Extrusion coated textile laminate with improved peel strength

Abstract

The present invention relates to nonbreathable extrusion coated nonwoven structures. The structures comprise a nonwoven web comprised of monocomponent or bicomponent fibers having a coating comprising LDPE optionally blended with LLDPE and / or an elastomer. The monocomponent or bicomponent fibers comprise an ethylene based polymer, preferably at the surface of the fiber.

Description

FIELD OF INVENTION[0001]The present invention relates to non-breathable extrusion coated nonwoven structures comprising a nonwoven web of ethylene based fibers onto which has been extrusion coated a non-breathable ethylene-based film.BACKGROUND AND BRIEF SUMMARY OF THE INVENTION[0002]Nonwoven webs or fabrics are desirable for use in a variety of products such as bandaging materials, garments, disposable diapers, and other personal hygiene products, including pre-moistened wipes. Nonwoven webs having high levels of strength, softness, and abrasion resistance are desirable for disposable absorbent garments, such as diapers, incontinence briefs, training pants, feminine hygiene garments, and the like. For example, in a disposable diaper, it is highly desirable to have soft, strong, nonwoven components, such as top sheets or backsheets (also known as outer covers). For use in applications such as diapers it is desired that the fabric be non-breathable. Typically, this is achieved by lam...

AI Technical Summary

Benefits of technology

The patent describes a coating made of a mixture of LDPE and LLDPE or elastomer applied to non-wovens made from polyethylene bico or mono fibers that improves the softness and elongation at break of textile backsheets made from these non-wovens. This coating can be applied using an extrusion coating process, which allows for a thinner film layer to be applied to the non-woven and improves abrasion resistance compared to polypropylene non-wovens. The use of this coated non-woven results in a more comfortable and conforming textile product for hygiene and medical applications.

Problems solved by technology

Fabrics made from hPP, particularly nonwoven fabrics, exhibit high modulus but poor elasticity and softness.

In comparison, polyethylene-based elastomers, and the fibers and fabrics made from these polymers, tend to exhibit low modulus and good elasticity, but they also tend to have low tenacity, stickiness and exhibit a hand feel which is generally considered as unacceptable for many applications.

In contrast, a fabric made from a higher modulus fiber, e.g., hPP, will feel harsher (stiffer) and will drape less well resulting in a poorer fit.

Fabrics made from polyethylene-based elastomers also tend to lack adequate hand feel as they tend to have an undesirable feel to the skin commonly characterized by descriptors such as tacky, sticky, clammy, rubbery, or wet.

This obviously limits further downgauging of the film.

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