Extrusion bonded laminates for absorbent articles
An absorbent article of the present invention may comprise a topsheet, an outer cover, and an absorbent core disposed therebetween. The outer cover may comprise an extrusion bonded laminate. The EBL may comprise a multi-layer coextruded elastomeric film and a nonwoven. The film may comprise a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers. The nonwoven may comprise fibers and/or filaments. The first outer layer may be non-adhesively joined to the nonwoven via extrusion coating. Further, the outer cover may be elastic to at least about 50% engineering strain. The nonwoven may have high chemical affinity for the first outer layer. The first outer layer may have a low chemical affinity for the core layer. And, the first outer layer may comprise an amount of draw down polymer greater than about 45 wt %.
1. An absorbent article comprising:
a topsheet;
an outer cover;
an absorbent core disposed between the topsheet and outer cover;
wherein the outer cover comprises an extrusion bonded laminate, the extrusion bonded laminate comprising:
a multi-layer coextruded elastomeric film, comprising a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers;
a nonwoven consisting of fibers and/or filaments;
wherein the first outer layer is non-adhesively joined to the nonwoven via extrusion coating, such that the first outer layer is a tie layer between the core layer and the nonwoven;
wherein the second outer layer is non-adhesively joined to the core layer, such that the second outer layer is a skin layer;
wherein the first and second outer layers comprise polyolefin elastomers (POEs);
wherein the first and second outer layers comprise a blend of two ethylene-rich copolymers, wherein ethylene is between 10% and 97%
wherein the extrusion bonded laminate is mechanically activated using intermeshing gears;
wherein the outer cover is elastic to at least 50% engineering strain;
wherein the nonwoven has a high chemical affinity for the first outer layer;
wherein the first outer layer has a low chemical affinity for the core layer; and
wherein the first outer layer comprises an amount of draw down polymer greater than 45 wt%.
2. The absorbent article of claim 1 , wherein the first and second outer layers have a fusion index from about 10% to about 40%.
3. The absorbent article of claim 1 , wherein the nonwoven comprises bicomponent fibers, the fibers comprising a core and a sheath.
4. The absorbent article of claim 3 , wherein the sheath comprises polyethylene and the core comprises polypropylene.
5. The absorbent article of claim 4 , wherein the laminate bond strength is from about 2.2 to about 3.5 N/cm, as measured by the Tensile Test (Mode II).
6. The absorbent article of claim 3 , wherein the first outer layer comprises at least 45% of a polymer comprising more than 10 w% ethylene.
7. The absorbent article of claim 1 , wherein the core of the elastomeric film is selected from the group consisting of an ethylene copolymer having a fusion index from about 5% to about 20%, a propylene copolymer having a fusion index from about 5% to about 20%, and combinations thereof.
8. The absorbent article of claim 1 , wherein the multi-layer coextruded elastomeric film has a basis weight from about 20 gsm to about 30 gsm.
9. The absorbent article of claim 1 , wherein the extrusion bonded laminate further comprises an adhesive.
10. The absorbent article of claim 1 , wherein the nonwoven comprises fibers that are not round in cross section.
11. The absorbent article of claim 1 , further comprising a second nonwoven joined to the second outer layer.
12. The absorbent article of claim 1 , wherein an exterior surface of the second outer layer has a blocking force from 0.07 to 0.4 N/cm.
13. The absorbent article of claim 1 , wherein the extrusion bonded laminate is adhesive free.
14. The absorbent article of claim 1 , wherein the elastomeric film comprises at least 50%, by weight, of a polyolefinic elastomer.
15. The absorbent article of claim 1 , wherein the elastomeric film comprises:
at least one olefin-based elastomeric polymer; and
at least one draw down polymer;
wherein the elastomeric film has a permanent set of no more than 15% as measured by the Two-Cycle Hysteresis Test Method using 100% maximum engineering strain.
16. The absorbent article of claim 1 , wherein the first and second outer layers are compositionally identical.
17. The absorbent article of claim 1 , wherein the outer cover has an ultimate tensile strength from 3 N/cm to 5.3 N/cm.
18. An absorbent article comprising:
a topsheet;
an outer cover;
an absorbent core disposed between the topsheet and outer cover;
wherein the outer cover comprises an extrusion bonded laminate, the extrusion bonded laminate comprising:
a multi-layer coextruded elastomeric film, comprising a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers;
a nonwoven consisting of fibers and/or filaments;
wherein the first outer layer is non-adhesively joined to the nonwoven via extrusion coating such that the first outer layer is a tie layer between the core layer and the nonwoven;
wherein the second outer layer is non-adhesively joined to the core layer, such that the second outer layer is a skin layer;
wherein the first and second outer layers comprise polyolefin elastomers (POEs);
wherein the first and second outer layers comprise a blend of two ethylene-rich copolymers, wherein ethylene is between 10% and 97%
wherein the extrusion bonded laminate is mechanically activated using intermeshing gears;
wherein the outer cover is elastic to at least 50% engineering strain;
wherein the nonwoven has a high chemical affinity for the first outer layer;
wherein the first outer layer has a low chemical affinity for the core layer;
wherein the first outer layer comprises an amount of draw down polymer greater than 75 wt% ; and
wherein the multi-layer coextruded elastomeric film has a basis weight from 1 gsm to 25 gsm.