Elastomeric laminate having a soft non-crimp spunbond fiber web

Abstract

An 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 base structure having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and ear tabs joined to the base structure. The ear tabs include a laminate formed of a first nonwoven material, a second nonwoven material, and an elastomeric material sandwiched between the first nonwoven material and the second nonwoven material. The laminate further includes a plurality of ultrasonic bonds; and the first nonwoven material includes an outer surface having an average TS750 value of 5 dB V2rms or less.

Description

[0001] This application is a divisional application of an invention patent application with an application date of March 26, 2019, a priority date of March 27, 2018, an application number of 201980015257.5, and an invention name of "Elastomeric laminate with soft non-curled spunbond fiber web". Technical Field

[0002] The disclosure herein relates to spunbond fiber nonwoven webs and articles incorporating the same, and in particular to absorbent articles incorporating the spunbond fiber webs. Background Art

[0003] Elastomeric laminates are used in a variety of products, including absorbent articles (e.g., diapers, incontinence products, 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 suitable for providing durability and desired tactile properties. In this way, the laminate allows the components of the article to intimately and comfortably contact the wearer while providing desired appearance qualities.

[0004] The elastomeric laminate can be prepared by a variety of methods. For example, the laminate can be in the form of a gathered laminate, wherein the cover layer forms wrinkles when the elastic layer relaxes. The gathered laminate can be formed by extending the elastic layer material to a greater extent than the outer layer material when laminating. Alternatively, the outer layer material can be corrugated and the elastic material can be in its relaxed state when laminating. In either case, after lamination, the cover is gathered or gathered and wrinkles are formed when the laminate is in a relaxed state.

[0005] Another type of elastomeric laminate is a zero strain laminate. During lamination, the outer layer and the elastic layer are joined at approximately zero relative strain (i.e., the two layers are relaxed under approximately zero strain conditions). Zero strain laminates are activated by a mechanical straining process that creates a separation or deformation in the outer layer material, thereby making the laminate elastic.

[0006] Nonwoven fiber webs are commonly used as the outer layer in such laminates. Nonwoven materials can be formed by various techniques, many of which can have drawbacks with respect to forming the laminate. For example, nonwoven fiber webs made from carded staple fibers are generally softer and more extensible, having little resistance during mechanical activation, but the carded nonwoven materials are expensive and have a low breaking tensile strength. On the other hand, spunbond nonwoven materials are relatively inexpensive, but tend to be coarser in texture and are thus less appealing to consumers. Using a softer nonwoven material to improve the touch often results in a poorer performance of the laminate. In fact, there is often an inverse relationship between the strength and the softness of the laminate. Although it has been proposed to use crimped spunbond fiber nonwovens to enhance softness while maintaining strength, the crimped fibers involve additional steps and costs.

[0007] Accordingly, there is a need for a laminate including a nonwoven material that has a desired softness and texture while maintaining a suitable strength. There is also a need to reduce costs and increase the efficiency of forming the elastomeric laminate. SUMMARY OF THE INVENTION

[0008] An 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 base structure having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and ear tabs joined to the base structure. The ear tabs can include a laminate formed from a first nonwoven material, a second nonwoven material, and an elastomeric material sandwiched between the first nonwoven material and the second nonwoven material. The laminate can also include a plurality of ultrasonic bonds; and the first nonwoven material can include a non-crimped spunbond nonwoven fiber web.

[0009] In other aspects, the first nonwoven material can include an outer surface having an average TS750 value of 5 dB V 2 rms or less. In addition or alternatively, the fiber web can have an average bonded area of 12% or less and / or an average normalized peak force of at least 0.160 (N / cm) / (g / m 2 ).

[0010] These and other features are described in more detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Although this specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the invention, it is believed that the invention will be more readily understood from the following description taken in conjunction with the accompanying drawings, in which:

[0012] Figure 1A is a photograph showing crimped fibers;

[0013] Figure 1B Photograph showing straight fibers;

[0014] Figure 1C Schematic view of the nonwoven laminate of the present invention, shown in cross-section of the nonwoven laminate;

[0015] Figure 2 Photograph of exemplary nonwoven materials and bonding patterns;

[0016] Figure 3 Photograph of exemplary nonwoven materials and bonding patterns;

[0017] Figure 4 Photograph of exemplary nonwoven materials and bonding patterns;

[0018] Figure 5 Exploded schematic view of an exemplary elastomeric laminate according to the present invention;

[0019] Figure 6 Schematic plan view of an exemplary tab shape according to a non-limiting embodiment of the present invention;

[0020] Figure 6A Taken along the lateral centerline of the tab Figure 6 Schematic cross-sectional view of the tab;

[0021] Figure 6B Schematic plan view of an exemplary ultrasonic bonding pattern;

[0022] Figure 7 Graph showing the tensile properties of an exemplary nonwoven web;

[0023] Figure 8 Graph showing the extensional properties of an exemplary laminate;

[0024] Figure 9 Schematic plan view of an exemplary absorbent article according to a non-limiting embodiment of the present invention. The absorbent article is shown in a flat, unshrunk state;

[0025] Figure 10 Schematic perspective view of a package according to an embodiment of the present invention;

[0026] Figure 11 Schematic perspective view of a gripper suitable for the tensile test method described herein; and

[0027] Figure 12 Schematic side elevation view of a gripper suitable for the tensile test method described herein. DETAILED DESCRIPTION

[0028] "Activation" is a mechanical deformation of a material that is plastically extensible, which results in a permanent elongation of the extensible material or a portion of the extensible material in the X-Y plane of the material in the activation direction. For example, activation occurs when a fibrous web or a portion of a fibrous web is subjected to a stress that causes the material to strain beyond the onset of plasticity, which strain may or may not include complete mechanical failure of the material or a portion of the material. The activation process can be applied to a single substrate or laminate that includes multiple layers. The activation process is disclosed, for example, in U.S. Patent Publication 2013 / 0082418, U.S. Patent 5,167,897, and U.S. Patent 5,993,432. "Activated" means a material that has been subjected to activation.

[0029] A "ring-rolled" or "ring-rolled activated" component has been activated by a ring-rolling system as described in U.S. Patent 5,156,793 or 5,167,897 or by a High Speed Research Press (HSRP) as described in U.S. Patents 7,062,983 and 6,843,134, which were issued to Anderson et al.

[0030] A "bicomponent fiber" is a fiber that has been formed from at least two different polymers that are extruded from separate extruders but spun together to form a single fiber. Bicomponent fibers are sometimes also referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in different zones that are positioned substantially constantly across the cross-section of the bicomponent fiber and extend continuously along the length of the bicomponent fiber. For example, the configuration of such a bicomponent fiber can be a sheath / core arrangement, where one polymer is surrounded by another polymer; or it can be a side-by-side arrangement, a pie arrangement, or an "island-in-the-sea" arrangement.

[0031] A "bico fiber" is a fiber that has been formed by extruding at least two polymers as a blend from the same extruder. Bico fibers do not have various polymer components that are arranged in different zones that are positioned relatively constantly across the cross-sectional area of the fiber, and the various polymers are not typically continuous along the entire length of the fiber but instead typically form fibrils that randomly start and end. Bico fibers are sometimes also referred to as multicomponent fibers. In other examples, a bicomponent fiber can include a multicomponent component.

[0032] "Elastic," "elastomeric," and "elastically extensible" mean that a material is capable of being stretched at least 100% under a given load without breaking or fracturing, and when the load is released, the elastic material or component exhibits at least 80% recovery in one of the directions of the hysteresis test as described herein (i.e., has a permanent deformation rate of less than 20%). Stretching is sometimes referred to as strain, and the percentage of strain, engineering strain, draw ratio, or elongation, along with the recovery rate and the permanent deformation rate, can each be determined according to the "hysteresis test" described in more detail below. A material that is not elastic is referred to as inelastic.

[0033] "Extendable" means the ability to stretch or elongate (without breaking or fracturing) by at least 50% when stretched according to step 5(a) (substituting 50% strain for the specified 100% strain) in the hysteresis test herein.

[0034] "Laminate" means two or more materials bonded to each other by any suitable method known in the art, such as adhesive bonding, thermal bonding, ultrasonic bonding, or high-pressure bonding using a non-heated or heated pattern roll.

[0035] "Longitudinal" means the direction along the length in a component such that the longitudinal extends parallel to the maximum linear dimension in the x-y plane of the component. In an absorbent article as described herein, when the absorbent article is in a flat, unshrunk state, the longitudinal extends substantially perpendicularly from the waist edge to the opposite waist edge, or in a double-folded article, from the waist edge to the bottom of the crotch.

[0036] "Lateral" means a direction generally perpendicular to the longitudinal direction. In an absorbent article as described herein, the lateral extends substantially parallel from a side edge to the opposite side edge.

[0037] "Longitudinal" or "MD" is the direction parallel to the direction of travel of the web during the manufacturing process. The longitudinal is typically the longitudinal of an earpiece of a component such as an absorbent article. "Cross-direction" or "CD" is the direction substantially perpendicular to the MD and within the plane generally defined by the web.

[0038] "Nonwoven web" means a web having a structure of discrete fibers or filaments inserted therein, but not forming a repeating pattern such as in a woven fabric or a knitted fabric (which generally do not have randomly oriented fibers). The basis weight of a nonwoven fabric is typically expressed in grams per square meter (gsm). The basis weight of a nonwoven web is the total basis weight of the constituent layers and any other added components. Fiber diameter is typically expressed in microns; fiber size can also be expressed in denier, which is a unit of weight per unit length of fiber.

[0039] "Spunbond fiber" means a small-diameter fiber formed by extruding a molten thermoplastic material from a plurality of fine, generally circular capillaries of a spinneret into filaments, and then rapidly reducing the diameter of the extruded filaments. When spunbond fibers are deposited on a collecting surface, they generally do not stick. Spunbond fibers are generally continuous and have an average diameter (from at least 10 samples) greater than 7 microns, more specifically between about 8 microns and 40 microns.

[0040] The spunbond web may include crimped fibers or may be free of crimped fibers.

[0041] "Crimped fiber" or "crimped spunbond fiber" refers to a bicomponent spunbond fiber having crimps, which can be constructed in a side-by-side type, core-eccentric sheath, or other suitable configurations. The selection of suitable resin combinations and bicomponent fiber configurations can result in the formation of helical crimps or twists in the fibers. "Crimp" refers to the undulations, curls, or ripples in the fibers. Figure 1A is a photograph of a crimped spunbond fiber, while Figure 1B is a photograph of a straight, non-crimped fiber. The crimping can occur spontaneously during the spinning or laying process, or by itself after the web is formed. In some cases, the crimping can be mechanically or chemically induced during the fiber preparation or processing. The crimp can be helical, planar, or a combination of both. The purpose of the crimped fiber is to increase the volume of each fiber, which in turn helps to improve the softness of the substrate made from the crimped fibers. Microscopy or SEM analysis is typically used to evaluate whether the fibers have crimps.

[0042] "Non-crimped" refers to a fibrous web that is substantially free of crimped spunbond fibers.

[0043] Fiber web

[0044] The present invention relates to a spunbond nonwoven fibrous web 100 suitable for use in absorbent articles, such as disposable absorbent articles. Although shown as rectangular in Figure 1C , it should be understood that the fibrous web is fibrous rather than smooth, but generally planar. The fibrous web can include a non-crimped spunbond nonwoven fibrous web. The non-crimped spunbond web 101 includes one or more layers 102 of non-crimped spunbond fibers 103. In some non-limiting examples, most of the layers in the non-crimped spunbond web include non-crimped spunbond layers. In some embodiments, the nonwoven fibrous web 100 is only a non-crimped spunbond layer.

[0045] In other aspects, the fibrous 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 web, airlaid, or hydroentangled fibrous layers). The nonwoven layers 102 can include spunbond layers (S), nanofiber layers (N), and / or meltblown layers (M), and the fibrous web can have any suitable configuration, including but not limited to: SMS, SSS, SSMMSS, SSMS, and SSMNMS. The fibrous web 100 can be free of carded web fibrous layers and / or free of crimped spunbond fibrous layers.

[0046] The fibrous layers of the fibrous web can be joined by any suitable method, including calendering bonding. The layers can be joined by a plurality of bonding portions 104, as Figure 2As shown. In some embodiments, the fibrous web has an average bond area percentage 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%. Each 1% increment within each range is listed, and this is determined by the Bond Dimensions Test Method described herein.

[0047] The bonding portion 104 can have any suitable shape. In non-limiting examples, the bonding portion is circular, oval, ovoid, annular, rod-shaped, and combinations thereof. The bonding portion can include one or more curved portions. Multiple bonding portions can have the same shape or different shapes. Similarly, the bonding portions can have the same size or different sizes. In some embodiments, the fibrous web can include a bonding pattern 106 that includes one or more repeating units 108, such as, for example Figures 2 - 4 As shown. A repeating unit is a part of a pattern that can be replicated to form the entire pattern.

[0048] The bonding portion can have a bond height (N2), which is the longitudinal distance between the ends of the bonding portion. In non-limiting examples such as Figure 3 and Figure 4 the bond height can be at least 0.35 mm, or at least 0.75 mm, or at least 1 mm, or at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 3 mm, or about 0.45 mm to about 10 mm, or about 1 mm to about 8 mm. Each 0.1 mm increment within each range is listed. In addition or alternatively, the nonwoven material can have an average bond height (Average Bond Height (N2 av )) of at least 0.35 mm, or at least 0.75 mm, or at least 1 mm, or at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 3 mm, or about 0.45 mm to about 10 mm, or about 1 mm to about 8 mm. Each 0.1 mm increment within each range is listed. The bonding portion also has a bond width (N1), which is the lateral distance between the ends of the bonding portion. The bond width can be greater than or less than the bond height of a given bonding portion. Alternatively, the bond width can be approximately the same as the bond height. In non-limiting examples, the bond width can be at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 2.15 mm. In addition or alternatively, the nonwoven material can have an average bond width (Average Bond Width (N1 av )) of at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 2.15 mm. In such asFigure 3 and Figure 4 In some embodiments as shown, the bonding portion may have a primary dimension (i.e., the maximum dimension in any direction) of at least 1.25 mm, or at least 1.5 mm, or at least 1.75 mm, or at least 2 mm, or at least 2.15 mm, or at least 3 mm, or from about 1.25 mm to about 8 mm, with increments of every 0.1 mm listed for each of these ranges. The primary dimension may be the height or the width, or may extend in a direction set at an angle relative to the longitudinal and lateral directions. Additionally or alternatively, the fibrous web may have an average bonded primary dimension of at least 1.25 mm, or at least 1.5 mm, or at least 1.75 mm.

[0049] The bonding portion also has a bonding portion thickness (N3), which is the maximum lateral thickness of the bonding portion. In some non - limiting examples, the bonding height is the same as the bonding thickness, as can be seen, for example, Figure 4 in. However, in other examples, the thickness of the bonding portion is different from the bonding portion height as shown in Figure 3 The bonding thickness (N3) can be at least 0.5, or at least 0.75 mm, or at least 1 mm, or at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 2.15 mm, or from about 0.5 mm to about 3 mm, or from about 0.75 mm to about 2.25 mm, with increments of every 0.1 mm listed for each range. The fibrous web may have an average bond thickness (Average Bond Thickness (N3 av )) which can be at least 0.5, or at least.75 mm, or at least 1 mm, or at least 1.25 mm, or at least 1.5 mm, or at least 2 mm, or at least 2.15 mm, or from about 0.5 mm to about 3 mm, or from about.75 mm to about 2.25 mm, with increments of every 0.1 mm listed for each range.

[0050] Each bonding portion also includes a bonded area (N8), which is the two - dimensional area of the bonding portion. In certain embodiments, the bonded area is at least about 0.5 mm 2 or at least about 0.6 mm 2 or at least about 0.75 mm 2 or from about 0.5 mm 2 to about 2 mm 2 with increments of every 0.1 mm 2 listed for each of these ranges. The non - woven fibrous web may have at least about 0.5 mm 2 or at least about 0.6 mm 2 or at least about 0.75 mm 2 or from about 0.5 mm2 to about 2 mm 2 of the average bond site area (Average BondSite Area(N8 av )) and lists the increments for each 0.1 mm 2 within said range. The bond height, bond width, bond thickness, bond site area, and bond site area percentage, and their respective averages can be determined by the Bond Dimensions Test Method described herein.

[0051] The spacing between bond sites can be the same or can vary at different regions of the web. The web can include overlapping bond sites and / or an interleaved bond pattern. The bond sites can be arranged such that one or more rows and / or one or more columns of bond sites are formed, as can be seen, for example, Figures 2 - 4 in. The columns can extend longitudinally and the rows can extend laterally. Two laterally adjacent non-overlapping bond sites can have a minimum lateral bond distance (Minimum Lateral Bond Distance(N4)) of at least about 2.25 mm, or at least about 2.5 mm, or at least about 3 mm, or at least about 3.5 mm, or from about 2.25 mm to about 5 mm, or from about 2.5 mm to about 4 mm, or from about 3 mm to about 3.75 mm, and the increments for each 0.5 mm within each range are listed, and this is measured by the "Bond Dimensions Test Method" described herein. As Figure 3 shown, adjacent and non-overlapping means that when any overlapping bond sites (such as 104c) are ignored, there are no bond sites 104a, 104b between them in the measurement direction. The web can have an average minimum lateral bond distance (Average Minimum Lateral Bond Distance(N4 av )) of at least about 2.25 mm, or at least about 2.5 mm, or at least about 3 mm, or at least about 3.5 mm, or from about 2.25 mm to about 5 mm, or from about 2.5 mm to about 4 mm, or from about 3 mm to about 3.75 mm, and the increments for each 0.1 mm within each range are listed, and this is measured by the "Bond Dimensions TestMethod" described herein.

[0052] Two adjacent columns may have a minimum lateral column offset (Minimum Lateral Column Offset (N6)) of at least about 0.3 mm, or at least about 0.5 mm, or at least about 1 mm, or from about 0.3 mm to about 2 mm, or from about 0.5 mm to about 1.5 mm, with each 0.1 mm increment listed for each range. In addition or alternatively, the web may have an average minimum lateral column offset (Average Minimum Lateral Column Offset (N6 av )) with each 0.1 mm increment listed for each range.

[0053] Two longitudinally adjacent non - overlapping bond areas may have a minimum longitudinal bond distance (Minimum Longitudinal Bond Distance (N5)) of at least about 1.5 mm, or at least about 2 mm, or at least about 3 mm, or at least about 3.5 mm, or from about 1.4 mm to about 6 mm, or from about 2 mm to about 5 mm, or from about 3 mm to about 4.75 mm, with each 0.1 mm increment listed for each range. In addition or alternatively, the web may have an average minimum longitudinal bond distance (Average Minimum Longitudinal Bond Distance (N5 av )) with each 0.1 mm increment listed for each range.

[0054] Two adjacent rows may have a minimum longitudinal row offset (Minimum Longitudinal Row Offset (N7)) of at least about 1.05 mm, or at least about 1.1 mm, or from about 1 mm to about 2 mm, or from about 1.1 mm to about 1.6 mm, with each 0.5 mm increment listed for each range. In addition or alternatively, the web may have an average minimum longitudinal row offset (Average Minimum Longitudinal Row Offset (N7 av )) with each 0.5 mm increment listed for each range.

[0055] For the avoidance of doubt, the bond distance and the row or column spacing may be taken from different adjacent bonds. In other words, the nearest adjacent non-overlapping bond may not be in the nearest row or column. In the case of a staggered pattern as shown in Figure 3 , the Minimum Lateral Bond Distance (N4) is taken between the first bond 104a and the nearest non-overlapping bond 104b, while the Minimum Lateral Column Offset (N6) is taken on the lateral 104c between the first bond 104a and its nearest adjacent bond.

[0056] In addition, since multiple bonds may include overlapping portions, the distance may be measured "forward" within the scope of the present invention, as shown by N7 in, for example, Figure 4 , from the right edge of the first bond 104d to the left edge of the bond in the adjacent column 104e, or "backward", as shown by N7 in, for example, Figure 3 , from the right edge of the first bond 104d to the left edge of the bond in the adjacent column 104e (where the bonds overlap). Positive numbers will be used to represent the measurement, regardless of whether the bonds overlap or not.

[0057] According to the Tensile Test Method herein, a suitable non-crimp spunbond nonwoven web may have an average % strain at peak force of about 70% or less, or about 40% to about 60%, with each 1% increment listed for each range. In addition or alternatively, the nonwoven web may have an average normalized peak force of at least about 0.150 (N / cm) / (g / m 2 ), or at least about 0.160 (N / cm) / (g / m 2 ), or from about 0.160 (N / cm) / (g / m 2 ) to 0.230 (N / cm) / (g / m 2 ).

[0058] As shown in Figure 5 , the web 100 may include opposing surfaces 314, 316 further disclosed below. In certain embodiments, the web may include one or more surfaces having about 11 dB V 2 rms or less, or about 10 dB V 2 rms or less, or about 5 dB V 2 rms or less, or about 1 dB V 2rms to about 11 dB V 2 rms, or about 1.5 dB V 2 rms to about 6 dB V 2 rms, or about 2 dB V 2 rms to about 4 dB V 2 The average TS750 value in rms, with an increment of every 0.1 dB V for each range listed 2 In addition or alternatively, the web includes one or more surfaces having about 7 dB V 2 rms or less, or about 6.5 dB V 2 rms or less, or about 6.4 or less, or about 1 dB V 2 rms to about 7 dB V 2 rms, or about 4 dB V 2 rms to about 6.5 dB V 2 The average TS7 value in rms, with an increment of every 0.1 dB V for each range listed 2 Lower TS7 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, in other words, undesirable.

[0059] In some non - limiting examples, the nonwoven web 100 has a basis weight of about 25 gsm or less, or about 17 gsm or less, or about 14 gsm or less, or about 10 gsm to about 25 gsm.

[0060] Elastomeric laminate incorporating fiber web

[0061] Figure 5 An exemplary elastomeric laminate 310 including a non - crimp spunbond nonwoven web 100 is schematically shown. In Figure 6 the example shown, the ear tabs 30 of the absorbent article include an elastomeric laminate. It is also contemplated that other components of the absorbent article may include an elastomeric laminate, such as waistbands, tapes, and / or leg cuffs.

[0062] 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 - crimp spunbond fibers 103, which have any of the features described above and Figure 1C shown. Returning to Figure 5, the first nonwoven fibrous web 300 may include additional layers, such as a meltblown layer and / or a nanofiber layer. In a non-limiting example, the first nonwoven fibrous web 300 does not contain a carded and / or crimped spunbond fiber layer. The nonwoven fibrous web 300 may include a first outer surface 314 and a first inner surface 316. The first inner surface 316 is substantially opposite and faces the elastomeric layer 302. In certain embodiments, the non-crimped spunbond fiber nonwoven fibrous web 100 forms the outer surface 314.

[0063] The elastomeric layer may include 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., styrene 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., thermally fused elastomers, elastomeric adhesives, printed elastomers, or elastomers co-extruded onto another substrate), elastomeric nonwoven materials, scrims, and the like. The elastomeric materials may be formed from elastomeric polymers, including polymers comprising styrene derivatives, polyesters, polyurethanes, polyetherimides, polyolefins, combinations thereof; or any suitable known elastomers. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Pat. Nos. 8,618,350; 6,410,129; 7,819,853; 8,795,809; 7,806,883; 6,677,258, 9,834,667 and U.S. Patent Publication 2009 / 0258210. Commercially available elastomeric materials include KRATON (styrene 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), VISTAMAXX (homopolyolefins and random copolymers, and blends of random copolymers, available from Exxon Mobile, Spring, TX), VERSIFY (homopolyolefins and random copolymers, and blends of random copolymers, available from Dow Chemical Company, Midland, Michigan), TAFMER (polyolefin elastomer, available from Mitsui Chemicals), and INFUSE (olefin block copolymer, available from Dow Chemical, Midland Michigan).

[0064] 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 film 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 directions of the article. The elastomeric layer may have a width Y, such as, for example Figure 6 shown.( Figure 6 An ear tab 30 including an elastomeric laminate is shown.) In some embodiments, Y is at least about 10 mm less than the width W of the laminate. The elastomeric layer may have a length dimension that is the same as the length of the laminate along the entire width of the elastomeric layer, or may have a length dimension that is less than the length of the laminate at any point along the width of the second layer. In some embodiments, the elastomeric layer may have a basis weight of from about 5 gsm to about 150 gsm, or from about 10 gsm to about 100 gsm, or a basis weight less than about 150 gsm, with each 1 gsm increment listed for each range.

[0065] Similarly, as Figure 6 shown, the laminate may include an elastic region 306. The elastic region 306 is generally defined by the perimeter of the elastomeric material. In the elastic region, the laminate is elastically extensible. In some embodiments, for example when the ear tab 30 includes the laminate, the area of the elastic region is at least about 20% of the total area of the laminate, or from about 30% to about 80%, with each 5% increment listed for the range. In additional embodiments, Y (i.e., the maximum width of the elastomeric layer) is at least about 20% of the total width W of the laminate, or from about 25% to about 85%, or from about 35% to about 80%, with each 5% increment listed for each range. The laminate also includes one or more inelastic regions. In certain embodiments, the laminate includes a first inelastic region 308 that extends laterally outward from the proximal edge 38 and is adjacent to the elastic region 306 at the edge 307 of the first elastomeric material. The laminate may also include a second inelastic region 312 that may extend laterally inward from the distal 36 and may be adjacent to the elastic region 306 at the edge 309 of the second elastomeric material. The first inelastic region and the second inelastic region may be made of the same or different materials.

[0066] The elastomeric laminate may further include a second nonwoven fiber web 304. The elastomeric layer 302 may be sandwiched between the first nonwoven layer 300 and the second nonwoven layer 304. The second nonwoven fiber web may include one or more nonwoven layers 102, which may include a spunbond layer, a nanofiber layer, and / or a meltblown layer. The second nonwoven fiber web may include a non-crimp spunbond fiber web 100', which has any of the characteristics described above with respect to the non-crimp fiber web 100. Alternatively, the second nonwoven fiber web may not contain non-crimp spunbond fibers. In a non-limiting example, the second nonwoven fiber web 304 does not contain a carded and / or crimped spunbond fiber layer. The second nonwoven fiber web 304 may include a second outer surface 318 and a second inner surface 320. The second inner surface 320 is substantially opposite to and faces the elastomeric layer 302. In certain embodiments, the non-crimp spunbond fiber nonwoven fiber web 100 forms the outer surface 318.

[0067] In certain embodiments, the elastomeric laminate includes a gathered laminate, wherein during lamination, one of the layers is strained to a greater extent than the remaining layers. Thus, when the laminate is in a relaxed state, the layer with relatively poor extensibility (i.e., the nonwoven layer) will form a gather. In some embodiments, during lamination, at least a portion of the elastomeric layer is strained while one or more nonwoven fiber webs are in a relaxed state. The elastomeric layer can be stretched in one or more directions. Then, when the subsequently formed laminate is in a relaxed state, wrinkles are formed in the plurality of nonwoven fiber webs. 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 substrate after lamination, it will be oriented such that the laminate is stretchable and / or elastic in the lateral direction of the article. In another non-limiting example, the laminate is also stretchable and / or elastic in the longitudinal direction.

[0068] The laminate layers can 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.

[0069] In certain embodiments, according to the air permeability test method described herein, the elastomeric laminate 310 may have at least about 1 m 3 / m 2 / min, or about 1 m 3 / m 2 / min to about 125 m 3 / m 2 / min, or about 1 m 3 / m 2 / min to about 35 m 3 / m 2 / min air permeability value, with the increment per 1 m 3 / m 2 / min listed for each range.

[0070] In other embodiments, according to the tensile testing method herein, the elastomeric laminate may have an average breaking load of about 25 N or greater, or about 25 N to about 40 N. According to the tensile testing method herein, the laminate may have an average breaking load elongation of about 65 mm or greater, or about 70 mm or greater, or about 65 mm to about 85 mm, or about 70 mm to about 80 mm. Once the load exceeds a value of 10 N, the laminate may break within 50 mm, as Figure 8 shown.

[0071] In various embodiments, the elastomeric laminate may include one or more surfaces in the elastic region 306 having an average TS750 value of about 115 dB V 2 rms or less, or about 100 dB V 2 rms or less, or about 90 dB V 2 rms or less, or about 50 dB V 2 rms to about 115 dB V 2 rms, or about 60 dB V 2 rms to about 90 dB V 2 rms, with the increment per 1 dB V 2 rms listed for each range. The elastomeric laminate may include one or more surfaces in the inelastic regions 308, 312 having an average TS750 value of about 22 dB V2rms or less, or about 10 dB V 2 rms or less, or about 9 dB V 2 rms or less, or about 2 dB V 2 rms to about 22 dB V 2 rms, or about 6 dB V 2 rms to about 10 dB V 2 rms, with the increment per 1 dB V 2 rms listed for each range.

[0072] In addition or alternatively, the elastomeric laminate of the present invention may include one or more surfaces in the elastic region 306 having an average TS750 value of about 15 dB V 2 rms or less, or about 12 dB V 2 rms or less, or about 5 dB V 2 rms to about 15 dB V2 rms, or about 8 dB V 2 rms to about 12 dB V 2 The average TS7 value of rms, with an increment of each 1 dB V listed for each range 2 The elastomeric laminate of the present invention may include one or more surfaces in the inelastic region 308 having about 6 dB V or less according to the softness test method herein, or about 5.6 dBV 2 rms or less, or about 3 dB V 2 rms or less, or about 3 dB V 2 rms to about 6 dB V 2 rms, or about 4 dB V 2 rms to about 5.6 dB V 2 The average TS7 value of rms, with an increment of each 1 dB V listed for each range 2 The lower TS7 value and TS750 value indicate higher softness, which is highly desirable in absorbent articles. Consumers may find absorbent articles with high TS7 values and TS750 values uncomfortable and / or scratchy or, in other words, undesirable.

[0073] The first outer surface and / or the second outer surface may have any one of the TS7 and / or TS750 values disclosed herein. In various embodiments, the laminate does not contain a carded and / or crimped spunbond nonwoven fiber web.

[0074] Example

[0075] Table 1 below shows a comparison of nonwoven materials that can be used for the elastomeric laminate. Nonwoven material Example 1 includes a nonwoven material purchased from Avgol, USA under the trade name AVMN1073333001. The nonwoven material is made of polypropylene and additives and has an average basis weight of 17.2 ± 1 gsm as measured by the basis weight test method herein. The nonwoven material has an SMS structure, that is, it has three layers respectively: spunbond, meltblown, spunbond. The nonwoven material is thermally bonded and has a "diamond" shaped bonding pattern as Figure 2 shown. The bonding scale is listed in Table 1 below.

[0076] Nonwoven material Example 2 includes a nonwoven material purchased from Avgol, USA under the trade name AVMN1083134001. The nonwoven material is made of polypropylene and additives and has an average basis weight of 16.87 ± 0.3 gsm as measured by the basis weight test method herein. The nonwoven material has an SSS structure, that is, it has three layers respectively: spunbond, spunbond, spunbond. The nonwoven material is thermally bonded and has a Figure 3The "S"-shaped bonding pattern shown. The bonding scale is listed in Table 1 below.

[0077] Nonwoven material Example 3 comprises a nonwoven material purchased from Fitesa, Germany under the trade name SS6XX-99. The nonwoven material is made of polypropylene and additives and has an average basis weight of 16.2 ± 0.4 gsm as measured by the basis weight test method herein. The nonwoven material has an SSS structure, i.e., three layers respectively: spunbond, spunbond, spunbond. The nonwoven material is thermally bonded and has a "rod"-shaped bonding pattern as Figure 4 shown. The bonding scale is listed in Table 1 below.

[0078] Table 1: Nonwoven bond scale

[0079]

[0080] Table 2 and Figure 7 show a comparison of the tensile properties of the nonwoven material examples. As shown in Table 2 and Figure 7 it can be seen that, compared with the comparative nonwoven spunbond material examples, nonwoven material examples 2-3 have an average normalized peak force higher than 0.16 (N / cm) / (g / m 2 ).) and an average peak force strain % equal to or greater. Generally, such high normalized peak forces are difficult to obtain with softer spunbond nonwoven materials. Using a nonwoven web having the characteristics of nonwoven material example 2 and / or nonwoven material example 3 helps to deliver the desired elastic laminate properties for the comfort and conformability of absorbent articles.

[0081] Table 2: Nonwoven material tensile data

[0082] Example Average normalized peak force Average strain % at peak force Nonwoven material Example 1 <![CDATA[0.233±0.014N / cm / g / m 2 > 38.0 ± 1.0% strain Nonwoven material Example 2 <![CDATA[0.229±0.008N / cm / g / m 2 > 41.5 ± 3.1% strain Nonwoven material Example 3 <![CDATA[0.162±0.020N / cm / g / m 2 > 54.4 ± 6.3% strain

[0083] Example of ear tab laminate

[0084] Comparative laminate Example A comprises a first nonwoven material and a second nonwoven material, and an elastomeric film sandwiched between the first nonwoven material and the second nonwoven material. Each of the first nonwoven material and the second nonwoven material is nonwoven material Example 1 above, which has a width of approximately 250 mm. The elastomeric film is ElastiPro(TM) 4407 purchased from Clopay, USA and has a basis weight of 53.5 ± 1.2 gsm. The film has a width of 45 mm in the relaxed state. Using a ring rolling mill, with teeth having a pitch of 1.524 mm at 500 seconds -1The average strain rate pre-activates the membrane to 210% strain. Using a laminate preparation process, the pre-activated membrane is stretched to a total of 130% strain (i.e., 45 mm stretched to approximately 89 mm), which is described in U.S. Patent Application 15 / 674,625. The 7 mm lateral ends of the membrane are not stretched; only the 31 mm central portion is stretched to 75 mm. Due to the permanent deformation caused by the pre-activation and stretching steps, the membrane width increases by 2 - 4 mm. While stretching the membrane according to the description, use the bonding pattern as shown in Figure 2 and ultrasonically bond the first nonwoven material and the second nonwoven material to the membrane under an ultrasonic bonding pressure of 500 N. The first nonwoven web and the second nonwoven web are wider than the lateral width required to bond the membrane. The membrane is bonded to the outer lateral ends of the laminate, and the outer edge of the membrane is at least 25 mm from the corresponding outer edge of the nonwoven material, as measured laterally; thus creating inelastic regions 308, 312 (i.e., regions without the membrane) and an elastic region 306 (i.e., a region with the membrane) in the laminate. In both the inelastic and elastic regions, bond the laminate layers by ultrasonic bonding using the pattern as shown in Figure 6B , where Q is 0.7 mm 2 and represents the area of ultrasonic bonding, R is 2.5 mm and represents the lateral offset from bond center to bond center in adjacent longitudinal columns; S is 8 mm and represents the longitudinal pitch of adjacent non-overlapping ultrasonic bond portions along the longitudinal direction, T is 5 mm and represents the lateral pitch from center to center of adjacent non-overlapping ultrasonic bond portions along the lateral direction, and U is 4 mm and represents the longitudinal offset from center to center in adjacent lateral rows.

[0085] Prepare laminate Example 1 of the present invention in the same manner as Comparative Laminate Example A above, except that Nonwoven Example 2 is used as the first nonwoven material and the second nonwoven material.

[0086] Prepare laminate Example 2 of the present invention in the same manner as Comparative Laminate Example A above, except that Nonwoven Example 3 is used as the first nonwoven material and the second nonwoven material.

[0087] Cut each of the above exemplary tab laminates into samples having the shape of the dimensions detailed in Table 3 below. The dimensions are in Figure 6It is schematically shown and not drawn to scale. A die made of this shape is used to cut the samples. The samples are cut to have inelastic regions on both lateral sides in the elastic region. The samples are cut to have an inelastic region of at least about 10 mm, which is measured laterally inward from the outer edge 36. In each shape, the first lateral side 40 intersects the outer edge 36 at the first corner 37, and the second lateral side 42 intersects the inner edge 38 at the second corner 39. The longitudinal distance Loff between the corners indicates the position of the fastening system (i.e., towards the top of the tab, the middle of the tab, etc.).

[0088] Exemplary samples are tested using the tensile test method herein to determine their average breaking load and / or their average breaking elongation. In such tests, the outer lateral sides of the samples are mounted at position G1 in the top gripper, which is at a distance X as shown in Table 3 (which corresponds to the inner edge 52a of the fastening attachment bond 52 (see Figure 6A ). According to the tensile test method, the bottom gripper is mounted at position G2 with a gauge length of 55 mm.

[0089] Table 3: Laminate shape dimensions

[0090] In Table 3, the length is measured along a line perpendicular to the lateral centerline 43, and the width is measured along a line parallel to the lateral centerline.

[0091]

[0092] Laminate shapes are selected to provide the angles (α and β) commonly used in diaper tab applications. When testing the tabs under tensile conditions, higher α and β angles translate to higher stress enhancement (as described in the method below). Higher stress enhancement generally results in lower tab breaking strength.

[0093] The softness and tensile properties of the laminates are tested as shown in the table below. Table 4 shows a comparison of the softness values of exemplary nonwoven materials, and Tables 5 - 6 show a comparison of the softness values of exemplary laminates. The softness test herein is used to evaluate the softness of the nonwoven materials used in the laminates. The average TS7 value and TS750 value of the two surfaces of the nonwoven web are evaluated, as shown in Table 4. As shown in Table 4, the nonwoven material examples tend to have similar average TS7 values, but nonwoven material examples 2 and 3 have much lower average TS750 values compared to nonwoven material example 1.

[0094] Table 4: Nonwoven material softness data

[0095] Nonwoven material example Average TS7 Average TS750 Nonwoven material Example 1 Surface A 6.50±0.45 13.17±0.65 Nonwoven material Example 1 Surface B 6.56±0.24 12.02±0.46 Nonwoven material Example 2 Surface A 5.42±0.28 3.57±0.36 Nonwoven material Example 2 Surface B 6.37±0.25 3.76±0.35 Nonwoven material Example 3 Surface A 5.13±0.39 2.64±0.24 Nonwoven material Example 3 Surface B 6.78±0.31 3.80±0.46

[0096] Table 5-6 shows a comparison of the softness values of exemplary laminates. The softness of the laminate is evaluated in two different parts: the elastic part 306 and the inelastic part 308 (which consists of two laminated nonwoven materials and there is no elastic film between them). Each of Example 1 and Example 2 of the laminate of the present invention shows a lower average TS7 value and a significantly lower average TS750 value. The unique method of forming a stretch laminate by ultrasonic bonding can reduce the TS7 value, which is more significantly shown in Example 1 of the present invention. In addition, the ultrasonic bonding laminate forming process does not affect the trend of the TS750 value of the observed nonwoven material examples.

[0097] Table 5: Laminate film area softness data

[0098] Laminate (elastic region) TS7 TS750 Comparative laminate side A 14.08±2.19 123.33±24.38 Comparative laminate side B 17.38±2.54 121.21±19.23 Laminate 1 of the present invention side A 9.17±1.11 90.02±15.42 Laminate 1 of the present invention side B 9.22±0.78 61.63±3.14 Laminate 2 of the present invention side A 12.00±1.25 72.76±12.29 Laminate 2 of the present invention side B 14.56±0.49 75.04±10.16

[0099] Table 6: Laminate NW area softness data

[0100] Laminate (non - elastic region; nonwoven material only) TS7 TS750 Comparative laminate side A 5.89±0.52 28.52±2.38 Comparative laminate side B 6.45±0.43 25.72±2.68 Laminate 1 of the present invention side A 4.67±0.28 8.28±0.64 Laminate 1 of the present invention side B 4.48±0.54 8.28±0.64 Laminate 2 of the present invention side A 5.58±0.14 7.62±0.45 Laminate 2 of the present invention side B 5.96±0.24 7.01±1.11

[0101] The tensile properties of the laminate are evaluated in the above ear tab shape. When the ear tabs are used during the wearing of the absorbent article, an average strength (breaking load) higher than 25 N and an elongation at break (breaking load) greater than 40 mm are preferred. The high strength ensures that the ear tab laminate will not break during application. The high elongation at break indicates to the consumer that the absorbent article has sufficient tensile properties to provide the desired fit. As shown in Table 7 and Figure 8 shown, Comparative Laminate Example A delivers an average breaking load of 32.7 N and an average elongation at break greater than 60 mm required for absorbent article applications. However, the use of a softer nonwoven material in the laminate of the present invention improves the strength and / or the elongation at break. Laminate 1 of the present invention having a preferred softness delivers an excellent average breaking load of about 36.4 N and an average elongation at break greater than 70 mm. Example 2 of the laminate of the present invention exhibits an average breaking load of about 26.4 N while providing an extremely high elongation at break of about 80 mm. Importantly, all laminate examples were prepared under the same conditions.

[0102] Table 7: Laminate tensile data

[0103] Example Average breaking load Average breaking load elongation Comparative laminate 32.73±3.39N 63.16 ± 3.13 mm Laminate Example 1 (SB2’) 36.36±3.59N 70.80 ± 2.51 mm Laminate Example 2 (CD rod) 26.41±1.84N 79.54 ± 2.26 mm

[0104] Absorbent article

[0105] The absorbent article of the present invention can utilize the non-crimp spunbond fiber nonwoven web described herein in any suitable location. In certain embodiments, the nonwoven web comprising one or more non-crimp spunbond fiber layers is present in the ear tabs 30, waistband or side panels of the disposable article.

[0106] Figure 9 is a plan view of an exemplary non-limiting embodiment of an absorbent article 10 of the present invention in a flat, uncontracted state. The body-facing surface 115 of the absorbent article 10 faces the viewer. The absorbent article 10 includes a longitudinal centerline 90 and a lateral centerline 95.

[0107] The absorbent article 10 includes a chassis 20. The absorbent article 10 and chassis 20 are shown to have a first waist region 14, a second waist region 18 opposite the first waist region 14, and a crotch region 16 located between the first waist region 14 and the second waist region 18. The waist regions 14 and 18 generally include those portions of the absorbent article 10 that surround the waist of the wearer when worn. The waist regions 14 and 18 may include elastic members 55 so that they gather around the waist of the wearer to provide improved fit and restraint. The crotch region 16 is the portion of the absorbent article 10 that is generally positioned between the legs of the wearer when the absorbent article 10 is worn.

[0108] The outer periphery of the chassis 20 is defined by the longitudinal edges 12 and the waist edges (the first waist edge 13 in the first waist region 14 and the second waist edge 19 in the second waist region 18). The chassis 20 may have opposite longitudinal edges 12 oriented generally parallel to the longitudinal centerline 90. However, for better fit, the longitudinal edges 12 may be bent or angled to produce, for example, an "hourglass" shaped article when viewed in a plan view. The chassis 20 may have opposite lateral edges 13, 19 (i.e., the first waist edge 13 and the second waist edge 19) oriented generally parallel to the lateral centerline 95.

[0109] The chassis 20 may include a liquid permeable topsheet 24, a backsheet 26, and an absorbent core 28 between the topsheet 24 and the backsheet 26. The topsheet 24 may be joined to the core 28 and / or the backsheet 26. The backsheet 26 may be joined to the core 28 and / or the topsheet 24. It should be appreciated that other structures, elements, or substrates may also be positioned between the core 28 and the topsheet 24 and / or the backsheet 26. In some embodiments, an acquisition-distribution system 27 is disposed between the topsheet 24 and the absorbent core 28.

[0110] In certain embodiments, the chassis 20 comprises the main structure of the absorbent article 10, which together with other features added form a composite absorbent article structure. Although the top sheet 24, the back sheet 26 and the absorbent core 28 can be assembled in a variety of well-known configurations, the configuration of absorbent articles is generally described in the following patents: U.S. Patents 3,860,003, 5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and 6,004,306.

[0111] Top sheet :

[0112] The topsheet 24 is generally positionable on the absorbent article 10 to at least partially contact or be adjacent to a portion of the wearer. Suitable topsheets 24 can be made from a wide range of materials such as porous foams; reticulated foams; open-cell plastic films; or woven or non-woven fiber webs composed of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or combinations of natural and synthetic fibers. The topsheet 24 is generally compliant, feels soft, and is non-irritating to the wearer's skin. Typically, at least a portion of the topsheet 24 is liquid permeable to allow liquids to easily penetrate through the thickness of the topsheet 24. One topsheet 24 useful herein is available from BBA Fiberweb (Brentwood, TN) under the supplier code 055SLPV09U. The topsheet 24 can be open-celled.

[0113] As is well known in the art, any portion of the topsheet 24 can be coated with a lotion or skin care composition. Non-limiting examples of suitable lotions include those described in the following patents: U.S. Patents 5,607,760, 5,609,587; 5,635,191; and 5,643,588. The topsheet 24 can be fully or partially elasticized or can be shortened to provide interstitial space between the topsheet 24 and the core 28. Exemplary structures including elasticized or shortened topsheets are described in more detail in the following patents: U.S. Patents 4,892,536, 4,990,147; 5,037,416; and 5,269,775.

[0114] Absorbent core :

[0115] The absorbent core 28 can include a variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include comminuted wood pulp, which is generally referred to as airfelt creped cellulose wadding; meltblown polymers, including coformed meltblown polymers; chemically stiffened, modified or crosslinked cellulose fibers; tissue paper, including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any other known absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially free of cellulose and contains less than 10% by weight of cellulose fibers, less than 5% by weight of cellulose fibers, less than 1% by weight of cellulose fibers, no more than a non-significant amount of cellulose fibers or is free of cellulose fibers. It should be understood that a non-significant amount of cellulose material will not substantially affect at least one of the thinness, flexibility and absorbency of the portion of the absorbent core that is substantially free of cellulose. Among other beneficial effects, it is believed that when at least a portion of the absorbent core is substantially free of cellulose, that portion of the absorbent core is significantly thinner and more flexible than a similar absorbent core containing more than 10% by weight of cellulose fibers. The amount of absorbent material such as absorbent granular polymer material present in the absorbent core can vary, but in certain embodiments, the absorbent granular polymer material is present in the absorbent core in an amount greater than about 80% by weight of the absorbent core, or greater than about 85% by weight of the absorbent core, or greater than about 90% by weight of the absorbent core, or greater than about 95% by weight of the core. In some embodiments, the absorbent core can include one or more channels 29, where the channels are substantially free of absorbent granular polymer material. The channels 29 can extend longitudinally or laterally. The absorbent core can also include two or more channels. The channels can be straight, curved, angled or any feasible combination thereof. In a non-limiting example, two channels are disposed symmetrically about a longitudinal axis.

[0116] Exemplary absorbent structures used as the absorbent core 28 are described in the following patents: U.S. Patent Nos. 4,610,678, 4,673,402; 4,834,735; 4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; 5,397,316 and U.S. Patent Applications 13 / 491,642 and 15 / 232,901.

[0117] Back sheet :

[0118] The backsheet 26 is typically positioned such that it can be at least a portion of the garment-facing surface of the absorbent article 10. The backsheet 26 can be designed to prevent the exudates absorbed and contained within the absorbent article 10 from soiling articles, such as sheets and undergarments, that may come into contact with the absorbent article 10. In certain embodiments, the backsheet 26 is substantially water-impermeable. Suitable materials for the backsheet 26 include films such as those manufactured by Tredegar Industries Inc. (Terre Haute, IN) and sold under the trade names X15306, X10962, and X10964. Other suitable materials for the backsheet 26 can include breathable materials that allow vapor to escape from the absorbent article 10 while still preventing exudates from passing through the backsheet 26. Exemplary breathable materials can include materials such as woven fiber webs, nonwoven fiber webs, composite materials such as nonwoven fiber webs with a film coating, and microporous membranes such as those manufactured by Mitsui Toatsu Co. (Japan) under the name ESPOIR NO and by Exxon Chemical Co. (Bay City, TX) under the name EXXAIRE. A suitable breathable composite material containing a polymer blend is available from Clopay Corporation (Cincinnati, OH) under the name HYTREL blend P18-3097.

[0119] This breathable composite material is described in more detail in PCT application WO 95 / 16746 and U.S. Patent 5,865,823. Other breathable backsheets including nonwoven fiber webs and apertured formed films are described in U.S. Patent 5,571,096. Exemplary suitable backsheets are disclosed in U.S. Patent 6,107,537. Other suitable materials and / or manufacturing techniques can be used to provide a suitable backsheet 26, including but not limited to surface treatments, specific film selections and processing, specific filament selections and processing, etc.

[0120] The backsheet 26 can also be composed of more than one layer. The backsheet 26 can include an outer cover and an inner layer. The outer cover can be made of a soft nonwoven material. The inner layer can be made of a substantially liquid-impermeable film such as a polymer film. The outer cover and the inner layer can be joined together by an adhesive or any other suitable material or method. A particularly suitable outer cover is available from Corovin GmbH (Peine, Germany) under the supplier code A18AH0, and a particularly suitable inner layer is available from RKW Gronau GmbH (Gronau, Germany) under the supplier code PGBR4WPR. Although various backsheet configurations are envisioned herein, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention.

[0121] Ear tab / fastener :

[0122] Absorbent article 10 may include one or more ear flaps 30, which include, for example, a front ear flap disposed in the first waist region and / or a rear ear flap disposed in the second waist region. The ear flap 30 may be integral with the base structure or a discrete element joined to the base structure 20 at the base structure attachment bond 35, which attachment bond may join one or more layers of the ear flap to the base structure. The ear flap 30 may be extensible or elastic. The ear flap 30 may be formed from one or more of the following materials: nonwoven fiber webs, woven fiber webs, knitted fabrics, polymer films and elastomeric films, open-cell films, sponges, foams, scrims, or combinations and / or laminates of any of the foregoing materials.

[0123] As Figure 6 shown, the ear flap may include a distal edge 36 and a proximal edge 38. The distal edge 36 is the free distal longitudinal edge of the ear flap. The proximal edge 38 is generally opposite the distal edge 36. When the ear flap is joined to the base structure, the proximal edge 38 is joined to or overlaps the base structure, or is a side defined by a line extending from the longitudinal side 12 in the widest region of the crotch area and, in the case where the ear flap is integral, extending parallel to the longitudinal centerline. The ear flap may also include a first lateral edge 40 and an opposite second lateral edge 42. The ear flap may also include a maximum width W extending between the distal edge and the proximal edge and a length extending between the first lateral edge and the second lateral edge. In some cases, the length may vary at a portion along the width of the ear flap, as Figure 6 shown. For example, the ear flap may include a maximum length and slope (or in other words, variation) along its proximal edge 38 such that the ear flap has a minimum length at its distal edge 36.

[0124] In some embodiments, the ear flap 30 may include an elastomer such that the ear flap is stretchable. In certain embodiments, the ear flap 30 may be formed from a stretch laminate having an elastomeric layer, which also causes the ear flap to be stretchable. The ear flap 30 may be laterally extensible. In some embodiments, the ear flap is laterally elastic when stretched. In additional embodiments, the ear flap 30 may be more extensible laterally than longitudinally. As an alternative, the ear flap may be more extensible longitudinally than laterally.

[0125] In some embodiments, the ear flap includes a laminate 310 having any of the above characteristics.

[0126] Absorbent article 10 may also include a fastening system 50. When fastened, the fastening system 50 interconnects the first waist region 14 and the back waist region 18 so as to obtain a waist circumference that can surround the wearer during the wearing of the absorbent article 10. The fastening system 50 may include fastening elements such as tape tabs, hook-and-loop fastening components, interlocking fasteners such as tabs and slits, buckles, buttons, snaps, and / or hermaphroditic fastening components, but any other known fastening devices are generally also acceptable. The absorbent article may also include a landing zone to which the fastening element can be engaged and / or a release strip to protect the fastening element from being violated before use. Some exemplary surface fastening systems are disclosed in the following patents: U.S. Patent Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and 5,221,274. An exemplary interlocking fastening system is disclosed in U.S. Patent No. 6,432,098. In some embodiments, the fastening system 50 and / or the fastening element is foldable.

[0127] The fastening system 50 can be joined to any suitable part of the article 10 by any suitable means. In some embodiments, the fastening system is joined to the ear tab 30 at the fastening attachment bond 52. The fastening system can be joined to the ear tab between the layers, or to the outer surface of the ear tab, or to the body-facing surface or the garment-facing surface of the ear tab. In one non-limiting example, the fastening system 50 and / or the fastening element is ultrasonically bonded to the ear tab 30. The fastening attachment bond 52 has a maximum length, which is measured parallel to the longitudinal centerline. The maximum length can be about 30 mm or less, or about 28 mm or less, or about 20 mm to about 35 mm, with each 1 mm increment listed within this range. The fastening attachment bond can join the fastening system to one or more layers of the ear tab.

[0128] The fastening system 50 can be joined to the ear tab at the distal side 36. One or more nonwoven layers 300, 304 can be folded at the fastening attachment bond and / or at the distal side. The fastening system can be disposed in the second inelastic region 312. In additional embodiments, the fastening system 50 is joined in the elastic region 306 of the ear tab. Joining the fastening system to the ear tab in the elastic region 306 improves the overall strength of the ear tab / fastening system combination during use and / or application.

[0129] Leg cuff system :

[0130] Back to Figure 9, the absorbent article 10 may include a leg cuff system 70 attached to the substrate 20, which may include one or more cuffs 71. The leg cuff system may include a pair of barrier leg cuffs 72. Each barrier leg cuff may be formed from a piece of material that is bonded to the absorbent article so that it can extend upward from the wearer-facing surface of the absorbent article and provide improved containment of fluids and other bodily exudates near the junction of the wearer's torso and legs. The barrier leg cuffs are defined by the proximal edges and free end edges 75 that are directly or indirectly joined to the topsheet 24 and / or the backsheet 26, which are intended to contact the wearer's skin and form a seal. In some embodiments, the free end edge 75 includes a folded edge. The barrier leg cuffs 72 extend at least partially on opposite sides of the longitudinal centerline 90 between the front waist edge 13 and the back waist edge 19 of the absorbent article and are present at least in the crotch region. The barrier leg cuffs may be joined to the substrate of the article at the proximal edge by a bond that may be made by gluing, heat-sealing, or a combination of other suitable bonding processes.

[0131] The barrier leg cuffs may be integral with the topsheet 24 or the backsheet 26, or may be separate materials joined to the substrate of the article. Each barrier leg cuff 72 may include one, two, or more elastic elements 55 near the free end edge 75 to provide a better seal.

[0132] In addition to the barrier leg cuffs 72, the article may also include a cuff 76 that is joined to the substrate of the absorbent article, specifically to the topsheet 24 and / or the backsheet 26, and is placed externally relative to the barrier leg cuffs 72. The cuff 76 may provide a better seal around the wearer's thigh. The cuff may include a proximal edge and a free end edge 77. The free end edge 77 may include a folded edge. Each cuff may include one or more elastic elements 55 between the topsheet 24 and the backsheet 26 in the leg opening region of the substrate of the absorbent article. All or a portion of the barrier leg cuffs and / or the cuffs may be treated with a lotion or another skin care composition.

[0133] In additional embodiments, the leg cuff system includes a barrier leg cuff that is integral with the cuff. Suitable leg cuff systems that may be part of the absorbent article are disclosed in U.S. Patent Applications 62 / 134,622, 14 / 077,708; U.S. Patent 8,939,957; 3,860,003; 7,435,243; 8,062,279.

[0134] Elastic waist feature

[0135] The absorbent article 10 may include at least one elastic waist feature 80 that helps provide improved fit and containment, such as Figure 9As shown. The elastic waist feature 80 is generally intended to stretch and contract to dynamically conform to the wearer's waist. The elasticized waist feature includes a waistband, a waist hoop having a pocket formed by a portion of the waist feature 80 that is detached from the base structure 20, and a waist panel designed to fit snugly around the wearer's abdomen. Non-limiting examples of elasticized waist features are disclosed in U.S. Patent Applications 13 / 490,543; 14 / 533,472; and 62 / 134,622. The waist feature 80 may be joined to the base structure 20 in the first waist region 14 and / or the second waist region 18. The waist feature may be used with the tabs 30 to provide the desired stretch and flexibility for a proper fit of the article on the wearer.

[0136] Package

[0137] An absorbent article comprising the non-crimp spunbonded fiber nonwoven web or laminate of the present invention may be placed in a package. The package may comprise a polymeric film and / or other materials. Graphics or markings related to the characteristics of the absorbent article may be formed on, located on, and / or disposed on an outer portion of the package. Each package may include one or more absorbent articles. The absorbent articles may be stacked under compression to reduce the size or height of the package while each package still provides a sufficient amount of absorbent articles. By encapsulating the absorbent articles under compression, a caregiver can easily handle and store the package, and at the same time, it also provides savings in distribution for the manufacturer due to the size of the package.

[0138] Thus, according to the "stack height in pouch test" described herein, a package of the absorbent articles of the present disclosure may have a "stack height in pouch" of less than about 110 mm, less than about 105 mm, less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, less than about 74 mm, less than about 72 mm, or less than about 70 mm, specifically listing all 0.1 mm increments within the specified range and all ranges formed therein or formed therefrom. Alternatively, according to the "stack height in pouch test" described herein, a package of the absorbent articles of the present disclosure may have a "stack height in pouch" of from about 70 mm to about 110 mm, from about 70 mm to about 105 mm, from about 70 mm to about 100 mm, from about 70 mm to about 95 mm, from about 70 mm to about 90 mm, from about 70 mm to about 85 mm, from about 72 mm to about 80 mm, or from about 74 mm to about 78 mm, specifically listing all 0.1 mm increments within the specified range and all ranges formed therein or formed therefrom.

[0139] Figure 10An exemplary package 1000 including a plurality of absorbent articles 1004 is shown. The package 1000 defines an internal space 1002 in which the plurality of absorbent articles 1004 are located. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

[0140] Combination

[0141] A. An absorbent article comprising:

[0142] A first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region;

[0143] A chassis including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and

[0144] Ears attached to the chassis, and the ears comprising:

[0145] A laminate including a first nonwoven material, a second nonwoven material, and an elastomeric material sandwiched between the first nonwoven material and the second nonwoven material, wherein the laminate further includes a plurality of ultrasonic bonds; and wherein the first nonwoven material includes an outer surface having an average TS750 value of 5 dB V 2 rms or less.

[0146] B. The absorbent article according to paragraph A, wherein the laminate includes a first inelastic region and an elastic region, wherein the first inelastic region does not contain the elastomeric material, and wherein the outer surface of the first nonwoven material in the elastic region has an average TS7 value of 12 dB V 2 rms or less.

[0147] C. The absorbent article according to paragraph A or paragraph B, wherein the laminate includes a first inelastic region and an elastic region, wherein the first inelastic region does not contain the elastomeric material, and wherein the outer surface of the first nonwoven material in the elastic region has an average TS750 value of 100 dB V 2 rms or less.

[0148] D. The absorbent article according to any one of the preceding paragraphs, wherein the laminate includes a first inelastic region and an elastic region, wherein the first inelastic region does not contain the elastomeric material, and wherein the outer surface of the first nonwoven material in the first inelastic region has an average TS750 value of 10 dB V 2 rms or less.

[0149] E. The absorbent article according to any one of the preceding paragraphs, wherein the laminate has an average breaking load of 25 N or greater.

[0150] F. The absorbent article according to the preceding paragraph, wherein the first nonwoven material and / or the second nonwoven material comprises a spunbond non-crimp fiber nonwoven material.

[0151] G. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material and / or the second nonwoven material comprises an average normalized peak force of at least 0.160 (N / cm) / (g / m2).

[0152] H. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material and / or the second nonwoven material has an average lateral strain % at peak force of 60% or less.

[0153] I. The absorbent article according to paragraph H, wherein the average lateral strain % at peak force is 40% or greater.

[0154] J. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material and / or the second nonwoven material has an average bonded area of about 12% or less.

[0155] K. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material and / or the second nonwoven material has an average bonded major dimension of at least 1.25 mm.

[0156] L. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material and / or the second nonwoven material has a bonded site area of 0.5 mm 2 or greater.

[0157] M. The absorbent article according to any one of the preceding paragraphs, the second nonwoven material comprising a second outer surface having an average TS750 value of 5 dbV 2 rms or less.

[0158] N. The absorbent article according to any one of the preceding paragraphs, wherein the first nonwoven material does not contain crimped fibers.

[0159] O. The absorbent article according to the preceding paragraph, wherein the first nonwoven material has an average bonded width of 1.25 mm or greater.

[0160] P. The absorbent article according to the preceding paragraph, wherein the first nonwoven material has an average bonded height of 1.25 mm or greater.

[0161] Q. The absorbent article according to the preceding paragraph, wherein the first nonwoven material has 5 dbV 2An average TS750 value of rms or less.

[0162] Test method

[0163] Bond scale test method

[0164] Perform nonwoven material bond shape measurements on reflected light microscopic images generated using a stereoscopic optical microscope (such as a Zeiss V20 stereoscope) and an attached camera (such as a Carl Zeiss AxioCam MRc5). Measurements are made using Image Pro Plus software (version 7.0.0.591, Media Cybernetics, USA), which is calibrated relative to a scale placed within the image when the image is acquired.

[0165] Sample preparation and test method

[0166] For nonwoven materials, test samples are prepared by cutting a square sample of approximately 6.5 cm (longitudinal) × 3.5 cm (lateral) from the nonwoven web. For laminates, samples can be collected from areas where there are no wrinkles and the nonwoven material surface is flat, such as the inelastic region in the stretch tab construction disclosed above. It should be noted to distinguish the nonwoven thermal bond pattern from ultrasonic bond patterns or other forms of layer-to-layer lamination patterns (e.g., adhesive patterns). If larger samples are not available, smaller samples with one repeat of the nonwoven bond pattern can be used. These samples are Au-coated (film deposition of ~700 Å) in a sputter coater (such as a Denton Desk V) to give greater contrast to the bond sites. Images are acquired with a horizontal field width of 27.3 mm and a vertical field width of 19.4 mm. A scale is placed parallel to the MD direction in each image. All measurements except for the bond site area and the percentage of bond area are measured in the Image Pro Plus software using an online tool; the bond site area and the percentage of bond area are measured using the irregular area tool in the Image Pro Plus software. Figures 2 - 4 The following dimensions are shown, all measured to an accuracy of 0.01 mm:

[0167] Bond width (N1) – The distance between the lateral ends of a single bond measured laterally;

[0168] Bond height (N2) – The distance between the longitudinal ends of a single bond measured longitudinally;

[0169] Bond thickness (N3) - The maximum lateral thickness of a single bond;

[0170] Minimum lateral bonding distance (N4) – The minimum lateral distance between the lateral edges of two laterally adjacent non-overlapping bonding portions

[0171] Minimum longitudinal bonding distance (N5) – The minimum longitudinal distance between the longitudinal edges of two longitudinally adjacent non-overlapping bonding portions in the longitudinal direction

[0172] Minimum lateral row offset (N6) - The minimum lateral distance between two laterally adjacent rows measured between the edges of the rows

[0173] Minimum longitudinal column offset (N7) - The minimum longitudinal distance between two longitudinally adjacent columns measured between the edges of the columns

[0174] Bonding site area (N8), which is the two-dimensional area of a single bonding portion

[0175] The distances (N4, N5, N6, and N7) are measured between the closest edges of the corresponding bonding portions

[0176] Bonding area percentage: Identify the pattern of a single repeating bonding shape and the area between them, and magnify the image so that the area larger than at least one repeating pattern fills the field of view. In Image Pro Plus, draw a rectangle circumscribing the repeating pattern. Calculate and record the area of the rectangle to an accuracy of 0.01 mm 2 . Then, using the region area tool, trace each bonding site / shape. Calculate the bonding area percentage as follows

[0177]

[0178] A total of three measurements are made on one image, and the arithmetic mean of the three measurements of each parameter is recorded: average bonding area %, average bonding width (N1 av ), average bonding height (N2 av ), average bonding thickness (N3 av ), average maximum lateral bonding distance (N4 av ), average maximum longitudinal bonding distance (N5 av ), average minimum lateral row offset (N6 av ), average minimum longitudinal column offset (N7 av ), and average bonding site area (N8 av ). If the sample is not large enough or three good measurements of each parameter from one sample cannot be made, then three different samples, each having a repeating bonding pattern, should be used. If a sample wider than one repeating bonding pattern cannot be obtained, then multiple samples should be used to identify the repeating bonding pattern and measurements should be made as described above

[0179] Tensile test method

[0180] Tensile testing is used to measure the strength of a sample at a relatively high strain rate representative of product application. The method uses a suitable tensile tester, such as an MTS 810 from MTS Systems Corp., Eden Prairie, Minn., or equivalent, equipped with a servo-hydraulic actuator that can advance at a speed exceeding 5 m / s after a travel of 28 mm and approach 6 m / s after a stroke of 40 mm. The tensile tester is equipped with a 50-pound load cell (e.g., a load cell with product code 9712B50 (50 pounds) from Kistler North America, Amherst, N.Y.), and a signal conditioner with a dual-mode amplifier (e.g., a signal conditioner with product code 5010 from Kistler North America). As Figure 11 and 12 shown, the gripping members are applied to hold the sample during tensile testing. ( Figure 12 is Figure 11 a side view of one of the grippers in , which has material 505 therein to prevent slippage.) The opposing gripping members 500 may have the same or different widths as the specified width.

[0181] (a) Gripper

[0182] The wire gripping members 500 are selected to provide a well-defined gauge length and to avoid undue slippage. The sample is positioned such that it has minimal slack between the gripping members. The apex 507 of the gripping members 500 is polished to provide good gauge length definition while avoiding damaging or cutting the sample. The apex is polished to provide a radius in the range of 0.5 - 1.0 mm. A portion of one or both of the gripping members 500 may be configured to include a material 505 (e.g., a sheet of urethane or neoprene having a Shore hardness A between 50 and 70) that reduces the tendency of the sample to slide, as Figure 12 shown. Unless otherwise specified, six-inch-wide top and bottom gripping members are used to hold the sample.

[0183] (b) Tensile test of laminate or ear tab sample

[0184] Lug laminates are generally bonded to the underlying structure via thermal bonding or adhesive bonding or similar bonding. The lug should be separated from the underlying structure in a manner that leaves the lug undamaged and does not alter the properties of the lug. If the underlying structure is bonded too strongly, the portion of the underlying structure that joins the lug should be cut within the underlying structure material without damaging the lug. A fold-over fastening system (e.g., a peel strip covering a fastening element) should be unfolded.

[0185] The sample is clamped in the top clamp at the first clamping position G1, which is the inner edge 52a of the fastening attachment bond 52 (see Figure 6A ). The clamping line G1 remains parallel to the longitudinal centerline of the product. If the fastening attachment bond is angled, the sample is clamped at the center of the bonding area, and the clamping line is kept parallel to the longitudinal centerline of the product center. The width of the top clamp should be equal to the maximum length (L1) of the fastening attachment bond 52 measured parallel to the longitudinal centerline of the article. If, at the G1 position, the length of the sample is the same as the maximum length of the fastening attachment bond, any clamping width greater than the length of the sample at G1 can be used. The sample is mounted and suspended on the top clamp. The opposite edges 38 of the sample are mounted in the bottom clamp in a slack state. The bottom clamping position G2 is adjusted so that the sample is clamped at the outer edge 35b of the base structure bond. If the base structure bond is curved, the sample is clamped at the outer edge of the outermost bond. The bottom clamp is larger than the lug length at the second clamping position G2. The top clamp and the bottom clamp are parallel to each other.

[0186] The sample is tested as follows: Using a ruler, measure the vertical distance (perpendicular to the clamping line) from the first clamping position G1 to the second clamping position G2, making the measurement 0.1 mm, and use it as the gauge length for the test. The sample is tested at a test speed that provides a strain rate of 9.1 sec -1 The test speed in mm / sec is calculated by multiplying 9.1 sec -1 by the gauge length (in mm). Before testing, place a 5 mm slack sample between the clamps.

[0187] For independent laminates, cut the samples to the dimensions outlined in Table 3, except as listed in this paragraph. The width Y of the film remains as provided in the laminate. If the film width Y is less than W, maintain the X and Z distances as shown in Table 3. If the X and Z dimensions cannot be maintained, cut the sample into the shape shown in Table 3 and center the film. When testing the sample, the clamping line G1 still remains at a distance X. Determine the dimension Z based on the X and Y dimensions. If the film width Y is the same as W, G1 remains at the X distance as shown in Table 3. As described above, test the laminate at a gauge length of 55 mm and a test speed of 500 mm / sec.

[0188] Stretch each sample to break. During the test, one of the clamps remains stationary and the opposite clamp is moved. The force and actuator displacement data generated during the test are recorded using a MOOG SmarTEST ONE STO03014-205 independent controller, and the data acquisition frequency is set to 10 kHz. The maximum value of the resulting load data can be expressed as the breaking load in Newtons. For example, a total of five (5) samples are stretched. Record the average breaking load, average breaking load elongation, and standard deviation of at least 4 samples. If the recorded standard deviation is higher than 15%, run a new set of five samples.

[0189] (c) Tensile test of sample from nonwoven fiber web

[0190] Carefully cut a sample of the given nonwoven fibrous web measuring 16.8 mm (along the lateral direction of the fibrous web) by 127 mm (along the longitudinal direction of the fibrous web) from the fibrous web. For using the formula below, the sample length is 16.8 mm and the sample width is 127 mm. The sample is tested as follows: The gauge length of the vertical distance from the first clamping position to the second clamping position (i.e., the distance between the clamps) is 10 mm, and it is measured to an accuracy of 0.1 mm using a scale. The sample is tested at a test speed that provides a chuck displacement speed of approximately 6 m / s. Before the test, a 5-mm slack sample is placed between the clamps. The sample is placed between the clamps 500 such that the lateral side of the sample will elongate during the test.

[0191] Stretch each sample until it ruptures (i.e., the post-peak force correspondingly reaches less than 10% of the peak force). During the test, one of the clamps remains stationary and the opposite clamp is moved. The force and actuator displacement data generated during the test are recorded using a MOOG SmarTEST ONE STO03014-205 independent controller, and the data acquisition frequency is set to 10 kHz. For example, a total of five (5) samples are stretched. Using the following formula, the raw data of the length (elongation) and load (force) obtained from the tensiometer are smoothed using a 5-point simple moving average. The first moving average data point is the arithmetic mean of the raw data points 1 to 5, and the second data point is the arithmetic mean of the raw data points from 2 to 6. The moving average data table is used for subsequent calculations.

[0192]

[0193] To minimize the effect of the basis weight of each tested fibrous web sample, each sample curve (moving average data curve) is normalized for the basis weight of the tested sample (i.e., the value of the applied force is divided by the value of the total basis weight of the tested fibrous web sample), using the following formula:

[0194]

[0195] The strain of each sample is reported in % strain on the x-axis, while the force applied to each sample (from the moving average table) is reported in normalized force (N / cm) / (g / m 2 ) on the y-axis. % strain is calculated using the following formula from the length L between the grip lines and the initial gauge length L 0 as follows:

[0196]

[0197] Record the average normalized peak force (N / cm) / (g / m 2 ), average peak % strain, and standard deviation for at least 3 samples. If the recorded standard deviation is higher than 20%, then run a new set of four samples. Define the peak as the maximum force value following a substantial drop in the subsequent force. Define the break as the point where the material breaks or ruptures and the force rapidly drops to zero. Peak % strain is defined as the % strain at the maximum force.

[0198] Basis weight test method

[0199] Weigh each sample using a digital balance within ±0.1 mg. Measure the length and width of the sample using a digital vernier caliper or equivalent within ±0.1 mm. All tests are conducted at 22 ± 2 °C and 50 ± 10% relative humidity. Calculate the basis weight using the formula below.

[0200]

[0201] To calculate the basis weight of the substrate, use a total of 3 straight samples of at least 10 mm × 25 mm.

[0202] Record the average basis weight and standard deviation.

[0203] Obtain nonwoven samples from the tabs as follows. Samples should be taken from areas without additional materials (i.e., only nonwoven materials). Separate each nonwoven layer from the other layers of the tab without damaging or tearing the nonwoven layer. If a continuous nonwoven material covers the outer and inner inelastic regions of the tab, then the nonwoven material is separated from the inelastic regions and used as a sample. If the nonwoven layer is not separable from other tab layers, then collect samples from the outer inelastic region of the tab. If the outer inelastic region is smaller than the specified sample size or has additional materials (other than the nonwoven layer), and if the inner inelastic region has the same nonwoven material as the outer inelastic region, then collect samples from the inner inelastic region (nonwoven layer or combination of nonwoven layers). If the nonwoven layers in the inelastic regions are the same and / or not separable, then divide the calculated sample basis weight by the number of nonwoven layers to obtain the basis weight of a single nonwoven material.

[0204] Hysteresis test method

[0205] Hysteresis testing can be used for various specified strain values. "Hysteresis testing" makes use of a commercial tensile tester connected to a computer through an interface (e.g., from Instron Engineering Corp. (Canton, MA), SINTECH-MTS Systems Corporation (Eden Prairie, MN), or equivalents). The computer is used to control the test speed and other test parameters, and is used to collect, calculate, and report the data. These tests are conducted under laboratory conditions of 23°C ± 2°C and 50% ± 2% relative humidity. Prior to testing, the samples are conditioned for 24 hours.

[0206] Cut out samples with dimensions of 10 mm in the expected tensile direction of the laminate and 25.4 mm in the direction perpendicular to the expected tensile direction of the laminate. Samples are collected from the inelastic or elastic regions of the laminate (i.e., the samples do not cross into both the inelastic and elastic regions).

[0207] Test plan

[0208] 1. Select appropriate grips and load cells. The grips must have a flat surface and must be wide enough to grip the sample along its full width. In addition, the grips should also provide sufficient force and a suitable surface to ensure that the sample does not slip during testing. Select a load cell such that the tensile response of the sample being tested is between 25% and 75% of the range of the load cell being used.

[0209] 2. Calibrate the tester according to the manufacturer's instructions.

[0210] 3. Set the distance between the grips (gage length) to 7 mm.

[0211] 4. Place the sample in the flat surface of the grips such that the uniform width is along the direction perpendicular to the gage length direction. Fix the sample in the upper grip so that the sample hangs loosely, and then close the lower grip. Set the slack preload to 5 grams-force. This means that when the slack is removed with a force of 5 grams-force (at a constant chuck speed of 13 mm / min), data collection begins. Calculate the strain based on the adjusted gage length (l ini ), which is the length of the sample between the grips of the tensile tester at a force of 5 grams-force. Take this adjusted gage length as the initial sample length, and it corresponds to 0% strain. In this test, the percentage strain at any point is defined as the change in length relative to the adjusted gage length divided by the adjusted gage length, multiplied by 100.

[0212] 5(a) First cycle loading: The sample was pulled to 100% strain at a constant grip speed of 70 mm / min. The tensile sample length between the grips was reported as l max .

[0213] 5(b) First cycle unloading: The sample was held at 100% strain for 30 seconds and then the grips were returned to their starting position (0% strain or initial sample length l ini ) at a constant grip speed of 70 mm / min. The sample was held at zero strain for 1 minute.

[0214] 5(c) Second cycle loading: The sample was pulled to 100% strain at a constant grip speed of 70 mm / min.

[0215] 5(d) Second cycle unloading: Next, the sample was held at 100% strain for 30 seconds and then the grips were returned to their starting position (i.e., 0% strain) at a constant grip speed of 70 mm / min.

[0216] During the test, the computer data system recorded the force applied to the sample as a function of the applied strain. From the resulting data, the following quantities were reported.

[0217] i. The sample length (l ini ) between the grips at a relaxation preload of 5 grams force, accurate to 0.001 mm.

[0218] ii. The sample length (l max ) between the grips on the first cycle at 100% strain, accurate to 0.001 mm.

[0219] iii. The sample length (l ext ) between the grips at a second cycle load force of 7 grams force, accurate to 0.001 mm.

[0220] iv. The permanent deformation rate, which is defined as (l ext - l ini ) / (l max - l ini ) * 100%, accurate to 0.01%.

[0221] The test was repeated for six independent samples and the mean and standard deviation were reported.

[0222] Softness test method

[0223] The TS7 and TS750 values are measured using an EMTEC Tissue Softness Analyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany) connected to a computer running Emtec TSA software (version 3.19 or equivalent). According to Emtec, the TS7 value is related to the actual material softness, while the TS750 value is related to the felt smoothness / roughness of the material. The Emtec TSA includes a rotor with a vertical blade that rotates on the test sample at a defined and calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. The contact between the vertical blade and the test piece generates vibrations that produce sound, which is recorded by a microphone inside the instrument. The recorded sound file is then analyzed by the Emtec TSA software.

[0224] Sample preparation

[0225] Test samples are prepared by cutting square or circular samples from the finished product. The test samples are cut to dimensions of approximately 90 mm in length and width (or diameter if circular) and no greater than approximately 120 mm. If the finished product has discrete sections of elastic regions (i.e., the elastic regions are shorter than the nonwoven top sheet in one or more dimensions), then a set of straight samples with a length of 76 mm ± 3 mm in the main tensile direction and a width of 100 mm ± 3 mm in the perpendicular direction are cut from the product component, and the elastic region is centered within the straight sample. The test samples are selected to avoid creases or folds within the test area. Eight substantially similar replicate samples are prepared for testing. All samples are equilibrated for at least 1 hour under TAPPI standard temperature and relative humidity conditions (23°C ± 2°C and 50% ± 2%), and the TSA test is also conducted under TAPPI conditions.

[0226] Test procedure

[0227] Calibrate the instrument using the 1 - point calibration method of the Emtec reference standard (“ref.2 sample”) according to the manufacturer's instructions. If these reference samples are no longer available, use the appropriate reference samples provided by the manufacturer. Calibrate the instrument according to the manufacturer's recommendations and instructions such that the results are comparable to those obtained when using the 1 - point calibration method of the Emtec reference standard (“ref.2 sample”).

[0228] Install the test sample into the instrument and ensure that the sample is correctly clamped into the TSA instrument with its first surface facing up. For samples with discrete portions having an elastic region, ensure that the elastic region is centered under the Emtec vertical blade and then perform the test according to the manufacturer's instructions. After completion, the software will display the values of TS7 and TS750. Record each of these values to an accuracy of 0.01 dB V 2 rms. Then remove the test strip from the instrument and discard it. This test is performed on the first surface of four replicate samples and then subsequently on the second surface of the other four replicate samples.

[0229] Average the TS7 and TS750 values of the four test results from the first surface (using a simple numerical average); also average the TS7 and TS750 values of the four test results from the second surface. Report the average of each of the TS7 and TS750 for the first and second surfaces on a particular test sample to an accuracy of 0.01 dB V 2 rms.

[0230] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, each such dimension is intended to mean the recited value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0231] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or for which it claims benefit, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone or in any combination with any one or more other references anticipates, suggests, or discloses any such invention. Further, when any meaning or definition of a term in this invention conflicts with the same term's meaning or definition in a document incorporated by reference, the meaning or definition assigned to the term in this invention shall govern.

[0232] Although specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that many other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications that fall within the scope of the invention be covered by the appended claims.

Claims

1. An absorbent article, comprising: a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region; a base structure including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and ear tabs joined to the base structure, and the ear tabs comprising: a laminate including a first spunbond nonwoven material and an elastomeric material, wherein the laminate further includes a plurality of ultrasonic bond sites; and The first spunbond nonwoven material includes a plurality of layers bonded together and has an average bond area of 12% or less and an average normalized peak force of at least 0.160 (N / cm) / (g / m 2 ). wherein the first spunbond nonwoven material has an average bond major dimension of at least 1.25 mm, wherein the laminate has an average breaking load of 25 N or greater, and wherein the first spunbond nonwoven material has a bonded area of 0.5 mm 2 or greater, the first spunbond nonwoven material comprises a spunbonded non-crimp fiber nonwoven material.

2. The absorbent article according to claim 1, wherein the first spunbond nonwoven material does not contain crimped fibers.

3. The absorbent article according to claim 1, wherein the first spunbond nonwoven material comprises an outer surface having an average TS750 value of 5 dB V 2 rms or less.

4. The absorbent article according to claim 1, wherein the first spunbond nonwoven material has an average strain % at peak force of 60% or less.

5. The absorbent article according to claim 1, the absorbent article including a second nonwoven material, wherein the elastomeric material is sandwiched between the first spunbond nonwoven material and the second nonwoven material.

6. The absorbent article according to claim 5, wherein the second nonwoven material comprises a second outer surface having an average TS750 value of 5 dB V 2 rms or less.

7. The absorbent article according to claim 5, wherein the second nonwoven material includes a non-crimp fiber nonwoven material.

8. The absorbent article according to claim 5, wherein the second nonwoven material includes a spunbond nonwoven material.

9. The absorbent article according to claim 1, wherein the laminate includes a first inelastic region and an elastic region, wherein the first inelastic region does not contain the elastomeric material.

10. The absorbent article according to claim 9, wherein an outer surface of the first spunbond nonwoven material in the elastic region has an average TS7 value of 12 dB V 2 rms or less.

11. The absorbent article according to claim 9, wherein the outer surface of the first spunbond nonwoven material in the elastic region has an average TS750 value of 100 dB V 2 rms or less.

12. The absorbent article according to claim 9, wherein an outer surface of the first spunbond nonwoven material in the first inelastic region has an average TS750 value of 10 dB V 2 rms or less.

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