Stretchable laminates of nonwoven web(s) and elastic film

1. A stretchable laminate comprising:

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

a first layer of fibers comprising spunbond fibers, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein the top surface of said second layer faces said bottom surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the top surface of said third layer faces the bottom surface of said second layer such that said second layer is positioned between said first and said third layers; and;

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

wherein said 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 said spunbond fibers of said first layer comprise multi-component fibers comprising at least a first and a second polymer.

3. The stretchable laminate of claim 2 wherein said multi-component fibers have a core made of said first polymer having a melt temperature and a sheath made of said second polymer having a melt temperature.

4. The stretchable laminate of claim 3 wherein the melt temperature of said second polymer is lower than the melt temperature of said core.

5. The stretchable laminate of claim 1 further comprising:

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

6. The stretchable laminate of claim 5 wherein said second nonwoven web comprises:

a first layer of fibers comprising spunbond fibers, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said first layer having a top and a bottom surface wherein the bottom surface of said second layer faces said top surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the bottom surface of said third layer faces the top surface of said second layer such that said second layer is positioned between said first and said third layers;

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

7. The stretchable laminate of claim 1 wherein said elastomeric web is a film of an elastomeric material.

8. The stretchable laminate of claim 7 wherein said film comprises an elastomeric polyolefin.

9. The stretchable laminate of claim 1 wherein said first nonwoven web is adhesively bonded to said elastomeric web.

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

11. 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, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein the top surface of said second layer faces said bottom surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the top surface of said third layer faces the bottom surface of said second layer such that said second layer is positioned between said first and said third layers;

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

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

12. The process of claim 11 wherein spunbond fibers of said first layer comprise multi-component fibers comprising at least a first and a second polymer wherein said multi-component fibers have a core made of said first polymer having a melt temperature and a sheath made of said second polymer having a melt temperature.

13. The process of claim 12 wherein the melt temperature of said second polymer is lower than the melt temperature of said core.

14. The process of claim 11 further comprising:

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

15. The process of claim 14 wherein said second nonwoven web comprises:

a first layer of fibers comprising spunbond fibers, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said first layer having a top and a bottom surface wherein the bottom surface of said second layer faces said top surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the bottom surface of said third layer faces the top surface of said second layer such that said second layer is positioned between said first and said third layers;

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

16. The process of claim 11 wherein said elastomeric web is a film comprising an elastomeric polyolefin.

17. The process of claim 11 further comprising:

mechanically activating at least a portion of said stretchable laminate.

18. A disposable absorbent article comprising:

a chasis 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, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said second layer having a top and a bottom surface wherein the top surface of said second layer faces said bottom surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the top surface of said third layer faces the bottom surface of said second layer such that said second layer is positioned between said first and said third layers; and;

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

wherein said 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.

19. The disposable absorbent article of claim 18 wherein said stretchable laminate further comprises:

c. a second nonwoven web comprising:

a first layer of fibers comprising spunbond fibers, said first layer having a top and a bottom surface, said fibers of said first layer forming a plurality of interstices;

a second layer of fibers comprising meltblown fibers, said first layer having a top and a bottom surface wherein the bottom surface of said second layer faces said top surface of said first layer, and wherein at least some of said meltblown fibers are located inside some of the interstices of said first layer; and

a third layer of fibers comprising spunbond fibers, said third layer having a top and a bottom surface, wherein the bottom surface of said third layer faces the top surface of said second layer such that said second layer is positioned between said first and said third layers;

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

20. The disposable absorbent article of claim 19 wherein at least a portion of said stretchable laminate is mechanically activated.