/or scratchy or otherwise undesirable.

In some non-limiting examples, the nonwoven web 100 has a basis weight of about 25gsm or less, or about 17gsm or less, or about 14gsm or less, or about 10gsm to about 25 gsm.

Elastomeric laminates incorporating webs

Fig. 5 schematically illustrates an exemplary elastomeric laminate 310 comprising a non-crimped spunbond nonwoven web 100. In the example shown in fig. 6, the ears 30 of the absorbent article comprise an elastomeric laminate. It is also contemplated that other components of the absorbent article may include elastomeric laminates such as waistbands, belts, and/or leg cuffs.

The elastomeric laminate may include a first nonwoven web 300 and an elastomeric layer 302. The first nonwoven web 300 may include one or more layers 102 having non-crimped spunbond fibers 103 having any of the characteristics described above and shown in fig. 1C. Returning to fig. 5, the first nonwoven web 300 may include additional layers, such as a meltblown layer and/or a nanofiber layer. In a non-limiting example, the first nonwoven web 300 is free of a carded and/or crimped spunbond fiber layer. The nonwoven web 300 may include a first outer surface 314 and a first inner surface 316. The first inner surface 316 is substantially opposite the first outer surface and faces the elastomeric layer 302. In certain embodiments, the non-crimped spunbond fibrous nonwoven web 100 forms the outer surface 314.

The elastomeric layer may comprise one or more elastomeric materials that provide elasticity to at least a portion of the layer. Non-limiting examples of elastomeric materials include films (e.g., styrenic block copolymer films, elastomeric polyolefin films, polyurethane films, films derived from rubber and/or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded to another substrate), elastomeric nonwovens, scrims, and the like. The elastomeric material may be formed from an elastomeric polymer, including polymers comprising: styrene derivatives, polyesters, polyurethanes, polyetherimides, polyolefins, combinations thereof; or any suitable known elastomer. Exemplary elastomers and/or elastomeric materials are disclosed in U.S. patent 8,618,350; 6,410,129, respectively; 7,819,853, respectively; 8,795,809, respectively; 7,806,883, respectively; 6,677,258, 9,834,667, and U.S. patent publication 2009/0258210. Commercially available elastomeric materials include KRATON (a styrenic block copolymer; available from Kraton Chemical Company, Houston, TX)); SEPTON (styrene block copolymer; available from Kuraray America, Inc. (New York, NY)); VECTOR (styrene block copolymer; available from TSRC Dexco Chemical Company (Houston, TX)); ESTANE (polyurethane; available from Lubrizol, Inc, Ohio); PEBAX (polyether block amide; available from Arkema Chemicals, Philadelphia, Pa.); HYTREL (polyester; available from DuPont, Wilmington, DE), VISTA MAXX (homo-and random copolymers, and blends of random copolymers, available from Exxon Mobile, Spring, TX), VERSIFY (homo-and random copolymers, and blends of random copolymers, available from Dow Chemical Company, Midland, Mich.), TAFMER (polyolefin elastomer, available from Mitsui Chemicals), and INFUSE (olefin block copolymer, available from Dow Chemical, Midland, Mich.).

In a non-limiting example, the elastomeric layer comprises a film. The film may comprise a single layer or multiple layers. The film may be pre-activated or non-activated. The membrane may be elastic in one or more directions. For example, when incorporated into an absorbent article, the film may be elastic in the lateral and/or longitudinal direction of the article. The elastomeric layer may have a width Y as shown, for example, in fig. 6. (fig. 6 shows ears 30 comprising an elastomeric laminate.) in some embodiments, Y is at least about 10mm less than the width W of the laminate. The elastomeric layer may have the same length dimension as the laminate length along the entire width of the elastomeric layer, or may have a length dimension that is less than the laminate length at any point along the width of the second layer. In some embodiments, the elastomeric layer may have a basis weight of from about 5gsm to about 150gsm, or a basis weight of from about 10gsm to about 100gsm, or a basis weight of less than about 150gsm, with increments of every 1gsm listed for each range.

As also shown in fig. 6, the laminate may include elastic regions 306. The elastic region 306 is generally defined by a perimeter of elastomeric material. In the elastic region, the laminate is elastically extensible. In some embodiments, such as when the ear 30 comprises a laminate, the area of the elastic region comprises at least about 20%, or from about 30% to about 80%, of the total area of the laminate, with increments of every 5% listed for the range. In further embodiments, Y (i.e., the maximum width of the elastomeric layer) is at least about 20%, or from about 25% to about 85%, or from about 35% to about 80%, of the total width W of the laminate, with increments of every 5% being listed for each range. The laminate further comprises one or more inelastic regions. In certain embodiments, the laminate includes a first inelastic region 308 extending laterally outward from the proximal edge 38 and adjacent the elastic region 306 at the first elastomeric material edge 307. The laminate may further include a second inelastic region 312 which may extend laterally inward from the distal side 36 and may be adjacent the elastic region 306 at the second elastomeric material edge 309. The first inelastic region and the second inelastic region can be made of the same or different materials.

The elastomeric laminate may also include a second nonwoven web 304. The elastomeric layer 302 may be sandwiched between the first nonwoven layer 300 and the second nonwoven layer 304. The second nonwoven web may comprise one or more nonwoven layers 102, which may comprise a spunbond layer, a nanofiber layer, and/or a meltblown layer. The second nonwoven web may comprise a non-crimped spunbond web 100' having any of the features described above with respect to the non-crimped web 100. Alternatively, the second nonwoven web may be free of non-crimped spunbond fibers. In a non-limiting example, the second nonwoven web 304 is free of a carded and/or crimped spunbond fiber layer. The second nonwoven web 304 may include a second outer surface 318 and a second inner surface 320. The second inner surface 320 is substantially opposite the second outer surface and faces the elastomeric layer 302. In certain embodiments, the non-crimped spunbond fibrous nonwoven web 100 forms the outer surface 318.

In certain embodiments, the elastomeric laminate comprises a gathered laminate wherein one of the layers is strained to a greater extent than the remaining layers during lamination. In this way, the relatively less extensible layer (i.e., the nonwoven layer) will form gathers when the laminate is in a relaxed state. In some embodiments, at least a portion of the elastomeric layer is strained when the one or more nonwoven webs are in a relaxed state during lamination. The elastomeric layer may be stretched in one or more directions. Pleats are then formed in the plurality of nonwoven webs while the subsequently formed laminate is in a relaxed state. In a non-limiting example, the elastomeric layer is stretched in a direction corresponding to the lateral direction of the article. In other words, when the laminate is joined to the chassis after lamination, it will be oriented such that the laminate is stretchable and/or elastic in the lateral direction of the article. In further non-limiting examples, the laminate is also stretchable and/or elastic in the machine direction.

The laminate layers may be joined by any suitable method. In some non-limiting examples, the elastomeric layer is joined to the first nonwoven layer and/or the second nonwoven layer by a plurality of ultrasonic bonds.

In certain embodiments, the elastomeric laminate 310 may have at least about 1m according to the air permeability test method herein³/m²Min, or about 1m³/m²Min to about 125m³/m²Min, or about 1m³/m²Min to about 35m³/m²Permeability values per min, listed for each range, where each 1m³/m²Increment of/min.

In other embodiments, the elastomeric laminate may have an average load at break of about 25N or greater, or from about 25N to about 40N, according to the tensile test method herein. The laminate may have an average elongation at break load of about 65mm or greater, or about 70mm or greater, or from about 65mm to about 85mm, or from about 70mm to about 80mm, according to the tensile test method herein. Once the load exceeds a value of 10N, the laminate may break within 50mm, as shown in fig. 8.

In various embodiments, the elastomeric laminate may include one or more surfaces in the elastic region 306 having about 115dB V2rms or less, or about 100dB V according to the softness test method herein²rms or less, or about 90dB V²rms or less, or about 50dB V²rms to about 115dB V²rms, or about 60dB V²rms to about 90dB V²Average TS750 values for rms, listed for each range, where V is every 1dB²Increment of rms. ElasticityThe body laminate may include one or more surfaces in the inelastic regions 308, 312 having about 22dB V2rms or less, or about 10dB V according to the softness test method herein²rms or less, or about 9dB V²rms or less, or about 2dB V²rms to about 22dB V²rms, or about 6dB V²rms to about 10dB V²Average TS750 values for rms, listed for each range, where V is every 1dB²Increment of rms.

Additionally or alternatively, the elastomeric laminate of the present invention may include one or more surfaces in the elastic region 306 having about 15dB V according to the softness test method herein²rms or less, or about 12dB V²rms or less, or about 5dB V²rms to about 15dB V²rms, or about 8dB V²rms to about 12dB V²Average TS7 values for rms, listed for each range, where V is every 1dB²Increment of rms. The elastomeric laminates of the present disclosure may include one or more surfaces in the inelastic region 308 having about 6dB V according to the softness test method herein²rms or less, or about 5.6dBV²rms or less, or about 3dB V²rms to about 6dB V²rms, or about 4dB V²rms to about 5.6dB V²Average TS7 values for rms, listed for each range, where V is every 1dB²Increment of rms. Lower TS7 values and TS750 values indicate higher softness, which is highly desirable in absorbent articles. Consumers may find absorbent articles with high TS7 and TS750 values uncomfortable and/or scratchy or otherwise undesirable.

The first outer surface and/or the second outer surface can have any of the TS7 and/or TS750 values disclosed herein. In various embodiments, the laminate is free of carded and/or crimped spunbond nonwoven webs.