Highly extensible nonwoven webs and absorbent articles having such webs
A highly extensible nonwoven web is provided. The highly extensible nonwoven web may include continuous multi-component fibers. The continuous multi-component fibers may include polypropylene, wherein the polypropylene has a crystallinity of less than about 41%. The polypropylene may have a melting temperature of less than about 161° C. The highly extensible nonwoven web may define a plurality of apertures. The apertures may be patterned. The highly extensible nonwoven web may form a portion of an absorbent article.
1. An absorbent article comprising:
a nonwoven topsheet comprising:
a first nonwoven web comprising:
continuous multi-component fibers comprising bi-component fibers, wherein a first polymer component comprises polypropylene, wherein the polypropylene has a crystallinity of between about 20% and about 41%, according to a Crystallinity Test, and wherein the polypropylene has a melting temperature of between about 130° C. and about 161° C. according to an Enthalpies of Fusion and Crystallinity Test;
wherein a second polymer component comprises polyethylene, wherein the polyethylene has a crystallinity of between 45% and about 75% according to a Crystallinity Test, and wherein the polyethylene has a speed of crystallization between about 1300 ms and about 1360 ms according to a Flash DSC Method, and a melting temperature of between about 100° C. and about 140° C. according to an Enthalpies of Fusion and Crystallinity Test;
wherein the nonwoven topsheet defines a plurality of apertures, and wherein a maximum measurable aperture area equivalent diameter is between about 1.2 mm and about 10 mm, according to an Aperture Area Equivalent Diameter Test;
a liquid impermeable backsheet; and
an absorbent core positioned at least partially intermediate the topsheet and the backsheet.
2. The absorbent article of claim 1 , wherein the bi-component fibers have a sheath-core configuration comprising a sheath and a core, wherein the sheath comprises the polyethylene, and wherein the core comprises the polypropylene.
3. The absorbent article of claim 1 , wherein the first nonwoven web comprises a primary bond area of about 10% to about 35%, according to a Primary Bond Area Test.
4. The absorbent article of claim 1 , wherein at least a portion of the plurality of apertures are formed from overbonds, and wherein portions of perimeters of at least some of the apertures comprise a melt lip.
5. The absorbent article of claim 4 , wherein the nonwoven topsheet has an extensibility of between about 300% and about 450%, according to a High Speed Tensile Test; and wherein every gram per square meter of nonwoven topsheet has a neckdown modulus of greater than 56 N/m, according to a Neckdown Modulus Test.
6. The absorbent article of claim 1 , wherein the nonwoven topsheet has an Effective Open Area of between about 7% and about 30%, according to an Effective Open Area Test.
7. The absorbent article of claim 1 , wherein the nonwoven topsheet comprises a second nonwoven web, and wherein the first nonwoven web is hydrophobic.
8. The absorbent article of claim 1 , wherein the apertures are non-homogeneous.
9. The absorbent article of claim 1 , wherein the nonwoven topsheet comprises three-dimensional features.
10. The absorbent article of claim 1 , wherein the nonwoven topsheet has a lint production of between about 3% and about 9%, according to a Tape Stripping Test.
11. A nonwoven web for an absorbent article, the nonwoven web comprising:
spunbond bi-component fibers, wherein a first polymer component comprises polypropylene, wherein the polypropylene has a crystallinity of between about 20% and about 41%, according to a Crystallinity Test, and wherein the polypropylene has a melting temperature of between about 130° C. and about 161° C. according to an Enthalpies of Fusion and Crystallinity Test; and
wherein a second polymer component comprises polyethylene, wherein the polyethylene has a crystallinity of between 45% and about 75% according to a Crystallinity Test, and wherein the polyethylene has a speed of crystallization between about 1300 ms and about 1360 ms according to a Flash DSC Method, and has a melting temperature of between about 100° C. and about 140° C. according to an Enthalpies of Fusion and Crystallinity Test.
12. The nonwoven web of claim 11 , wherein the spunbond bi-component fibers have a sheath-core configuration comprising a sheath and a core, wherein the sheath comprises the polyethylene, and wherein the core comprises the polypropylene.
13. The nonwoven web of claim 11 ,
wherein the nonwoven web has an extensibility of between about 300% and about 450%, according to a High Speed Tensile Test; and
wherein every gram per square meter of nonwoven web has a neckdown modulus of greater than 56 N/m, according to a Neckdown Modulus Test.
14. The nonwoven web of claim 11 , wherein the nonwoven web comprises a plurality of overbonds.
15. The nonwoven web of claim 11 , comprising a plurality of nonhomogeneous apertures, wherein the nonwoven web has a maximum measurable aperture area equivalent diameter between about 1.5 mm and about 10 mm, according to an Aperture Area Equivalent Diameter Test.
16. The nonwoven web of claim 15 , wherein portions of perimeters of at least some of the apertures comprise a melt lip.
17. The nonwoven web of claim 11 , wherein the nonwoven web has an Effective Open Area of between about 7% and about 25%, according to an Effective Open Area Test.
18. The nonwoven web of claim 11 , wherein the nonwoven web is joined to a second nonwoven web to form a laminate, wherein the nonwoven web is hydrophobic, wherein the second nonwoven web is hydrophilic, the second nonwoven web comprising second spunbond bi-component fibers comprising a second polypropylene, wherein the second polypropylene has a crystallinity of between about 20% and about 41%, according to the Crystallinity Test, and wherein the second polypropylene has a melting temperature of between about 130° C. and about 161° C.
19. The nonwoven web of claim 11 , wherein the nonwoven web has a lint production of between about 3% and about 9%, according to a Tape Stripping Test.
20. An absorbent article comprising:
a nonwoven topsheet comprising:
a nonwoven web comprising:
continuous multi-component fibers comprising:
polypropylene, wherein the polypropylene has a crystallinity of between about 20% and about 41%, according to a Crystallinity Test, and wherein the polypropylene has a melting temperature of between about 130° C. and about 161° C., and polyethylene, wherein the polyethylene reaches a crystallization peak maximum in less than 1360 ms, according to a Flash DSC Method; and
polyethylene, wherein the polyethylene has a crystallinity of between 45% and about 75% according to a Crystallinity Test, and wherein the polyethylene has a speed of crystallization between about 1300 ms and about 1360 ms according to a Flash DSC Method, and has a melting temperature of between about 100° C. and about 140° C. according to an Enthalpies of Fusion and Crystallinity Test;
wherein the nonwoven topsheet defines a plurality of apertures, wherein a maximum measurable aperture area equivalent diameter is between about 1.2 mm and about 6 mm, according to an Aperture Area Equivalent Diameter Test, and wherein the nonwoven web has a lint production of between about 3% and about 9%, according to a Tape Stripping Test;
a liquid impermeable backsheet; and
an absorbent core positioned at least partially intermediate the topsheet and the backsheet.