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.

What is claimed is: 
     
         1 . A non-breathable extrusion coated nonwoven structure comprising
 a. a nonwoven web comprised of monocomponent or bicomponent fibers, wherein the monocomponent or bicomponent fibers comprise an ethylene based polymer;   b. a non-breathable extrusion coating layer, wherein the coating layer is comprised of an ethylene based polymer.   
     
     
         2 . The structure of  claim 1  wherein the coating layer has a basis weight of less than 20 gsm 
     
     
         3 . The structure of  claim 1  wherein the nonwoven web has a basis weight of less than 20 gsm. 
     
     
         4 . The structure of  claim 1  wherein the structure has an abrasion resistance of lower than 0.5 mg/cm 3 . 
     
     
         5 . The structure of  claim 1  wherein the structure has an elongation at break in CD of greater than 50% 
     
     
         6 . The structure of  claim 1  wherein the structure has softness lower than 45 as measured by handle-o-meter 
     
     
         7 . The structure of  claim 1  wherein the structure has a peel strength exceeding the test method capabilities. 
     
     
         8 . The structure of  claim 1  wherein the coating layer comprises
 a. 5 to 100 percent by weight of LDPE; and 
 b. from 0 to 95 percent by weight of LLDPE. 
 
     
     
         9 . The structure of  claim 8  wherein the LLDPE has a Comonomer Distribution Constant in the range of greater than 45 to 400 and a zero shear viscosity range of 2 to 20. 
     
     
         10 . The structure of  claim 1  wherein the coating layer further comprises an adhesion promoter. 
     
     
         11 . The structure of  claim 10  wherein the adhesion promoter is blended with the ethylene based polymer. 
     
     
         12 . The structure of  claim 10  wherein the adhesion promoter is a tie layer located between the coating layer and the nonwoven web. 
     
     
         13 . The structure of  claim 11  wherein the adhesion promoter is selected from the group consisting of PBPEs, olefin block copolymers and linear polyethylenes having a density of less than 0.905 g/cm 3 . 
     
     
         14 . The structure of  claim 1  wherein the structure has a basis weight of from 9 to 40 gsm. 
     
     
         15 . The structure of  claim 1  wherein the structure has a basis weight of from 12 to 25 gsm. 
     
     
         16 . The structure of  claim 1  wherein the nonwoven web is a spunbond web, a carded web, airlaid web, spunlaced web, meltblown web, or combinations thereof in a multilayer structure. 
     
     
         17 . The structure of  claim 1  wherein the structure is used in a medical application and has a basis weight in the range of 10-50 gsm 
     
     
         18 . The structure of  claim 1  wherein the structure is used in hygiene application and has a basis weight in the range of 6-30 gsm 
     
     
         19 . The structure of  claim 1  wherein the structure is used in industrial application and has a basis weight in the range of 10-50 gsm. 
     
     
         20 . The structure of  claim 1  wherein the coating layer contains less than 25% filler by weight of the coating layer.