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EP-4525804-B1 - ABSORBENT ARTICLE WITH LAMINATE BOND PATTERN

EP4525804B1EP 4525804 B1EP4525804 B1EP 4525804B1EP-4525804-B1

Inventors

  • DALAL, URMISH, POPATLAL
  • SHEEHAN, ASTRID, ANNETTE

Dates

Publication Date
20260506
Application Date
20230519

Claims (14)

  1. An absorbent article (100) comprising: a topsheet (124); a backsheet (126); an absorbent core (128) disposed between the topsheet and the backsheet; and at least one elastic ear (130) comprising a laminate (10) having an elastomeric layer (14) and a nonwoven layer (12, 16), wherein the laminate has a plurality of discrete primary ultrasonic bonds (34) and a plurality of secondary ultrasonic bonds (36), wherein the elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and releasably attached by the secondary ultrasonic bonds, and wherein the secondary ultrasonic bonds release when the laminate is extended greater than about 5 mm in a stretch direction.
  2. The absorbent article according to claim 1, wherein the bond ratio between the permanent bonds (34) to the releasable bonds (36), as measured by the Bond Ratio Test Method disclosed herein, is greater than about 1.
  3. The absorbent article according to claim 1, wherein the plurality of primary discrete ultrasonic bonds are greater in number than the plurality of secondary ultrasonic bonds.
  4. The absorbent article according to any of the preceding claims, wherein the laminate peel force is greater than or equal to 0.3 N/cm, as measured by the Peel Force Test Method disclosed herein.
  5. The absorbent article according to any of the preceding claims 1, wherein the at least one elastic ear comprises a first portion and a second portion opposite the first portion, wherein the first portion of the at least one elastic ear is bonded to at least one of the topsheet and the backsheet at a chassis attachment bond.
  6. The absorbent article according to claim 5, wherein the plurality of secondary ultrasonic bonds do not overlap the chassis attachment bond (102).
  7. The absorbent article according to any of the preceding claims, wherein at least a portion of the plurality of secondary ultrasonic bonds are released when the absorbent article is first applied to a wearer.
  8. The absorbent article according to any of the preceding claims, wherein the plurality of secondary ultrasonic bonds are uniformly distributed across the laminate.
  9. The absorbent article according to any of the preceding claims, wherein the plurality of primary ultrasonic bonds form one or more closed cell units (304), and wherein at least a portion of the secondary ultrasonic bonds are disposed within the one or more closed cell units.
  10. The absorbent article according to any of the preceding claims, wherein the primary ultrasonic bonds form a bond pattern upon release of the plurality of secondary ultrasonic bonds.
  11. The absorbent article according to any of the preceding claims, wherein the elastomeric layer is preactivated.
  12. The absorbent article according to any of the preceding claims, wherein the laminate comprises one or more apertures.
  13. The absorbent article according to any of the preceding claims, wherein the nonwoven layer of the laminate comprises at least one of a spunbonded nonwoven, carded nonwoven, hydroentangled nonwoven, air-through bonded nonwoven, and spunlaced nonwoven.
  14. The absorbent article according to any of the preceding claims, wherein the laminate has a plurality of corrugations.

Description

FIELD The present disclosure relates to absorbent articles having stretch laminates with bond patterns. More specifically the present disclosure related to stretch laminates including one or more permanent bonds and one or more releasable bonds. BACKGROUND Elastomeric laminates are used in various products including absorbent articles (e.g., diapers, incontinence articles, 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 desirable tactile properties. In this way, the laminate permits a component of an article to closely and comfortably contact the wearer while providing desirable exterior qualities. Layers of the elastomeric laminate may be combined by various means, including for example thermal bonds in a gathered laminate configuration where corrugations are present in one or more layers. Ultrasonic bonding is also used to bond stretch laminates, see e.g. WO2021/252442A1. In bonding the layers, manufacturers must balance strength, extensibility, and comfort considerations. These considerations, however, often counteract one another. For example, while more bonds may provide greater lamination strength, it may undermine extensibility. Likewise, more resilient materials may provide greater tear resistance but less softness or breathability. Therefore, there is a continued need to balance strength, comfort, and extensibility for stretch laminates. There is also a need to provide bond patterns that maximize desired laminate properties while minimizing undesirable traits. Further, there is a need to convey laminate properties through bond patterns. SUMMARY An absorbent article including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent core includes at least one elastic ear having a laminate. The laminate includes an elastomeric layer and a nonwoven layer. The laminate includes a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and releasably attached by the secondary ultrasonic bonds. The secondary ultrasonic bonds release when the laminate is extended greater than about 5 mm in a stretch direction. BRIEF DESCRIPTION OF THE DRAWINGS The above-mentioned and other features and advantages of the present disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of example forms of the disclosure taken in conjunction with the accompanying drawing. Figure 1 is an exploded perspective view of an exemplary laminate according to a nonlimiting embodiment of the present disclosure.Figure 2A is a plan view of an exemplary laminate according to a nonlimiting embodiment of the present disclosure.Figure 2B is a plan view of an exemplary laminate according to a nonlimiting embodiment of the present disclosure.Figure 2C is a plan view of an exemplary laminate according to a nonlimiting embodiment of the present disclosure.Fig. 2D is a schematic illustration of a stretch laminate being subjected to a lateral pull force.Figs. 2E-2G is a schematic illustration of a stretch laminate with various types of releasable bond sites after being subjected to a lateral pull force.Figures 3A-3C are schematic representations of exemplary patterns for a laminate according to nonlimiting embodiments of the present disclosure.Figures 4A-4D are schematic representations of exemplary patterns for a laminate according to nonlimiting embodiments of the present disclosure.Figures 5A and 5B are schematic representations of exemplary patterns according to nonlimiting embodiments of the present disclosure.Figure 6 is a cross-sectional view of a laminate according to a nonlimiting embodiment of the present disclosure.Figure 7 is a plan view of the exterior surfaces of a laminate according to a nonlimiting embodiment of the present disclosure.Figure 8 is a plan view of an exemplary laminate according to a nonlimiting embodiment of the present disclosure.Figure 9 is a plan view of another exemplary laminate according to a nonlimiting embodiment of the present disclosure.Figure 10 is schematic plan view of an exemplary absorbent article according to one nonlimiting embodiment of the present disclosure. The absorbent article is shown in a flat, uncontracted state.Figure 11A is a schematic perspective view of an exemplary embodiment of an absorbent pant.Figure 11B is a schematic plan view of an exemplary embodiment of an absorbent pant precursor structure, prior to joining of the front and rear sections of the belt.Figure 12 is a schematic perspective view of a package in accordance with one embodiment of the present disclosure.Figure 13 is an illustration of a bond pattern in accordance