FIELD OF THE INVENTION

The disclosure herein relates to a crimped spunbond fiber nonwoven web and an article incorporating the nonwoven web.

BACKGROUND OF THE INVENTION

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.

Elastomeric laminates can be produced by multiple methods. For example, the laminate may be in the form a gathered laminate, wherein the coverstock layer forms rugosities when the elastic layer is relaxed. Said gathered laminates may be formed by extending the elastic layer material to a greater extent than the outer material at the time of lamination. Alternatively, the outer layer material may be corrugated and the elastic material may be in its relaxed state at the time of lamination. In either scenario, following lamination, the coverstock gathers or bunches and forms rugosities when the laminate is in a relaxed state.

Another type of elastomeric laminate is a zero strain laminate. During lamination, the outer and elastic layers are joined at approximately zero relative strain (i.e., both layers are relaxed at approximately zero strain). Zero strain laminates are activated by a mechanical straining process, which creates separations or deformations in the outer layer materials and renders the laminate elastic. Nonwoven webs are typically used as the outer layer in such laminates. Nonwovens may be formed by various techniques, many of which may have drawbacks with respect to forming laminates. For instance, nonwoven webs made of carded staple fibers are typically easily extensible, offering little resistance during mechanical activation, but said carded nonwovens are expensive. On the other hand, spunbond nonwovens are relatively inexpensive but tend to be more difficult to extend without tearing. In addition, spunbond webs typically lack the softness of carded nonwovens.

Therefore, there is a need for a laminate that includes a nonwoven having adequate extensibility and strength properties. There is a further need for reducing costs and increasing efficiency in creating elastomeric laminates. There is also a need to provide elastomeric laminates with desirable softness and texture.

SUMMARY OF THE INVENTION

The present invention addresses one or more of the foregoing needs. In one form, an article comprises a chassis having a topsheet, backsheet and an absorbent core disposed between the topsheet and backsheet; and an ear joined to the chassis. The ear may comprise a ring-rolled laminate having a first nonwoven web and an elastomeric film, wherein the first nonwoven web comprises a crimped spunbond fiber nonwoven web. In another form, an article comprises a chassis having a topsheet, a backsheet and an absorbent core disposed between the topsheet and backsheet; and an ear joined to the chassis. The ear may comprise a laminate having a first nonwoven, a second nonwoven and an elastomeric film disposed between the first and second nonwovens, wherein the laminate further comprises a plurality of ultrasonic bonds. The first nonwoven comprises a first crimped spunbond nonwoven web and the laminate may comprise an Average Extension at 2N of about 5 mm or greater according to the Extension Test Method herein. In certain embodiments, an elastic laminate has one or more nonwoven webs and an elastomeric film. At least one nonwoven web comprises an external surface and an interior surface opposite the external surface, wherein the interior surface faces the elastomeric film. Said nonwoven also comprises a crimped spunbond nonwoven layer, and the crimped spunbond nonwoven layer forms the external surface. The external surface may comprise an Average TS7 softness value of about 7 dB V2rms or less as determined by the Softness Test Method herein.

