# US 10,500,107 B2 · Extrusion bonded laminates for absorbent articles

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- Number: US 10,500,107 B2
- Document ID: US10500107B2
- Status: Granted
- Kind: B2
- Application number: 14/867,046
- Filed: 2015-09-28
- Published: 2016-01-21
- Granted: 2019-12-10
- Earliest claimed: 2008-01-24
- Assignees: The Procter & Gamble Company
- Applicants: The Procter & Gamble Company
- Inventors: Jean-Philippe Marie Autran; Iyad Muslet; David G. Bland; Leopoldo V. Cancio; Janet Neton; Todd Leon Mansfield
- Web page: https://patentgrep.com/patent/US10500107B2

## CPC

- A61F 13/51121: {characterised by the material}
- A61F 13/15593: {having elastic ribbons fixed thereto; Devices for applying the ribbons}
- A61F 13/4902: {characterised by the elastic material}
- B32B 5/022: {Non-woven fabric}
- B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 25/042: {of natural rubber or synthetic rubber}
- B32B 25/08: of synthetic resin
- B32B 25/10: next to a fibrous or filamentary layer
- B32B 25/12: comprising natural rubber
- B32B 25/16: comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)}
- B32B 25/18: comprising butyl or halobutyl rubber
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 27/285: {comprising polyethers}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- C08L 23/0815: {with aliphatic 1-olefins containing one carbon-to-carbon double bond}
- C08L 23/142: {at least partially crystalline copolymers of propene with other olefins}
- C08L 23/16: Ethylene-propylene or ethylene-propylene-diene copolymers
- C08L 53/00: Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L 53/02: of vinyl-aromatic monomers and conjugated dienes
- C08L 53/025: {modified}
- A61F 2013/51023: {being polymeric fibres}
- A61F 2013/51026: {being in thermoplastic material}
- A61F 2013/51147: {being polymeric films}
- A61F 2013/51165: {with the combination of films and nonwovens}
- A61F 2013/51322: {being elastomeric or stretchable}
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0292: Polyurethane fibres
- B32B 2262/04: Cellulosic plastic fibres, e.g. rayon
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/12: Conjugate fibres, e.g. core/sheath or side-by-side
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/51: Elastic
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2555/02: Diapers or napkins
- C08L 23/06: Polyethylene
- C08L 23/12: Polypropene
- C08L 2205/02: containing two or more polymers of the same C08L -group
- Y10T 442/659: Including an additional nonwoven fabric
- Y10T 442/674: Nonwoven fabric with a preformed polymeric film or sheet
- Y10T 442/678: Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An absorbent article of the present invention may comprise a topsheet, an outer cover, and an absorbent core disposed therebetween. The outer cover may comprise an extrusion bonded laminate. The EBL may comprise a multi-layer coextruded elastomeric film and a nonwoven. The film may comprise a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers. The nonwoven may comprise fibers and/or filaments. The first outer layer may be non-adhesively joined to the nonwoven via extrusion coating. Further, the outer cover may be elastic to at least about 50% engineering strain. The nonwoven may have high chemical affinity for the first outer layer. The first outer layer may have a low chemical affinity for the core layer; and the multi-layer coextruded elastomeric film may have a basis weight no greater than about 40 gsm.

## Claims

### Claim 1

An absorbent article comprising:
a topsheet;
an outer cover;
an absorbent core disposed between the topsheet and the outer cover;
wherein the outer cover comprises an extrusion bonded laminate, the extrusion bonded laminate comprising:
a multi-layer coextruded elastomeric film, comprising a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers;
a nonwoven consisting of fibers and/or filaments;
wherein the first outer layer is non-adhesively joined to the nonwoven via extrusion coating, such that the first outer layer is a tie layer between the core layer and the nonwoven;
wherein the second outer layer is non-adhesively joined to the core layer, such that the second outer layer is a skin layer;
wherein the first and second outer layers comprise polyolefin elastomers (POEs);
wherein the first and second outer layers comprise a blend of two ethylene rich copolymers, and wherein ethylene is between 10% and 97%;
wherein the extrusion bonded laminate is mechanically activated using intermeshing gears;
wherein the outer cover is elastic at 50% engineering strain;
wherein the nonwoven has a high chemical affinity for the first outer layer;
wherein the first outer layer has a low chemical affinity for the core layer;
wherein the laminate bond strength is from 1 N/cm to 3.5 N/cm; and
wherein the core layer comprises at least one thermoplastic elastomeric polymer.

### Claim 2 (depends on 1)

The absorbent article of claim 1, wherein the thermoplastic elastomeric polymer is selected from the group consisting of thermoplastic elastomers based on multi-block copolymers, thermoplastic elastomers based on polyurethanes, polyesters, polyether amides, elastomeric polyolefins, polyethylenes, polypropylenes, elastomeric polyolefin blends, and combinations thereof.

### Claim 3 (depends on 2)

The absorbent article of claim 2, wherein the thermoplastic elastomers based on multi-block copolymers are copolymerized rubber elastomeric blocks with polystyrene blocks, selected from the group consisting of styrene-isoprene-styrene, styrene-butadiene-styrene, styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene, styrene-ethylene-ethylene/propylene-styrene, and styrene-butadiene/isoprene-styrene, including their hydrogenated and non-hydrogenated forms, and combinations thereof.

### Claim 4 (depends on 1)

The absorbent article of claim 1, wherein the outer cover is substantially free of holes having a diameter of greater in size than about 1 mm.

### Claim 5 (depends on 1)

The absorbent article of claim 1, wherein the first and second outer layers have a fusion index from 10% to 20%.

### Claim 6 (depends on 1)

The absorbent article of claim 1, wherein the nonwoven comprises bicomponent fibers, the fibers comprising a core and a sheath.

### Claim 7 (depends on 6)

The absorbent article of claim 6, wherein the sheath comprises polyethylene and the core comprises polypropylene.

### Claim 8 (depends on 1)

The absorbent article of claim 1, wherein the core of the elastomeric film is selected from the group consisting of an ethylene copolymer having a fusion index from about 5% to about 20%, a propylene copolymer having a fusion index from about 5% to about 20%, and combinations thereof.

### Claim 9 (depends on 1)

The absorbent article of claim 1, wherein the extrusion bonded laminate has a basis weight from about 30 gsm to about 70 gsm.

### Claim 10 (depends on 1)

The absorbent article of claim 1, wherein the extrusion bonded laminate further comprises an adhesive.

### Claim 11 (depends on 1)

The absorbent article of claim 1, further comprising a second nonwoven joined to the second outer layer.

### Claim 12 (depends on 1)

The absorbent article of claim 1, wherein the extrusion bonded laminate is adhesive free.

### Claim 13 (depends on 1)

The absorbent article of claim 1, wherein the elastomeric film comprises at least about 20% to about 80%, by weight, of a styrenic block copolymer elastomer resin.

### Claim 14 (depends on 1)

The absorbent article of claim 1, wherein the first and second outer layers are compositionally identical.

### Claim 15 (depends on 1)

The absorbent article of claim 1, wherein the elastomeric film comprises:
at least one olefin-based elastomeric polymer;
at least one styrene block copolymer elastomer resin; and
at least one draw down polymer;
wherein the elastomeric film has a permanent set from 8 to 15%, as measured by the Two-Cycle Hysteresis Test Method using 100% maximum engineering strain.

### Claim 16 (depends on 1)

The absorbent article of claim 1, wherein the level of stretch of the activated laminate (% engineering strain at 1 N/cm force, as measured by the tensile test) is about 50% to about 144%.

### Claim 17 (depends on 1)

The absorbent article of claim 1, wherein the multi-layer coextruded elastomeric film has a basis weight from 10 gsm to 40 gsm.

### Claim 18

An absorbent article comprising an extrusion bonded laminate, wherein the extrusion bonded laminate is at least a portion of one or more components of the absorbent article, the components selected from the group consisting of a backsheet, an outer cover, a side panel, a waistband, a front ear, a back ear, and combinations thereof;
wherein the extrusion bonded laminate comprises:
a multi-layer coextruded elastomeric film, comprising a core layer, a first outer layer, and a second outer layer, wherein the core layer is between the first and second outer layers;
a nonwoven consisting of fibers and/or filaments;
wherein the first outer layer is non-adhesively joined to the nonwoven via extrusion coating, such that the first outer layer is a tie layer between the core layer and the nonwoven;
wherein the second outer layer is non-adhesively joined to the core layer, such that the second outer layer is a skin layer;
wherein the first and second outer layers comprise polyolefin elastomers (POEs);
wherein the first and second outer layers comprise a blend of two ethylene rich copolymers, and wherein ethylene is between 10% and 97%;
wherein the extrusion bonded laminate is mechanically activated using intermeshing gears;
wherein the component comprising the extrusion bonded laminate is elastic at 50% engineering strain;
wherein the nonwoven has a high chemical affinity for the first outer layer;
wherein the first outer layer has a low chemical affinity for the core layer;
wherein the laminate bond strength is from 1 N/cm to 3.5 N/cm; and
wherein the core layer comprises at least one thermoplastic elastomeric polymer.

### Claim 19 (depends on 18)

The absorbent article of claim 18, wherein at least one of the components of the absorbent article comprising the extrusion bonded laminate has apertures.

### Claim 20 (depends on 18)

The absorbent article of claim 18, wherein the thermoplastic elastomeric polymer is selected from the group consisting of thermoplastic elastomers based on multi-block copolymers, thermoplastic elastomers based on polyurethanes, polyesters, polyether amides, elastomeric polyolefins, polyethylenes, polypropylenes, elastomeric polyolefin blends, and combinations thereof; and
wherein the thermoplastic elastomers based on multi-block copolymers are copolymerized rubber elastomeric blocks with polystyrene blocks, selected from the group consisting of styrene-isoprene-styrene, styrene-butadiene-styrene, styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene, styrene-ethylene-ethylene/propylene-styrene, and styrene-butadiene/isoprene-styrene, including their hydrogenated and non-hydrogenated forms, and combinations thereof.