Absorbent article with polymeric filler composition

Abstract

An absorbent article comprising a first nonwoven material joined to a second nonwoven material by at least one bond area, wherein a polymeric filler composition is disposed within the bond area and the composition comprises at least one polymer selected from the group consisting of polypropylene homopolymers, propylene-ethylene copolymers, and mixtures thereof, wherein the composition is substantially free of tackifiers. It was found that such polymer filler compositions having a Toughness of at least 25 MPa, as measured according to the Extensional Test Method described herein, provide bonds with good resistance to peel creep force.

What is claimed is: 
     
         1 . An absorbent article comprising:
 a wearer-facing surface and an opposing garment-facing surface;
 a first nonwoven material; 
 a second nonwoven material; 
 at least one bond area joining a portion of the first nonwoven material and a portion of the second nonwoven material; and 
 a polymeric filler composition disposed within the bond area, wherein the polymeric filler composition comprises:
 one or more polymers selected from the group consisting of polypropylene homopolymers, propylene-ethylene copolymers, and mixtures thereof; and 
 from 0% to less than 5% of a tackifier, by weight of the polymeric filler composition; 
 
 wherein the polymeric filler composition has a Toughness of at least 25 MJ·m −3 , wherein Toughness is measured according to the Extensional Test Method. 
   
     
     
         2 . The absorbent article according to  claim 1 , wherein the polymeric filler composition has a Yield Stress of at least 5 MPa, wherein the Yield Stress is measured according to the Extensional Test Method. 
     
     
         3 . The absorbent article according to  claim 1 , wherein the polymeric filler composition consists essentially of an unblended polymer selected from a polypropylene homopolymer or a propylene-ethylene copolymer. 
     
     
         4 . The absorbent article according to  claim 1 , wherein the polymeric filler composition consists essentially of a semi-crystalline propylene-ethylene copolymer having an enthalpy of fusion of between about 20 J/g and about 200 J/g. 
     
     
         5 . The absorbent article according to  claim 1 , wherein the polymeric filler composition consists essentially of a semi-crystalline propylene-ethylene copolymer having an enthalpy of fusion of at least 20 J/g. 
     
     
         6 . The absorbent article according to  claim 5 , wherein a percentage of propene monomer units in the copolymer is from about 50% to about 99% by weight of the copolymer. 
     
     
         7 . The absorbent article according to  claim 1 , wherein the polymeric filler composition is present at a basis weight of from about 5 gsm to about 30 gsm in the bond area. 
     
     
         8 . The absorbent article according to  claim 7 , wherein the polymeric filler composition is present at a basis weight of from about 10 gsm to about 20 gsm in the bond area. 
     
     
         9 . The absorbent article according to  claim 1 , wherein the first nonwoven forms a portion of a nonwoven landing zone, and the second nonwoven forms a portion of a backsheet outer cover of the absorbent article. 
     
     
         10 . The absorbent article according to  claim 1 , wherein the absorbent article comprises an absorbent core, wherein the first nonwoven material forms a portion of a core wrap top layer disposed between the absorbent core and the wearer-facing surface, and wherein the second nonwoven material forms a portion of a core wrap bottom layer disposed between the absorbent core and the garment-facing surface. 
     
     
         11 . The absorbent article according to  claim 10 , comprising core perimeter bonds disposed along lateral and longitudinal edges of the absorbent core, wherein the bond area forms some of the core perimeter bonds. 
     
     
         12 . The absorbent article according to  claim 10 , wherein the absorbent core comprises at least one channel, and wherein the bond area forms a portion of a channel bond area. 
     
     
         13 . The absorbent article according to  claim 1 , wherein the polymeric filler composition has a viscosity at 170 deg C. from about 1,000 mPa·s to about 5,000 mPa·s, according to the Viscosity Test Method. 
     
     
         14 . The absorbent article according to  claim 1 , wherein at least one of the first nonwoven material and the second nonwoven material comprise natural or recycled fibers. 
     
     
         15 . The absorbent article according to  claim 1 , wherein the bond area has a Static Peel Force Time of least 500 minutes per 10 mm bonded length, according to the Static Peel Force Time Test Method. 
     
     
         16 . A package comprising a plurality of the absorbent articles according to  claim 1 . 
     
     
         17 . A nonwoven laminate for an absorbent article comprising:
 a first nonwoven material;   a second nonwoven material; and   at least one bond area disposed between the first nonwoven material and the second nonwoven material, wherein a polymeric filler composition is disposed within the bond area, and wherein the polymeric filler composition comprises:
 one or more polymers selected from the group consisting of polypropylene homopolymers, propylene-ethylene copolymers, and mixtures thereof; and 
 from 0% to less than 5% of a tackifier, by weight of the polymeric filler composition; 
 wherein the polymer filler composition has a Toughness of at least 25 MJ·m −3 , according to the Extensional Test Method. 
   
     
     
         18 . A method of bonding a first nonwoven material to a second nonwoven material, the method comprising the step of:
 applying a polymeric filler composition to a bonding area on the first nonwoven material, and bonding the second nonwoven material to the first nonwoven material in the bonding area, wherein the polymeric filler composition comprises:
 one or more polymers selected from the group consisting of polypropylene homopolymers, propylene-ethylene copolymers, and mixtures thereof; and 
 from 0% to less than 5% of a tackifier, by weight of the polymeric filler composition; wherein the polymeric filler composition has a Toughness of at least 25 MJ·m −3 , according to the Extensional Test Method.