FLUID DISTRIBUTION MATERIAL FOR ABSORBENT ARTICLES

A fluid distribution material for use in an absorbent article includes a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side. The formed film layer includes a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch. Each of the protuberances includes a continuous sidewall extending from the user-facing side. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. A nonwoven layer is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of continuous fibers extending across the land areas and the plurality of apertures of the formed film layer and attached to the land areas at bond sites. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi. 1. A fluid distribution material for use in an absorbent article , the fluid distribution material comprising:a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side, the formed film layer comprising a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch, each of the protuberances comprising a continuous sidewall extending from the user-facing side, the garment-facing side having a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures; anda nonwoven layer laminated to the garment-facing side of the formed film layer, the nonwoven layer comprising a plurality of continuous fibers extending across the land areas and the plurality of apertures of the formed film layer and attached to the land areas at bond sites,wherein the fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.2. The fluid distribution material according to ...

METHOD OF MANUFACTURING AN ACTIVATED COMPOSITE WEB AND AN ACTIVATED COMPOSITE WEB FOR ABSORPTIVE DEVICES

A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided. 1. A method of manufacturing an activated composite web , comprising:laminating a film layer to a nonwoven web to form a composite web;forming a plurality of apertured protuberances in the film layer with a pin punching unit; andpassing the composite web through intermeshing elements to form an activated composite web, the intermeshing elements being constructed and arranged to form a plurality of first lanes substantially unaffected by activation aligned in a first direction and having a first width in a second direction substantially perpendicular to the first direction, and a plurality of second lanes aligned in the first direction and having a second width less than the first width in the second direction in the activated composite web,wherein a first portion of the plurality of apertured protuberances forms a plurality of first apertured protuberances having a plurality of corresponding first apertures with first cross-sectional areas, the first apertured protuberances being located in the first lanes, and a second portion ...

ACTIVATED COMPOSITE WEB FOR ABSORPTIVE DEVICES

An activated composite web includes a nonwoven layer, and a formed film layer attached to the nonwoven layer. The formed film layer includes a plurality of first apertured protuberances having a mesh count of at least 35, and a plurality of second apertured protuberances. Each of the second apertured protuberances has a cross-sectional area larger than each of the first apertured protuberances. A plurality of first lanes are aligned in a first direction and have a first width extending in a second direction substantially perpendicular to the first direction. The first apertured protuberances are located in the first lanes. A plurality of second lanes are aligned in the first direction and have a second width, less than the first width, extending in the second direction. The first lanes and the second lanes alternate with each other in the second direction. The second apertured protuberances are located in the second lanes. 1. An activated composite web , comprising:a nonwoven layer;a formed film layer attached to the nonwoven layer, the formed film layer comprising a plurality of first apertured protuberances having a mesh count of at least 35, the first apertured protuberances having a plurality of first apertures with first cross-sectional areas, and a plurality of second apertured protuberances, the second apertured protuberances having a plurality of second apertures with second cross-sectional areas, each of the second cross-sectional areas being larger than each of the first cross-sectional areas;a plurality of first lanes aligned in a first direction and having a first width extending in a second direction substantially perpendicular to the first direction, the first apertured protuberances located in the first lanes; anda plurality of second lanes aligned in the first direction and having a second width, less than the first width, extending in the second direction, the first lanes and the second lanes alternating with each other in the second direction, the ...

Contoured film with micro-protrusions

A polymeric film is provided, the film comprising one or more land portions that are substantially coplanar in a base plane and a plurality of distended portions separated from one another by the one or more land portions. The distended portions bow distally outward from the base plane. The polymeric film further comprises a plurality of annular micro-protrusions extending outward from the distal film surface, each protrusion having an apex. A portion of the plurality of annular micro-protrusions extends from each of the one or more land portions of the polymeric film and from each of the distended portions of the polymeric film.

FORMED FILMS AND APPARATUS FOR MANUFACTURING THE SAME

A formed film includes a first surface generally located in a first plane, a second surface generally located in a second plane parallel to and spaced from the first plane, and a third surface generally located in a third plane parallel to and spaced from the first plane and the second plane, in between the first plane and the second plane. A porous structure extends between the second surface and the third surface. A plurality of raised areas have sidewalls that extend between the first surface and the third surface, and top portions that define the first surface. The plurality of sidewalls, the porous structure, and the first plane define a plurality of gathering volumes. 1. A formed film comprising:a first surface generally located in a first plane;a second surface generally located in a second plane parallel to and spaced from the first plane;a third surface generally located in a third plane parallel to and spaced from the first plane and the second plane, in between the first plane and the second plane;a porous structure extending between the second surface and the third surface; anda plurality of raised areas having sidewalls extending between the first surface and the third surface, and top portions defining the first surface, the plurality of sidewalls, the porous structure and the first plane defining a plurality of gathering volumes.2. The formed film according to claim 1 , wherein the plurality of raised areas comprise a plurality of micro-apertures.3. The formed film according to claim 2 , wherein the micro-apertures are arranged in a 40 to 120 mesh pattern.4. The formed film according to claim 3 , wherein the micro-apertures are arranged in an 80 mesh pattern.5. The formed film according to claim 3 , wherein the micro-apertures are arranged in a 100 mesh pattern.6. The formed film according to claim 1 , wherein a distance between the first plane and the second plane is between about 500 μm and about 1200 μm.7. The formed film according to claim 6 , ...

APERTURED EXTRUSION COATED NONWOVEN WEB FOR ABSORBENT ARTICLES AND ABSORBENT ARTICLES INCLUDING SAME

An apertured extrusion coated nonwoven web for use as a topsheet in an absorbent article includes a nonwoven material having a user-facing side and a garment-facing side opposite the user-facing side. The nonwoven material includes a plurality of fibers. The apertured extrusion coated nonwoven web also includes a polymer coating on the garment-facing side of the nonwoven material, the polymer coating having a basis weight of about 2 gsm to about 6 gsm, and a plurality of three-dimensional apertures that extend through the nonwoven material and the polymer coating. Each of the plurality of three-dimensional apertures includes a continuous sidewall extending from a garment-facing side of the polymer coating. The apertured extrusion coated nonwoven web has an open area of greater than 5% when subjected to a pressure of 0.6 psi. 1. An apertured extrusion coated nonwoven web for use as a topsheet in an absorbent article , the extrusion coated nonwoven web comprising:a nonwoven material having a user-facing side and a garment-facing side opposite the user-facing side, the nonwoven material comprising a plurality of fibers;a polymer coating on the garment-facing side of the nonwoven material, the polymer coating having a basis weight of about 2 gsm to about 6 gsm; anda plurality of three-dimensional apertures extending through the nonwoven material and the polymer coating, each of the plurality of three-dimensional apertures comprising a continuous sidewall extending from a garment-facing side of the polymer coating,wherein the apertured extrusion coated nonwoven web has an open area of greater than 5% when subjected to a pressure of 0.6 psi.2. The apertured extrusion coated nonwoven web according to claim 1 , wherein the apertured extrusion coated nonwoven web has an open area of at least 50% of an original open area after the pressure of 0.6 psi is decreased to 0.0 psi.3. The apertured extrusion coated nonwoven web according to claim 1 , wherein the apertured extrusion ...

FORMED FILMS AND APPARATUS FOR MANUFACTURING THE SAME

An apparatus for manufacturing a formed film includes a first forming station configured to receive a polymer web and a second forming station configured to receive the polymer web from the first forming station after the polymer web has been apertured. The first forming station has a first forming structure with a plurality of first openings configured to form a plurality of apertures in the polymer web. The second forming station includes a second forming structure with a plurality of second openings and an overlying pattern configured to form raised areas in the polymer web to create a three-dimensional formed film. 1. An apparatus for manufacturing a formed film , the apparatus comprising:a first forming station configured to receive a polymer web, the first forming station having a first forming structure comprising a plurality of first openings configured to form a plurality of apertures in the polymer web; anda second forming station configured to receive the polymer web from the first forming station after the polymer web has been apertured, the second forming station comprising a second forming structure comprising a plurality of second openings and an overlying pattern configured to form raised areas in the polymer web to create a three-dimensional formed film.240120. The apparatus according to claim 1 , wherein the plurality of first openings are arranged in a to mesh pattern.340. The apparatus according to claim 1 , wherein the plurality of second openings are arranged in a mesh pattern.4. The apparatus according to claim 1 , wherein the overlying pattern configured to form raised areas comprises a spiral pattern. This application is a divisional of U.S. patent application Ser. No. 15/584,968, filed on Mar. 2, 2017, which claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/330,589, filed on May 2, 2016, and U.S. Provisional Patent Application Ser. No. 62/369,624, filed Aug. 1, 2016, the entire contents of all of which are ...

FLUID DISTRIBUTION MATERIAL FOR ABSORBENT ARTICLES

A fluid distribution material for use in an absorbent article includes a formed film layer, with a basis weight of between about 10 gsm and about 25 gsm, a user-facing side, and a garment-facing side. The formed film layer includes a plurality of apertured protuberances, numbering 10 to 40 per linear inch. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances, with land areas therebetween. A nonwoven layer, with a basis weight of between about 10 gsm and about 15 gsm, is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of fibers adjacent the land areas. Fibers adjacent the land areas are gathered a higher density than fibers located adjacent the plurality of apertures. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi. 1. A fluid distribution material for use in an absorbent article , the fluid distribution material comprising:a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side, the formed film layer comprising a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch, each of the protuberances comprising a continuous sidewall extending from the user-facing side, the garment-facing side having a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures, the formed film layer having a basis weight of between about 10 gsm and about 25 gsm; anda nonwoven layer laminated to the garment-facing side of the formed film layer, the nonwoven layer comprising a plurality of fibers adjacent the land areas and the plurality of apertures of the formed film layer, the nonwoven layer having a basis weight of between about 10 gsm and about 15 gsm,wherein the plurality of fibers adjacent the land areas are gathered a higher density than fibers located adjacent ...

Fluid distribution material for absorbent articles

A fluid distribution material for use in an absorbent article includes a formed film layer having first and second sides and a basis weight of between about 10 gsm and about 25 gsm, and a nonwoven layer having a basis weight of between about 10 gsm and about 15 gsm and laminated to the formed film layer. The formed film layer includes a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch. Each of the protuberances includes a continuous sidewall extending from the first side, and the second side has a plurality of apertures aligned with the plurality of protuberances, and land areas in between the apertures. The nonwoven layer includes a plurality of fibers attached to the formed film layer at the land areas. The material has a rewet value of less than 0.075 grams in accordance with the Rewet Test Method.

Fluid distribution material for absorbent articles

A fluid distribution material for use in an absorbent article includes a formed film layer, with a basis weight of between about 10 gsm and about 25 gsm, a user-facing side, and a garment-facing side. The formed film layer includes a plurality of apertured protuberances, numbering 10 to 40 per linear inch. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances, with land areas therebetween. A nonwoven layer, with a basis weight of between about 10 gsm and about 15 gsm, is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of fibers adjacent the land areas. Fibers adjacent the land areas are gathered a higher density than fibers located adjacent the plurality of apertures. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.

Fluid distribution material for absorbent articles

A fluid distribution material for use in an absorbent article includes a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side. The formed film layer includes a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch. Each of the protuberances includes a continuous sidewall extending from the user-facing side. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. A nonwoven layer is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of continuous fibers extending across the land areas and the plurality of apertures of the formed film layer and attached to the land areas at bond sites. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.

Method of manufacturing an activated composite web and an activated composite web for absorptive devices

A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

Contoured film with micro-protrusions

A polymeric film is provided, the film comprising one or more land portions that are substantially coplanar in a base plane and a plurality of distended portions separated from one another by the one or more land portions. The distended portions bow distally outward from the base plane. The polymeric film further comprises a plurality of annular micro-protrusions extending outward from the distal film surface, each protrusion having an apex. A portion of the plurality of annular micro-protrusions extends from each of the one or more land portions of the polymeric film and from each of the distended portions of the polymeric film.

Película contornada com microprotrusões

Uma película polimérica é fornecida, a película compreende uma ou mais porções de zona que são substancialmente coplanares num plano base e uma pluralidade de porções distendidas separadas umas das outras por uma ou mais porções de zona. As porções distendidas curvam-se distalmente para fora a partir do plano base. A película polimérica compreende, adicionalmente, uma pluralidade de microprotrusões anulares que se prolongam para fora a partir da superfície de película distal, cada protrusão tendo um vértice. Uma porção da pluralidade de microprotrusões anulares se prolonga a partir de cada uma das uma ou mais porções de zona da película polimérica e a partir de cada uma das porções distendidas da película polimérica.

Activated composite web for absorptive devices

Apertured extrusion coated nonwoven web for absorbent articles and absorbent articles including same

Apertured extrusion coated nonwoven web for absorbent articles and absorbent articles including same

An apertured extrusion coated nonwoven web for use as a topsheet in an absorbent article includes a nonwoven material having a user-facing side and a garment-facing side opposite the user-facing side. The nonwoven material includes a plurality of fibers. The apertured extrusion coated nonwoven web also includes a polymer coating on the garment-facing side of the nonwoven material, the polymer coating having a basis weight of about 2 gsm to about 6 gsm, and a plurality of three-dimensional apertures that extend through the nonwoven material and the polymer coating. Each of the plurality of three-dimensional apertures includes a continuous sidewall extending from a garment-facing side of the polymer coating. The apertured extrusion coated nonwoven web has an open area of greater than 5% when subjected to a pressure of 0.6 psi.

Films and laminates for absorbent articles

A film for use in an absorbent article includes a first side and a second side opposite the first side, and a plurality of apertured protuberances arranged in a pattern having 60 to 120 protuberances per linear inch in at least one direction. Each of the protuberances includes a continuous sidewall extending from the first side. The second side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. The film has a melt index of at least about 8 g/10 min, and an air permeability of at least about 80 m3/m2/min.