US20030003269A1 - Apertured polymeric film webs and absorbent articles using such webs - Google Patents

Apertured polymeric film webs and absorbent articles using such webs Download PDF

Info

Publication number
US20030003269A1
US20030003269A1 US10/217,911 US21791102A US2003003269A1 US 20030003269 A1 US20030003269 A1 US 20030003269A1 US 21791102 A US21791102 A US 21791102A US 2003003269 A1 US2003003269 A1 US 2003003269A1
Authority
US
United States
Prior art keywords
ply
web
polymeric film
composite structure
article
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/217,911
Inventor
Yann-Per Lee
Saeed Fereshtehkhou
Keith Stone
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=24174003&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20030003269(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Priority to US10/217,911 priority Critical patent/US20030003269A1/en
Publication of US20030003269A1 publication Critical patent/US20030003269A1/en
Priority to US11/130,877 priority patent/US9700463B2/en
Priority to US12/193,325 priority patent/US9744080B2/en
Priority to US15/584,165 priority patent/US10124556B2/en
Priority to US15/992,647 priority patent/US10272635B2/en
Priority to US15/995,193 priority patent/US10611119B2/en
Priority to US16/007,286 priority patent/US20180290422A1/en
Priority to US16/813,804 priority patent/US10850475B2/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203Properties of the article, e.g. stiffness or absorbency
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577Apparatus or processes for manufacturing
    • A61F13/15707Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15731Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/512Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B26HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26FPERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/02Perforating by punching, e.g. with relatively-reciprocating punch and bed
    • B26F1/06Perforating by punching, e.g. with relatively-reciprocating punch and bed with punching tools moving with the work
    • B26F1/10Roller type punches
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B26HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26FPERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/24Perforating by needles or pins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B26HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26FPERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/26Perforating by non-mechanical means, e.g. by fluid jet
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0022Combinations of extrusion moulding with other shaping operations combined with cutting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/14Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the particular extruding conditions, e.g. in a modified atmosphere or by using vibration
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/5116Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203Properties of the article, e.g. stiffness or absorbency
    • A61F2013/15284Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
    • A61F2013/15422Density
    • A61F2013/1543Density with a density gradient in the horizontal plane
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/5116Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
    • A61F2013/51165Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers with the combination of films and nonwovens
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/513Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
    • A61F2013/51338Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability having improved touch or feeling, e.g. smooth film
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/513Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
    • A61F2013/51355Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability for improving fluid flow
    • A61F2013/51366Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability for improving fluid flow with hydrophilic lower face
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/48Wearing apparel
    • B29L2031/4871Underwear
    • B29L2031/4878Diapers, napkins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/728Hydrophilic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/73Hydrophobic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00Personal care
    • B32B2555/02Diapers or napkins
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322Composite web or sheet
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]

Definitions

  • the present invention relates to an apertured polymeric film web exhibiting a soft and silky tactile impression on at least one of its surfaces.
  • the present invention also relates to absorbent articles incorporating a topsheet comprised of a web according to the present invention.
  • absorptive devices such as disposable diapers, sanitary napkins, incontinent briefs, bandages, wound dressings, and the like, presenting a soft, silky, cloth-like surface feel to the user to improve wearing comfort and confidence.
  • thermoplastic film webs have been developed which further include microscopic surface texturing (microtexture) and/or microscopic apertures (microapertures) to further enhance the visual and tactile impression of such webs.
  • Representative film webs of this variety are disclosed in commonly assigned U.S. Pat. No. 4,463,045, issued to Ahr et al. on Jul. 31, 1984, U.S. Pat. No. 4,629,643, issued Dec. 16, 1986 to Curro et al., and U.S. Pat. No. 4,609,518, issued Sep. 2, 1986 to Curro et al., the disclosures of which are hereby incorporated herein by reference.
  • a fibrous material as a covering or topsheet on such articles, alone or as an overlay or laminate over other materials.
  • a representative topsheet structure of this variety is disclosed in Statutory Invention Registration H1670 published in the name of Aziz et al. on Jul. 1, 1997, the disclosure of which is hereby incorporated herein by reference.
  • Such fibrous materials may take the form of a woven or nonwoven web of a suitable fiber variety, and may or may not include discretely formed apertures in addition to the inherent porosity of the web itself.
  • Such fibrous webs exhibit an aesthetically-pleasing, cloth-like surface appearance and tactile impression due to the fibrous nature of the surface.
  • the present invention meets the needs described above.
  • a novel polymeric film web that enhances softness and silkiness is described below.
  • the present invention pertains to an apertured polymeric film web provided with a multiplicity of substantially three dimensional surface structures on at least one of the web's surfaces and provided with a multiplicity of fluid transport apertures.
  • the web material shall exhibit a soft and silky tactile impression on at least one of its surfaces such that it has a softness index greater than about 35 and/or a compressibility index greater than about 25 percent.
  • Further embodiments of the present invention include utilizing unique combinations of processes to provide the polymeric film web with three dimensional surface structures and fluid transport apertures.
  • a still further embodiment of the present invention is a multi-ply composite structure.
  • the multi-ply composite structure is comprised of at least two ply: a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply.
  • the thermoplastic formed film ply can be comprised of web material as claimed herein and the sub-ply is adjacent to the garment facing surface of the thermoplastic formed web ply.
  • Still further embodiments of the present invention may include multi-ply composite structures comprised of materials with varying degrees of permeability.
  • fluid transport apertures are provided to form fluid pathways common to all ply.
  • Still further embodiments of the present invention may include any number of layers.
  • the intermediate layer or layers may comprise any thermoplastic material. Any number of intermediate layers may be utilized in forming the thermoplastic formed web plies of the present invention.
  • the web material of the present invention provides many advantages.
  • the unique combination of manufacturing processes selected and materials used results in a polymeric film web that is softer, silkier, and more cloth-like than prior film materials as measured by the softness index and compressibility index described herein.
  • the present invention also pertains to absorbent articles which preferably include a topsheet formed from the web material of the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.
  • FIG. 1 is a plan view scanning electron micrograph showing one embodiment of thermoplastic web of the present invention
  • FIG. 2 is an enlarged cross-sectional scanning electron micrograph showing an arrangement of three dimensional surface structures and fluid transport apertures according to the present invention
  • FIG. 3 is a plan view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention
  • FIG. 4 is a tilt view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention
  • FIG. 5 is a cross-sectional view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention.
  • FIG. 6 is a cross-sectional view that shows one embodiment of a multi-ply composite structure according to the present invention.
  • hydrophilic is used to refer to surfaces that are wettable by aqueous fluids (e.g., aqueous body fluids) deposited thereon. Hydrophilicity and wettability are typically defined in terms of water contact angle and the surface tension of the fluids and solid surfaces involved. This is discussed in detail in the American Chemical Society publication entitled Contact Angle, Wettability and Adhesion, edited by Robert F. Gould (Copyright 1964), which is hereby incorporated herein by reference. A surface is said to be wetted by a fluid (hydrophilic) when the fluid tends to spread spontaneously across the surface as opposed to forming discrete droplets.
  • a surface is considered to be “hydrophobic” if the fluid tends to form discrete droplets and does not spread spontaneously across the surface.
  • a “hydrophilic web or layer” generally has a water contact angle less than about 50 degrees.
  • a “hydrophobic web or layer” generally has a water contact angle greater than about 50 degrees.
  • the term “permanently hydrophilic” as used herein refers to a web that retains its low contact angle over long periods of time or after exposure to conditions that would otherwise remove surfactants.
  • a film can be comprised of a block copolymer of a polyether and another polymer.
  • Such a composition renders the web permanently hydrophilic thereby giving the web durable wettability without the need for surfactant treatment.
  • the water contact angle depends on surface inhomogeneities (e.g., chemical and physical properties, such as roughness), contamination, chemical/physical treatment of the solid surface, or composition of the solid surface, as well as contamination of the water.
  • the surface energy of the solid also influences the water contact angle. As the surface energy of the solid decreases, the water contact angle increases. As the surface energy of the solid increases, the water contact angle decreases.
  • the term “gradient” when applied to differences in surface energy or work of adhesion is intended to describe a change in surface energy or work of adhesion occurring over a measurable distance.
  • discontinuity is intended to refer to a type of “gradient” or transition, wherein the change in surface energy occurs over an essentially zero distance. Accordingly, as used herein all “discontinuities” fall within the definition of “gradient”.
  • capillary and “capillarity” are used to refer to passageways, apertures, pores, or spaces within a structure which are capable of fluid transport in accordance with the principles of capillarity generally represented by the Laplace equation (1):
  • p is the capillary pressure
  • R is the internal radius of the capillary (capillary radius).
  • G is the surface tension of the liquid measured in dyne/cm
  • A is the liquid-solid water contact angle measured in degrees.
  • incompatible represents the lack of miscibility between two materials such that each phase substantially retains its original properties.
  • Example properties include glass transition temperature or melting point.
  • Another characterization of incompatible materials is that the strength of the interface is significantly weaker than the strength of the weakest individual phase (material). Thus, the work of adhesion between the two materials is much lower than the lowest cohesive energy of either material, and the risk of delamination is high.
  • tie layer refers to any layer in a web ply that is comprised of material that serves to tie or join two incompatible materials.
  • topsheet generally refers to the cover layer, in an absorbent article such as a diaper or catamenial pad, that faces the wearer of the absorbent article.
  • wearer-contacting layer or surface refers to the surface of a topsheet or other absorbent article component that is nearest the wearer of the article.
  • garment-facing layer or surface refers to the surface of a topsheet or other absorbent article component that faces away from the wearer when the component is used in an absorbent article.
  • Z-dimension refers to the dimension orthogonal to the length and width of the layer, structure or article.
  • the Z-dimension usually corresponds to the thickness of the layer, structure or article.
  • three dimensional surface structure refers to any three dimensional structure residing on the web surface that serves to enhance the soft and silky tactile impression of the web. Examples of such structures include but are not limited to the following: aberrations; fibrils; incongruities; cone structures; and apertures. Methods for providing three dimensional surface structures can be broken into two groups: 1) apertured methods; and 2) non-apertured methods.
  • Apertured methods include but are not limited to the following: vacuum forming, hydroforming, needle punching (solid or hollow), hydrosonics, ultrasonics, and any combination thereof.
  • Non-apertured methods include but are not limited to the following: mechanical embossing, flocking, delamination of viscous melts or optionally delamination of viscous melts from porous surfaces, printed hair, brushing, and any combination thereof.
  • fluid transport aperture refers to any aperture in the web that serves to transport fluids within the web.
  • fluid transport aperturing processes include but are not limited to the following: mechanical embossing; stretch rupturing; vacuum forming; hydroforming; hydrocutting; needle punching (solid or hollow); hydrosonics; ultrasonics; slitting; ring-rolling; structural elastic-like web; and any combination thereof.
  • fluid passageway is intended to encompass enclosed or at least partially enclosed structures or channels which may communicate fluids.
  • the term fluid passageway is thus intended to encompass the terms “aperture”, “channel”, “capillary”, as well as other similar terms.
  • the passageways inherent in fluid permeable materials are another example. Many other examples of fluid passageways exist in the art and may be used in the present invention.
  • the term “monolayer” refers to a ply that is comprised of a single layer of material.
  • sub-ply refers to a ply located beneath the body contacting ply.
  • web refers to a structure comprised of one or more ply.
  • layer refers to an individual layer or layers of material that are joined to form a ply.
  • the term “ply” as used herein refers to a structure that is comprised of one or more layers of material.
  • surface refers to a top or first side of a layer and/or a bottom or second side of a layer.
  • softness index refers to the panel score unit achieved by a test material in the Panel Softness Test described below.
  • the term “compressibility index” refers to the percent compression at 0.2 psi achieved by a test material in the Caliper vs. Z-compression Test described below.
  • the term “absorbent article” refers to devices which absorb and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body.
  • the term “disposable” is used herein to describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use, and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner).
  • a “unitary” absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a separate holder and pad.
  • the apertured polymeric film web of the present invention is a web material that has been (1) provided with a multiplicity of substantially three dimensional surface structures that cause the web material to exhibit a soft, silky surface to improve the wearer's comfort and (2) provided with fluid transport apertures for improved fluid handling.
  • FIG. 1 is a plan view scanning electron micrograph of one embodiment of the formed web and depicts the three dimensional surface structures 100 and the fluid transport apertures 110 of the present invention web.
  • FIG. 2 depicts an enlarged cross-sectional scanning electron micrograph along line A-A of FIG. 1 that shows the dimensional relationship of the three dimensional surface structures 200 and fluid transport apertures 210 according to the present invention.
  • the size of both the three dimensional surface structures 200 and fluid transport apertures 210 may be varied.
  • the three dimensional surface structures are comprised of microapertures having a diameter of about 0.02-0.2 mm, a height of about 0.02-0.2 mm, and fluid transport apertures having a minimum diameter of about 0.05 mm.
  • smaller fluid transport apertures will require apertures comprised of more hydrophilic materials to ensure sufficient fluid management properties.
  • FIGS. 3 - 5 are enlarged scanning electron micrograph depicting the plan view, tilt view, and cross section view of the following: (1) a typical prior art web wherein both three dimensional surface structures 300 and fluid transport apertures 310 were developed using hydroforming processes; and (2) a typical present invention web wherein the three dimensional surface structures 320 were developed by hydroforming but the fluid transport apertures 330 were developed by mechanical aperturing means.
  • a comparison of these scanning electron micrographs reveals that the three dimensional surface structures 320 of the present invention as depicted in FIG. 3 are substantially less damaged than the three dimensional surface structures 310 developed by the double-hydroforming processes.
  • One aspect of the present invention is a fluid pervious web suitable for use as a topsheet in an absorbent article.
  • the fluid pervious web of the present invention contains a plurality of microapertures.
  • the fluid pervious web of the present invention is described herein as a topsheet for use in an absorbent article, one having ordinary skill in the art would recognize that the fluid pervious web of the present invention would have other uses, such as bandages, agricultural coverings, and similar uses where it is desirable to manage fluid flow through a web or ply.
  • fluid transport apertures provide the fluid handling properties of the web.
  • fluid transport apertures are provided to the web using means that leave the three dimensional surface structures substantially unaltered relative to their as-made state.
  • fluid transport apertures are provided by mechanically embossing and stretch rupturing the web as discussed below.
  • a topsheet comprising the polymeric film web of the present invention.
  • the material selected for the polymeric film web of the present invention, and therefore for the topsheet formed therefrom, is preferably machinable and capable of being formed into a sheet. Since the topsheet is to be used in consumer products which contact the human body, the material utilized in the polymeric film web and used to form the topsheet is safe for epidermal or other human contact.
  • the web material selected creates a surface energy gradient between at least two of the web surfaces.
  • the wearer-contacting layer and the garment-facing layer of the topsheet of the present invention comprise materials having different layer properties (eg., one of the layers is hydrophobic and the other is hydrophilic), a surface energy gradient is created.
  • Surface energy gradients have been found to be useful in promoting fluid transport. A comprehensive explanation of surface energy gradients is described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference.
  • the web material used is comprised of hydrophobic and permanently hydrophilic layers, as described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference.
  • the performance properties of the topsheet of the present invention may be manipulated depending on the orientation of the hydrophilic layer and the hydrophobic layer in the thermoplastic formed web ply from which the topsheet is formed.
  • the thermoplastic formed web ply of the present invention may comprise any number of layers.
  • the topsheet may be formed so that the wearer-contacting layer is a hydrophobic layer and the garment-facing layer is hydrophilic (known as “phobic/philic”), or so that the wearer-contacting layer is hydrophilic and the garment facing layer is hydrophobic (known as “philic/phobic”).
  • phobic/philic hydrophilic
  • hydrophilic/phobic hydrophilic/phobic
  • the highly compressible webs of the present invention enhance the soft and silky tactile impression when used as topsheets.
  • a consequence of these highly compressible materials is that the void volume between the topsheet material and the adjacent material is easily lost under in-use pressures. This can have the negative consequence of poor fluid management. Therefore, by combining the webs of the present invention described above with a sub-ply that is relatively non-compressible, the void volume can be protected and serve to provide better fluid management.
  • An alternative topsheet orientation shown in FIG. 6, includes a thermoplastic formed film ply 610 comprised of polymeric film web material exhibiting preferred softness and/or compressibility indices as described herein and a sub-ply 620 to form a multi-ply composite structure 600 .
  • the multi-ply composite structure 600 may be formed utilizing various combinations of non-apertured and apertured materials with varying degrees of permeability so long as the multi-ply composite structure 600 serves to transport fluids through the structure.
  • the materials comprising the multi-ply composite structure 600 may be selected such that a surface energy gradient is formed between at least two exterior surfaces of the structure.
  • both ply are provided with fluid transport apertures that form fluid pathways common to both ply.
  • the multi-ply composite structure 600 is formed such that it maintains a protected void volume during use.
  • the sub-ply can be comprised of a variety of different materials or combinations thereof. Suitable sub-ply materials include 1) apertured formed webs 2) cloth-like formed webs; 3) nonwovens; 4) wovens; 5) foams; 6) cellulosic webs; and 7) combinations thereof.
  • Suitable sub-ply formed films are described in U.S. Pat. No. 3,929,135, issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,246, issued to Mullane, et al. on Apr. 13, 1982; U.S. Pat. No. 4,342,314, issued to Radel, et al. on Aug. 3, 1982; U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31, 1984; and U.S. Pat. No. 5,006,394, issued to Baird on Apr. 9, 1991.
  • One especially preferred formed web is described in one or more of the above patents and marketed on sanitary napkins by the Procter & Gamble Company of Cincinnati, Ohio as “DRI-WEAVE”.
  • cloth-like formed films may comprise the sub-ply.
  • Such webs have a softer, more cloth-like feel.
  • Cloth-like formed webs are developed by providing the web surface with either microapertures (as described above), surface texture (described below), or surface treatment (described below), or a combination thereof.
  • the sub-ply may also be comprised of any nonwoven or woven material capable of transporting blood, menses, and/or urine. Other materials not listed herein, but capable of transporting blood, menses, and/or urine, are included in the present invention.
  • thermoplastic formed web ply of the present invention may include any number of layers as long as there is a tie layer between any adjacent layers that comprise incompatible materials.
  • the intermediate layer or layers may comprise any thermoplastic material as long as there is a tie layer between any adjacent incompatible layers. Any number of intermediate layers may be utilized in forming the thermoplastic formed web plies of the present invention.
  • the polymeric film web of the present invention may be processed using conventional procedures for producing multi-layer webs on conventional coextruded web-making equipment.
  • polymers can be melt processed into webs using either cast or blown web extrusion methods both of which are described in Plastics Extrusion Technology -2nd Ed., by Allan A. Griff (Van Nostrand Reinhold 1976), which is hereby incorporated herein by reference.
  • a cast web is extruded through a linear slot die.
  • the flat web is cooled on a large moving polished metal roll (chill roll). It quickly cools, and peels off the first roll, passes over one or more auxiliary rolls, then through a set of rubber-coated pull or “haul-off” rolls, and finally to a winder.
  • melt In blown web extrusion the melt is extruded upward through a thin annular die opening. This process is also referred to as tubular web extrusion. Air is introduced through the center of the die to inflate the tube and causes it to expand. A moving bubble is thus formed which is held at constant size by simultaneous control of internal air pressure, extrusion rate, and haul-off speed.
  • the tube of web is cooled by air blown through one or more chill rings surrounding the tube. The tube is next collapsed by drawing it into a flattened frame through a pair of pull rolls and into a winder.
  • a coextrusion process requires more than one extruder and either a coextrusion feedblock or a multi-manifold die system or combination of the two to achieve the multilayer web structure.
  • the flow channels are designed such that, at their point of confluence, the materials flow together at the same velocities and pressure, minimizing interfacial stress and flow instabilities.
  • feedblock and die systems are disclosed in Extrusion Dies for Plastics and Rubber, W. Michaeli, Hanser, N.Y., 2nd Ed., 1992, hereby incorporated herein by reference. It may be important in such processes that the melt viscosities, normal stress differences, and melt temperatures of the material do not differ too greatly. Otherwise, layer encapsulation or flow instabilities may result in the die leading to poor control of layer thickness distribution and defects from non-planar interfaces (e.g. fish eye) in the multilayer web.
  • non-planar interfaces e.g. fish eye
  • melt streams are brought together outside and prior to entering the die body, in a multi-manifold or vane die each melt stream has its own manifold in the die where the polymers spread independently in their respective manifolds.
  • the melt streams are married near the die exit with each melt stream at full die width.
  • Moveable vanes provide adjustability of the exit of each flow channel in direct proportion to the volume of material flowing through it, allowing the melts to flow together at the same velocity, pressure, and desired width.
  • melt flow properties and melt temperatures of polymers vary widely, use of a vane die has several advantages.
  • the die lends itself toward thermal isolation characteristics wherein polymers of greatly differing melt temperatures, for example up to 175°F. (80° C.), can be processed together.
  • Each manifold in a vane die can be designed and tailored to a specific polymer.
  • the flow of each polymer is influenced only by the design of its manifold, and not forces imposed by other polymers.
  • This allows materials with greatly differing melt viscosities to be coextruded into multi-layer webs.
  • the vane die also provides the ability to tailor the width of individual manifolds, such that an internal layer can be completely surrounded by the outer layer leaving no exposed edges.
  • the aforementioned patents also disclose the combined use of feedblock systems and vane dies to achieve more complex multilayer structures.
  • extruders used to produce the webs of the present invention depends on the desired production rate and that several sizes of extruders may be used. Suitable examples include extruders having a 1 (2.5 cm) to 1.5 inch (3.7 cm) diameter with a length/diameter ratio of 24 or 30. If required by greater production demands, the extruder diameter can range upwards. For example, extruders having a diameter between about 2.5 inches (6.4 cm) and about 4 inches (10 cm) can be used to produce the webs of the present invention. A general purpose screw may be used.
  • a suitable feedblock is a single temperature zone, fixed plate block. The distribution plate is machined to provide specific layer thicknesses.
  • a suitable die is a single temperature zone flat die with “flex-lip” die gap adjustment.
  • the die gap is typically adjusted to be less than 0.020 inches (0.5 mm) and each segment is adjusted to provide for uniform thickness across the web. Any size die may be used as production needs may require, however, 10-14 inch (25-35 cm) dies have been found to be suitable.
  • the chill roll is typically water-cooled. Edge pinning is generally used and occasionally an air knife may be employed.
  • the placement of a tacky hydrophilic material onto the chill roll may be necessary.
  • release paper may be fed between the die and the chill roll to minimize contact of the tacky material with the rolls.
  • a preferred arrangement is to extrude the tacky material on the side away from the chill roll. This arrangement generally avoids sticking material onto the chill roll.
  • An extra stripping roll placed above the chill roll may also assist the removal of tacky material and also can provide for additional residence time on the chill roll to assist cooling the web.
  • tacky material may stick to downstream rolls. This problem may be minimized by either placing a low layer energy (e.g. Teflon®) sleeve on the affected rolls, wrapping Teflon tape on the effected rolls, or by feeding release paper in front of the effected rolls. Finally, if it appears that the tacky material may block to itself on the wound roll, release paper may be added immediately prior to winding. This is a standard method of preventing blocking of web during storage on wound rolls. Processing aids, release agents or contaminants should be minimized. In some cases, these additives can bloom to the layer and reduce the layer energy (raise the contact angle) of the hydrophilic layer.
  • a low layer energy e.g. Teflon®
  • An alternative method of making the multi-layer webs of the present invention is to extrude a web comprising a material suitable for one of the individual layers. Extrusion methods as may be known to the art for forming flat webs are suitable. Such webs may then be laminated to form a multi-layer web suitable for formation into a fluid pervious web using the methods discussed below. As will be recognized, a suitable material, such as a hot melt adhesive, can be used to join the webs to form the multi-layer web.
  • a preferred adhesive is a pressure sensitive hot melt adhesive such as a linear styrene isoprene styrene (“SIS”) hotmelt adhesive, but it is anticipated that other adhesives, such as polyester of polyamide powdered adhesives, hotmelt adhesives with a compatibilizer such as polyester, polyamide or low residual monomer polyurethanes, other hotmelt adhesives, or other pressure sensitive adhesives could be utilized in making the multi-layer webs of the present invention.
  • Alternative methods of joining the webs to form the multi-layer web include, but are not limited to, ultrasonic bonding, thermal bonding, or any other suitable means as are known in the art.
  • a base or carrier web can be separately extruded and one or more layers can be extruded thereon using an extrusion coating process to form a multi-layer formed web ply according to the present invention.
  • the carrier web passes under an extrusion die at a speed that is coordinated with the extruder speed so as to form a very thin web having a thickness of less than about 25 microns.
  • the molten polymer and the carrier web are brought into intimate contact as the molten polymer cools and bonds with the carrier web.
  • a tie layer may enhance bonding between the layers.
  • a tie layer is typically comprised of a thermoplastic material that is able to bond with both adjacent layers. Tie layers are joined to adjacent layers using bonding means including, but not limited to, chemical bonds, physical entanglement of thermoplastic chains, and combinations thereof. Contact and bonding are also normally enhanced by passing the layers through a nip formed between two rolls. The bonding may be further enhanced by subjecting the layer of the carrier web that is to contact the web to layer treatment, such as corona treatment, as is known in the art and described in Modern Plastics Encyclopedia Handbook, p. 236 (1994), which is hereby incorporated by reference.
  • layer treatment such as corona treatment
  • the thermoplastic formed web can be provided with substantially three dimensional surface structures using any process known in the art. Providing the web with three dimensional surface structures will provide the exterior surfaces of the web with a softer, more cloth-like texture, provide the web with a more cloth-like appearance, and increase the overall caliper of the web. Examples of three dimensional surface structures processes include but are not limited to the following: hydroforming, vacuum forming, needle punching (solid or hollow), mechanical embossing, flocking, ultrasonics, delamination of viscous melts from porous surfaces, printed hair, brushing, and any combination thereof.
  • three dimensional surface structures comprising microapertures are formed by applying a high pressure fluid jet comprised of water or the like against one surface of the formed web ply, preferably while applying a vacuum adjacent the opposite surface of the formed web ply.
  • the formed web ply is supported on one layer of a forming structure having opposed layers.
  • the forming structure is provided with a multiplicity of apertures there through which place the opposed layers in fluid communication with one another. While the forming structure may be stationary or moving, a preferred embodiment uses the forming structure as part of a continuous process where the formed web ply has a direction of travel and the forming structure carries formed web ply in the direction of travel while supporting the web.
  • the fluid jet and, preferably, the vacuum cooperate to provide a fluid pressure differential across the thickness of the web causing the web to be urged into conformity with the forming structure and to rupture in areas that coincide with the apertures in the forming structure.
  • the surface treated web of the present invention may also be formed by methods such as vacuum formation, mechanical methods such as punching, mechanical embossing, flocking, hydrosonics, ultrasonics, delamination of viscous melts or optionally delamination of viscous melts from porous surfaces, printed hair, and brushing.
  • Vacuum formation is disclosed in U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31, 1984, the disclosure of which is hereby incorporated herein by reference.
  • the polymeric film web can be provided with fluid transport apertures using any processes known in the art. Aperturing the web will increase the fluid handling properties of the web and provide the web with a more cloth-like, fiber-like appearance. Examples of such processes include but are not limited to the following: mechanical embossing, stretch rupturing, vacuum forming, hydroforming, hydrocutting, needle punching (solid or hollow), ultrasonics, slitting, ring-rolling, structural elastic-like web, and any combination thereof.
  • the fluid transport apertures are provided to the web by mechanically embossing and stretch rupturing the web material.
  • mechanical embossing are disclosed above.
  • stretch rupturing are disclosed in PCT Publication WO 97/31601, issued to Hansson on Sep. 4, 1997, and the Benson patents listed above. The disclosures of each of said patents are incorporated herein by reference with respect to aperturing also.
  • the term “absorbent article” refers to devices which absorb and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body.
  • the term “disposable” is used herein to describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use, and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner).
  • a “unitary” absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a separate holder and pad.
  • absorbent articles that incorporate the apertured polymeric film web and the multi-ply composite structure of the present invention include disposable articles including sanitary napkins, pantiliners, and diapers as described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference.
  • a Descriptive Analysis Panel of trained graders is used to compare the tactile softness, defined as fluffy, of a series of test products or topsheet materials.
  • fluffy is the attribute that describes the sensation of the nerve endings in the fingertips as they are stimulated by lightly stroking a sample.
  • the feel of 100% cotton flannel represents an extremely soft, fluffy material.
  • Graders are all female and are selected and trained for their ability to discriminate small differences in tactile softness. As part of this training, each grader identifies a “dominant” (i.e. most sensitive) hand which is used in all evaluations. Graders are monitored on a study to study basis and retrained as needed to minimize drift with time.
  • topsheet of sanitary pads When the topsheet of sanitary pads are evaluated, the pads are laid flat on the hard countertop surface with the topsheet facing up.
  • a felt sublayer is used to simulate the core.
  • a suitable material is 54 Polyester felt, Rainbow Classic, Royal Blue as is available from Kunin Felt of Hampton, N.H. Other sublayers may give different sensory outcomes.
  • Graders use the first three fingertips of their dominant hand arched in an upright position so only the fingertips contact the surface of the test sample. Graders use a floating stroke back and forth (5 cycles) across the entire length of the topsheet surface of the test sample. Graders grasp the edge of the test sample with their non-dominant hand using the thumb, forefinger and middle finger flatly against the counter surface to hold the sample in place. Graders are trained and calibrated on reference samples which provide a common sensory experience and demonstrate differences in the range of intensity for fluffiness. Relative intensities are indicated on a 6 inch, 0 to 60, line scale where 0 is defined as not fluffy at all and 60 is identified as very fluffy.
  • the scale is calibrated with two commercially available sanitary napkin products: Procter and Gamble's Always Ultra with Dri-weave (a vacuum-formed film topsheet) is defined as having a fluffiness score of “10” and Kao's Whyr Soft Mesh Slim Regular (with a nonwoven topsheet) is defined as a “50” on the fluffiness scale.
  • the room designed for sensory evaluations has individual booths for grader separation.
  • the booths have visual barriers that prevent the graders from seeing samples during evaluations.
  • test samples Up to six test samples may be evaluated in any one test period. Samples are presented to each grader in a random order. All samples are marked for direction prior to presentation so all graders evaluate the samples in the same direction. When topsheet-only samples are evaluated, the sample is first spread smoothly on the felt before presentation to the grader. Each sample is only graded one time. The grader grades each sample using the 60 point scale for softness by marking the grade on a linear scale. A minimum of 12 graders evaluate each sample.
  • the average and standard deviation are calculated for each sample tested. Outliers are excluded if they are more than two times the standard deviation away from the average.
  • the “softness index” is the average for each sample excluding any outliers. Known methods of determining statistically significant differences (e.g. analysis of variance, Newman-Keuls Multiple Range Test, etc.) may be used.
  • Strain gauge e.g. Ames Co. mechanical caliper gauge (Jeweled Shockless Model #482 Walthan, Mass., USA) capable of measuring to the nearest 0.001 inch and using a foot with area between 1-2 in 2 .
  • An extruded trilayer polymeric film web should be prepared in accordance with pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference.
  • Other embodiments of the present invention include webs extruded with materials exhibiting varying characteristics as described above (i.e., philic/philic, phobic, philic, surface energy gradient, permeability, etc.).
  • the extruded trilayer web comprising a polyethylene layer, a Bynel® 3860 layer and a 50/50 Hytrel® HTR 8171/Hytrel® HTR 8206 layer (80/10/10 layer weight ratio) described above is hydroformed on a 100-mesh screen with holes approximately 7 mil in diameter, under a water pressure of approximately 1,000 pounds per square inch (psi), at a temperature of 160° Fahrenheit (F.), and at a rate of 20 fpm.
  • psi pounds per square inch
  • F. 160° Fahrenheit
  • the three dimensional surface structures made in this way are cone-shaped microapertures with dimensions of approximately 3-7 mil diameter and 5-7 mil height.
  • the hydroformed web from A. above is fed through the “weakening roller arrangement” (see U.S. Pat. No. 5,628,097—FIGS. 2&3, which is incorporated herein by reference) preferably comprising a patterned calendar roller and the smooth anvil roller.
  • One or both of the rollers may be heated. Pressure between the two rollers may be adjusted to weaken and melt-stabilize the web at a plurality of locations.
  • the web is then passed through a nip formed by the incremental stretching system employing opposed pressure applicators having three-dimensional surfaces which at least to a degree are complimentary to one-another.
  • the incrementally stretching roller has a plurality of teeth and corresponding grooves which extend about the entire circumference of the roller.
  • the web is subjected to tensioning in the CD to cause the weakened melt-stabilized locations to rupture, creating a plurality of apertures coincident with the weakened melt stabilized locations in the web.
  • a polymeric film made of polyethylene (1.05 mil thick, 50/50 low density polyethylene/linear low density polyethylene) was processed for both steps A & B as in Example 1 above.
  • thermoplastic web as described above is abraded as described in Examples 1-4 of PCT Publication WO 99/06623 as cited above to create a fibrillated surface.
  • thermoplastic hydroformed web from Example 1. A. above is subjected to an abrasion step as described in PCT Publication WO 99/06623 as cited above.
  • the apertured polymeric film webs described in Examples 1-5 above may also be placed adjacent or joined to a sub-ply to form a multi-ply composite structure.
  • the ply may be apertured separately prior to forming the structure or apertured simultaneously to create common fluid communication pathways between the ply.

Abstract

The present invention pertains to an apertured polymeric film web material provided with a multiplicity of substantially three dimensional surface structures and provided with a multiplicity of fluid transport apertures. In one embodiment, the fluid transport apertures are formed using a process that substantially preserves the integrity of the surface structures. Methods of producing webs are also disclosed. The present invention also includes multi-ply composite structures formed using apertured polymeric film web materials and a sub-ply. The present invention also pertains to absorbent articles which preferably include a topsheet in accordance with the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.

Description

    FIELD OF THE INVENTION
  • The present invention relates to an apertured polymeric film web exhibiting a soft and silky tactile impression on at least one of its surfaces. The present invention also relates to absorbent articles incorporating a topsheet comprised of a web according to the present invention. [0001]
  • BACKGROUND OF THE INVENTION
  • It has long been known in the field of disposable absorbent articles that it is extremely desirable to construct absorptive devices, such as disposable diapers, sanitary napkins, incontinent briefs, bandages, wound dressings, and the like, presenting a soft, silky, cloth-like surface feel to the user to improve wearing comfort and confidence. [0002]
  • One solution to the aforementioned problem has been to utilize a covering or topsheet on the exposed, wearer-contacting layer which comprises a web of formed, apertured thermoplastic film. Commonly assigned U.S. Pat. No. 4,342,314, issued to Radel et al. on Aug. 3, 1982, the disclosure of which is hereby incorporated herein by reference, discloses a representative formed film of this variety. In order to address consumer concerns with regard to plastic-like appearance and feel, webs of this variety have been developed which include an interconnected structure of fiber-like appearance in the interest of generating a more cloth-like, aesthetically-pleasing appearance. In addition, apertured, formed thermoplastic film webs have been developed which further include microscopic surface texturing (microtexture) and/or microscopic apertures (microapertures) to further enhance the visual and tactile impression of such webs. Representative film webs of this variety are disclosed in commonly assigned U.S. Pat. No. 4,463,045, issued to Ahr et al. on Jul. 31, 1984, U.S. Pat. No. 4,629,643, issued Dec. 16, 1986 to Curro et al., and U.S. Pat. No. 4,609,518, issued Sep. 2, 1986 to Curro et al., the disclosures of which are hereby incorporated herein by reference. [0003]
  • Another solution has been to utilize a fibrous material as a covering or topsheet on such articles, alone or as an overlay or laminate over other materials. A representative topsheet structure of this variety is disclosed in Statutory Invention Registration H1670 published in the name of Aziz et al. on Jul. 1, 1997, the disclosure of which is hereby incorporated herein by reference. Such fibrous materials may take the form of a woven or nonwoven web of a suitable fiber variety, and may or may not include discretely formed apertures in addition to the inherent porosity of the web itself. Such fibrous webs exhibit an aesthetically-pleasing, cloth-like surface appearance and tactile impression due to the fibrous nature of the surface. [0004]
  • While fibrous webs tend to have more cloth-like aesthetics than film webs they also tend to retain fluid in the fiber interstices resulting in a wet topsheet versus films. What is needed then is a film-based web that has fibrous web-like aesthetics. The aforementioned Curro et al. patent makes some progress towards this end compared to the aforementioned Radel et al., but does not make a film web nearly as soft as the present invention. [0005]
  • SUMMARY OF THE INVENTION
  • The present invention meets the needs described above. A novel polymeric film web that enhances softness and silkiness is described below. [0006]
  • The present invention pertains to an apertured polymeric film web provided with a multiplicity of substantially three dimensional surface structures on at least one of the web's surfaces and provided with a multiplicity of fluid transport apertures. The web material shall exhibit a soft and silky tactile impression on at least one of its surfaces such that it has a softness index greater than about 35 and/or a compressibility index greater than about 25 percent. [0007]
  • Further embodiments of the present invention include utilizing unique combinations of processes to provide the polymeric film web with three dimensional surface structures and fluid transport apertures. [0008]
  • A still further embodiment of the present invention is a multi-ply composite structure. The multi-ply composite structure is comprised of at least two ply: a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply. The thermoplastic formed film ply can be comprised of web material as claimed herein and the sub-ply is adjacent to the garment facing surface of the thermoplastic formed web ply. [0009]
  • Still further embodiments of the present invention may include multi-ply composite structures comprised of materials with varying degrees of permeability. In such embodiments, fluid transport apertures are provided to form fluid pathways common to all ply. [0010]
  • Still further embodiments of the present invention may include any number of layers. In addition, the intermediate layer or layers may comprise any thermoplastic material. Any number of intermediate layers may be utilized in forming the thermoplastic formed web plies of the present invention. [0011]
  • The web material of the present invention provides many advantages. The unique combination of manufacturing processes selected and materials used results in a polymeric film web that is softer, silkier, and more cloth-like than prior film materials as measured by the softness index and compressibility index described herein. [0012]
  • The present invention also pertains to absorbent articles which preferably include a topsheet formed from the web material of the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.[0013]
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying drawings, in which like reference numbers identify like elements, and wherein: [0014]
  • FIG. 1 is a plan view scanning electron micrograph showing one embodiment of thermoplastic web of the present invention; [0015]
  • FIG. 2 is an enlarged cross-sectional scanning electron micrograph showing an arrangement of three dimensional surface structures and fluid transport apertures according to the present invention; [0016]
  • FIG. 3 is a plan view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention; [0017]
  • FIG. 4 is a tilt view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention; [0018]
  • FIG. 5 is a cross-sectional view scanning electron micrograph that shows (1) a web manufactured in a double hydroforming process as known in the prior art and (2) a web manufactured in accordance with the present invention; and [0019]
  • FIG. 6 is a cross-sectional view that shows one embodiment of a multi-ply composite structure according to the present invention.[0020]
  • DETAILED DESCRIPTION OF THE PRESENT INVENTION Definitions
  • As used herein, the term “hydrophilic” is used to refer to surfaces that are wettable by aqueous fluids (e.g., aqueous body fluids) deposited thereon. Hydrophilicity and wettability are typically defined in terms of water contact angle and the surface tension of the fluids and solid surfaces involved. This is discussed in detail in the American Chemical Society publication entitled [0021] Contact Angle, Wettability and Adhesion, edited by Robert F. Gould (Copyright 1964), which is hereby incorporated herein by reference. A surface is said to be wetted by a fluid (hydrophilic) when the fluid tends to spread spontaneously across the surface as opposed to forming discrete droplets. Conversely, a surface is considered to be “hydrophobic” if the fluid tends to form discrete droplets and does not spread spontaneously across the surface. As used herein, a “hydrophilic web or layer” generally has a water contact angle less than about 50 degrees. As used herein, a “hydrophobic web or layer” generally has a water contact angle greater than about 50 degrees.
  • The term “permanently hydrophilic” as used herein refers to a web that retains its low contact angle over long periods of time or after exposure to conditions that would otherwise remove surfactants. Such a film can be comprised of a block copolymer of a polyether and another polymer. Such a composition renders the web permanently hydrophilic thereby giving the web durable wettability without the need for surfactant treatment. [0022]
  • The water contact angle depends on surface inhomogeneities (e.g., chemical and physical properties, such as roughness), contamination, chemical/physical treatment of the solid surface, or composition of the solid surface, as well as contamination of the water. The surface energy of the solid also influences the water contact angle. As the surface energy of the solid decreases, the water contact angle increases. As the surface energy of the solid increases, the water contact angle decreases. [0023]
  • As used herein, the term “gradient” when applied to differences in surface energy or work of adhesion is intended to describe a change in surface energy or work of adhesion occurring over a measurable distance. The term “discontinuity” is intended to refer to a type of “gradient” or transition, wherein the change in surface energy occurs over an essentially zero distance. Accordingly, as used herein all “discontinuities” fall within the definition of “gradient”. [0024]
  • Also, as used herein the terms “capillary” and “capillarity” are used to refer to passageways, apertures, pores, or spaces within a structure which are capable of fluid transport in accordance with the principles of capillarity generally represented by the Laplace equation (1):[0025]
  • Δp=2 G(cos A)/R  (1)
  • where: [0026]
  • p is the capillary pressure; [0027]
  • R is the internal radius of the capillary (capillary radius); and [0028]
  • G is the surface tension of the liquid measured in dyne/cm, and [0029]
  • A is the liquid-solid water contact angle measured in degrees. [0030]
  • As noted in [0031] Penetration of Fabrics by Emery I. Valko, found in Chapter III of Chem. Aftertreat. Text. (1971), pp. 83-113, which is hereby incorporated herein by reference, for A=90°, the cosine of A is zero and there is no capillary pressure. For A>90°, the cosine of A is negative and the capillary pressure opposes the entry of fluid into the capillary. For A<90° the cosine of A is positive and the capillary pressure permits spontaneous entry of fluid into the capillary. Also, R must be sufficiently small for p to have a meaningful value, since as R increases (larger aperture/capillary structure) the capillary pressure decreases.
  • As utilized herein, the term “incompatible” represents the lack of miscibility between two materials such that each phase substantially retains its original properties. Example properties include glass transition temperature or melting point. Another characterization of incompatible materials is that the strength of the interface is significantly weaker than the strength of the weakest individual phase (material). Thus, the work of adhesion between the two materials is much lower than the lowest cohesive energy of either material, and the risk of delamination is high. [0032]
  • The term “tie layer” refers to any layer in a web ply that is comprised of material that serves to tie or join two incompatible materials. [0033]
  • The term “topsheet” generally refers to the cover layer, in an absorbent article such as a diaper or catamenial pad, that faces the wearer of the absorbent article. The term “wearer-contacting layer or surface” as used herein refers to the surface of a topsheet or other absorbent article component that is nearest the wearer of the article. The term “garment-facing layer or surface” refers to the surface of a topsheet or other absorbent article component that faces away from the wearer when the component is used in an absorbent article. [0034]
  • The term “Z-dimension” refers to the dimension orthogonal to the length and width of the layer, structure or article. The Z-dimension usually corresponds to the thickness of the layer, structure or article. [0035]
  • The term “three dimensional surface structure” refers to any three dimensional structure residing on the web surface that serves to enhance the soft and silky tactile impression of the web. Examples of such structures include but are not limited to the following: aberrations; fibrils; incongruities; cone structures; and apertures. Methods for providing three dimensional surface structures can be broken into two groups: 1) apertured methods; and 2) non-apertured methods. [0036]
  • Apertured methods include but are not limited to the following: vacuum forming, hydroforming, needle punching (solid or hollow), hydrosonics, ultrasonics, and any combination thereof. [0037]
  • Non-apertured methods include but are not limited to the following: mechanical embossing, flocking, delamination of viscous melts or optionally delamination of viscous melts from porous surfaces, printed hair, brushing, and any combination thereof. [0038]
  • The term “fluid transport aperture” refers to any aperture in the web that serves to transport fluids within the web. Examples of fluid transport aperturing processes include but are not limited to the following: mechanical embossing; stretch rupturing; vacuum forming; hydroforming; hydrocutting; needle punching (solid or hollow); hydrosonics; ultrasonics; slitting; ring-rolling; structural elastic-like web; and any combination thereof. [0039]
  • As utilized herein, the term “fluid passageway” is intended to encompass enclosed or at least partially enclosed structures or channels which may communicate fluids. The term fluid passageway is thus intended to encompass the terms “aperture”, “channel”, “capillary”, as well as other similar terms. The passageways inherent in fluid permeable materials are another example. Many other examples of fluid passageways exist in the art and may be used in the present invention. [0040]
  • The term “monolayer” refers to a ply that is comprised of a single layer of material. [0041]
  • The term “sub-ply” refers to a ply located beneath the body contacting ply. [0042]
  • The term “web” as used herein refers to a structure comprised of one or more ply. [0043]
  • The term “layer” as used herein refers to an individual layer or layers of material that are joined to form a ply. [0044]
  • The term “ply” as used herein refers to a structure that is comprised of one or more layers of material. [0045]
  • The term “surface” as used herein refers to a top or first side of a layer and/or a bottom or second side of a layer. [0046]
  • As used herein, the term “softness index” refers to the panel score unit achieved by a test material in the Panel Softness Test described below. [0047]
  • As used herein, the term “compressibility index” refers to the percent compression at 0.2 psi achieved by a test material in the Caliper vs. Z-compression Test described below. [0048]
  • As used herein, the term “absorbent article” refers to devices which absorb and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. The term “disposable” is used herein to describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use, and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). A “unitary” absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a separate holder and pad. [0049]
  • The Apertured Polymeric Web of the Present Invention
  • The apertured polymeric film web of the present invention is a web material that has been (1) provided with a multiplicity of substantially three dimensional surface structures that cause the web material to exhibit a soft, silky surface to improve the wearer's comfort and (2) provided with fluid transport apertures for improved fluid handling. [0050]
  • FIG. 1 is a plan view scanning electron micrograph of one embodiment of the formed web and depicts the three [0051] dimensional surface structures 100 and the fluid transport apertures 110 of the present invention web. FIG. 2 depicts an enlarged cross-sectional scanning electron micrograph along line A-A of FIG. 1 that shows the dimensional relationship of the three dimensional surface structures 200 and fluid transport apertures 210 according to the present invention. The size of both the three dimensional surface structures 200 and fluid transport apertures 210 may be varied. However, in a preferred embodiment the three dimensional surface structures are comprised of microapertures having a diameter of about 0.02-0.2 mm, a height of about 0.02-0.2 mm, and fluid transport apertures having a minimum diameter of about 0.05 mm. As is well known in the art, smaller fluid transport apertures will require apertures comprised of more hydrophilic materials to ensure sufficient fluid management properties.
  • FIGS. [0052] 3-5 are enlarged scanning electron micrograph depicting the plan view, tilt view, and cross section view of the following: (1) a typical prior art web wherein both three dimensional surface structures 300 and fluid transport apertures 310 were developed using hydroforming processes; and (2) a typical present invention web wherein the three dimensional surface structures 320 were developed by hydroforming but the fluid transport apertures 330 were developed by mechanical aperturing means. A comparison of these scanning electron micrographs reveals that the three dimensional surface structures 320 of the present invention as depicted in FIG. 3 are substantially less damaged than the three dimensional surface structures 310 developed by the double-hydroforming processes.
  • One aspect of the present invention is a fluid pervious web suitable for use as a topsheet in an absorbent article. In a preferred embodiment, the fluid pervious web of the present invention contains a plurality of microapertures. Although the fluid pervious web of the present invention is described herein as a topsheet for use in an absorbent article, one having ordinary skill in the art would recognize that the fluid pervious web of the present invention would have other uses, such as bandages, agricultural coverings, and similar uses where it is desirable to manage fluid flow through a web or ply. [0053]
  • Providing the fluid pervious web with fluid transport apertures provides the fluid handling properties of the web. In a preferred embodiment of the present invention, fluid transport apertures are provided to the web using means that leave the three dimensional surface structures substantially unaltered relative to their as-made state. In a preferred embodiment of the present invention, fluid transport apertures are provided by mechanically embossing and stretch rupturing the web as discussed below. [0054]
  • Web Material Characteristics
  • As described herein above, another aspect of the present invention is a topsheet comprising the polymeric film web of the present invention. The material selected for the polymeric film web of the present invention, and therefore for the topsheet formed therefrom, is preferably machinable and capable of being formed into a sheet. Since the topsheet is to be used in consumer products which contact the human body, the material utilized in the polymeric film web and used to form the topsheet is safe for epidermal or other human contact. [0055]
  • Examples of acceptable web materials are disclosed in commonly assigned U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31, 1984, and U.S. Pat. No. 4,629,643, issued Dec. 16, 1986 to Curro et al., the disclosures of which are hereby incorporated herein by reference. [0056]
  • In a preferred embodiment of the present invention, the web material selected creates a surface energy gradient between at least two of the web surfaces. Whenever the wearer-contacting layer and the garment-facing layer of the topsheet of the present invention comprise materials having different layer properties (eg., one of the layers is hydrophobic and the other is hydrophilic), a surface energy gradient is created. Surface energy gradients have been found to be useful in promoting fluid transport. A comprehensive explanation of surface energy gradients is described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference. [0057]
  • In a preferred embodiment of the present invention, the web material used is comprised of hydrophobic and permanently hydrophilic layers, as described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference. [0058]
  • The performance properties of the topsheet of the present invention may be manipulated depending on the orientation of the hydrophilic layer and the hydrophobic layer in the thermoplastic formed web ply from which the topsheet is formed. As described above, the thermoplastic formed web ply of the present invention may comprise any number of layers. The topsheet may be formed so that the wearer-contacting layer is a hydrophobic layer and the garment-facing layer is hydrophilic (known as “phobic/philic”), or so that the wearer-contacting layer is hydrophilic and the garment facing layer is hydrophobic (known as “philic/phobic”). In addition, by varying both the orientation of the hydrophilic and hydrophobic layers, many different topsheet structures, with different advantageous properties, can be formed according to the present invention. [0059]
  • The Multi-Ply Composite Structure of the Present Invention
  • As described above, the highly compressible webs of the present invention enhance the soft and silky tactile impression when used as topsheets. However, a consequence of these highly compressible materials is that the void volume between the topsheet material and the adjacent material is easily lost under in-use pressures. This can have the negative consequence of poor fluid management. Therefore, by combining the webs of the present invention described above with a sub-ply that is relatively non-compressible, the void volume can be protected and serve to provide better fluid management. [0060]
  • An alternative topsheet orientation, shown in FIG. 6, includes a thermoplastic formed film ply [0061] 610 comprised of polymeric film web material exhibiting preferred softness and/or compressibility indices as described herein and a sub-ply 620 to form a multi-ply composite structure 600.
  • The multi-ply [0062] composite structure 600 may be formed utilizing various combinations of non-apertured and apertured materials with varying degrees of permeability so long as the multi-ply composite structure 600 serves to transport fluids through the structure. In addition, the materials comprising the multi-ply composite structure 600 may be selected such that a surface energy gradient is formed between at least two exterior surfaces of the structure. In a preferred embodiment of the structure, both ply are provided with fluid transport apertures that form fluid pathways common to both ply. In another embodiment, the multi-ply composite structure 600 is formed such that it maintains a protected void volume during use.
  • The sub-ply can be comprised of a variety of different materials or combinations thereof. Suitable sub-ply materials include 1) apertured formed webs 2) cloth-like formed webs; 3) nonwovens; 4) wovens; 5) foams; 6) cellulosic webs; and 7) combinations thereof. [0063]
  • Suitable sub-ply formed films are described in U.S. Pat. No. 3,929,135, issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,246, issued to Mullane, et al. on Apr. 13, 1982; U.S. Pat. No. 4,342,314, issued to Radel, et al. on Aug. 3, 1982; U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31, 1984; and U.S. Pat. No. 5,006,394, issued to Baird on Apr. 9, 1991. One especially preferred formed web is described in one or more of the above patents and marketed on sanitary napkins by the Procter & Gamble Company of Cincinnati, Ohio as “DRI-WEAVE”. [0064]
  • Alternatively, cloth-like formed films may comprise the sub-ply. Such webs have a softer, more cloth-like feel. Cloth-like formed webs are developed by providing the web surface with either microapertures (as described above), surface texture (described below), or surface treatment (described below), or a combination thereof. The sub-ply may also be comprised of any nonwoven or woven material capable of transporting blood, menses, and/or urine. Other materials not listed herein, but capable of transporting blood, menses, and/or urine, are included in the present invention. [0065]
  • The thermoplastic formed web ply of the present invention may include any number of layers as long as there is a tie layer between any adjacent layers that comprise incompatible materials. In addition, the intermediate layer or layers may comprise any thermoplastic material as long as there is a tie layer between any adjacent incompatible layers. Any number of intermediate layers may be utilized in forming the thermoplastic formed web plies of the present invention. [0066]
  • Methods of Making
  • The polymeric film web of the present invention may be processed using conventional procedures for producing multi-layer webs on conventional coextruded web-making equipment. In general, polymers can be melt processed into webs using either cast or blown web extrusion methods both of which are described in [0067] Plastics Extrusion Technology-2nd Ed., by Allan A. Griff (Van Nostrand Reinhold 1976), which is hereby incorporated herein by reference. A cast web is extruded through a linear slot die. Generally, the flat web is cooled on a large moving polished metal roll (chill roll). It quickly cools, and peels off the first roll, passes over one or more auxiliary rolls, then through a set of rubber-coated pull or “haul-off” rolls, and finally to a winder.
  • In blown web extrusion the melt is extruded upward through a thin annular die opening. This process is also referred to as tubular web extrusion. Air is introduced through the center of the die to inflate the tube and causes it to expand. A moving bubble is thus formed which is held at constant size by simultaneous control of internal air pressure, extrusion rate, and haul-off speed. The tube of web is cooled by air blown through one or more chill rings surrounding the tube. The tube is next collapsed by drawing it into a flattened frame through a pair of pull rolls and into a winder. [0068]
  • A coextrusion process requires more than one extruder and either a coextrusion feedblock or a multi-manifold die system or combination of the two to achieve the multilayer web structure. U.S. Pat. Nos. 4,152,387 and 4,197,069, issued May 1, 1979 and Apr. 8, 1980, respectively, both to Cloeren, which are hereby incorporated herein by reference, disclose the feedblock and multi-manifold die principle of coextrusion. Multiple extruders are connected to the feedblock which can employ moveable flow dividers to proportionally change the geometry of each individual flow channel in direct relation to the volume of polymer passing through the flow channels. The flow channels are designed such that, at their point of confluence, the materials flow together at the same velocities and pressure, minimizing interfacial stress and flow instabilities. Once the materials are joined in the feedblock, they flow into a single manifold die as a composite structure. Other examples of feedblock and die systems are disclosed in [0069] Extrusion Dies for Plastics and Rubber, W. Michaeli, Hanser, N.Y., 2nd Ed., 1992, hereby incorporated herein by reference. It may be important in such processes that the melt viscosities, normal stress differences, and melt temperatures of the material do not differ too greatly. Otherwise, layer encapsulation or flow instabilities may result in the die leading to poor control of layer thickness distribution and defects from non-planar interfaces (e.g. fish eye) in the multilayer web.
  • An alternative to feedblock coextrusion is a multi-manifold or vane die as disclosed in aforementioned U.S. Pat. Nos. 4,152,387 and 4,197,069, as well as U.S. Pat. No. 4,533,308, issued Aug. 6, 1985 to Cloeren, hereby incorporated herein by reference. Whereas in the feedblock system melt streams are brought together outside and prior to entering the die body, in a multi-manifold or vane die each melt stream has its own manifold in the die where the polymers spread independently in their respective manifolds. The melt streams are married near the die exit with each melt stream at full die width. Moveable vanes provide adjustability of the exit of each flow channel in direct proportion to the volume of material flowing through it, allowing the melts to flow together at the same velocity, pressure, and desired width. [0070]
  • Since the melt flow properties and melt temperatures of polymers vary widely, use of a vane die has several advantages. The die lends itself toward thermal isolation characteristics wherein polymers of greatly differing melt temperatures, for example up to 175°F. (80° C.), can be processed together. [0071]
  • Each manifold in a vane die can be designed and tailored to a specific polymer. Thus the flow of each polymer is influenced only by the design of its manifold, and not forces imposed by other polymers. This allows materials with greatly differing melt viscosities to be coextruded into multi-layer webs. In addition, the vane die also provides the ability to tailor the width of individual manifolds, such that an internal layer can be completely surrounded by the outer layer leaving no exposed edges. The aforementioned patents also disclose the combined use of feedblock systems and vane dies to achieve more complex multilayer structures. [0072]
  • One of skill in the art will recognize that the size of an extruder used to produce the webs of the present invention depends on the desired production rate and that several sizes of extruders may be used. Suitable examples include extruders having a 1 (2.5 cm) to 1.5 inch (3.7 cm) diameter with a length/diameter ratio of 24 or 30. If required by greater production demands, the extruder diameter can range upwards. For example, extruders having a diameter between about 2.5 inches (6.4 cm) and about 4 inches (10 cm) can be used to produce the webs of the present invention. A general purpose screw may be used. A suitable feedblock is a single temperature zone, fixed plate block. The distribution plate is machined to provide specific layer thicknesses. For example, for a three layer web, the plate provides layers in an 80/10/10 thickness arrangement, a suitable die is a single temperature zone flat die with “flex-lip” die gap adjustment. The die gap is typically adjusted to be less than 0.020 inches (0.5 mm) and each segment is adjusted to provide for uniform thickness across the web. Any size die may be used as production needs may require, however, 10-14 inch (25-35 cm) dies have been found to be suitable. The chill roll is typically water-cooled. Edge pinning is generally used and occasionally an air knife may be employed. [0073]
  • For some coextruded webs, the placement of a tacky hydrophilic material onto the chill roll may be necessary. When the arrangement places the tacky material onto the chill roll, release paper may be fed between the die and the chill roll to minimize contact of the tacky material with the rolls. However, a preferred arrangement is to extrude the tacky material on the side away from the chill roll. This arrangement generally avoids sticking material onto the chill roll. An extra stripping roll placed above the chill roll may also assist the removal of tacky material and also can provide for additional residence time on the chill roll to assist cooling the web. [0074]
  • Occasionally, tacky material may stick to downstream rolls. This problem may be minimized by either placing a low layer energy (e.g. Teflon®) sleeve on the affected rolls, wrapping Teflon tape on the effected rolls, or by feeding release paper in front of the effected rolls. Finally, if it appears that the tacky material may block to itself on the wound roll, release paper may be added immediately prior to winding. This is a standard method of preventing blocking of web during storage on wound rolls. Processing aids, release agents or contaminants should be minimized. In some cases, these additives can bloom to the layer and reduce the layer energy (raise the contact angle) of the hydrophilic layer. [0075]
  • An alternative method of making the multi-layer webs of the present invention is to extrude a web comprising a material suitable for one of the individual layers. Extrusion methods as may be known to the art for forming flat webs are suitable. Such webs may then be laminated to form a multi-layer web suitable for formation into a fluid pervious web using the methods discussed below. As will be recognized, a suitable material, such as a hot melt adhesive, can be used to join the webs to form the multi-layer web. A preferred adhesive is a pressure sensitive hot melt adhesive such as a linear styrene isoprene styrene (“SIS”) hotmelt adhesive, but it is anticipated that other adhesives, such as polyester of polyamide powdered adhesives, hotmelt adhesives with a compatibilizer such as polyester, polyamide or low residual monomer polyurethanes, other hotmelt adhesives, or other pressure sensitive adhesives could be utilized in making the multi-layer webs of the present invention. Alternative methods of joining the webs to form the multi-layer web include, but are not limited to, ultrasonic bonding, thermal bonding, or any other suitable means as are known in the art. [0076]
  • In another alternative method of making the multi-layer formed web plies of the present invention, a base or carrier web can be separately extruded and one or more layers can be extruded thereon using an extrusion coating process to form a multi-layer formed web ply according to the present invention. Preferably, the carrier web passes under an extrusion die at a speed that is coordinated with the extruder speed so as to form a very thin web having a thickness of less than about 25 microns. The molten polymer and the carrier web are brought into intimate contact as the molten polymer cools and bonds with the carrier web. As noted above, a tie layer may enhance bonding between the layers. A tie layer is typically comprised of a thermoplastic material that is able to bond with both adjacent layers. Tie layers are joined to adjacent layers using bonding means including, but not limited to, chemical bonds, physical entanglement of thermoplastic chains, and combinations thereof. Contact and bonding are also normally enhanced by passing the layers through a nip formed between two rolls. The bonding may be further enhanced by subjecting the layer of the carrier web that is to contact the web to layer treatment, such as corona treatment, as is known in the art and described in [0077] Modern Plastics Encyclopedia Handbook, p. 236 (1994), which is hereby incorporated by reference.
  • The thermoplastic formed web can be provided with substantially three dimensional surface structures using any process known in the art. Providing the web with three dimensional surface structures will provide the exterior surfaces of the web with a softer, more cloth-like texture, provide the web with a more cloth-like appearance, and increase the overall caliper of the web. Examples of three dimensional surface structures processes include but are not limited to the following: hydroforming, vacuum forming, needle punching (solid or hollow), mechanical embossing, flocking, ultrasonics, delamination of viscous melts from porous surfaces, printed hair, brushing, and any combination thereof. [0078]
  • In a preferred embodiment, three dimensional surface structures comprising microapertures are formed by applying a high pressure fluid jet comprised of water or the like against one surface of the formed web ply, preferably while applying a vacuum adjacent the opposite surface of the formed web ply. In general, the formed web ply is supported on one layer of a forming structure having opposed layers. The forming structure is provided with a multiplicity of apertures there through which place the opposed layers in fluid communication with one another. While the forming structure may be stationary or moving, a preferred embodiment uses the forming structure as part of a continuous process where the formed web ply has a direction of travel and the forming structure carries formed web ply in the direction of travel while supporting the web. The fluid jet and, preferably, the vacuum cooperate to provide a fluid pressure differential across the thickness of the web causing the web to be urged into conformity with the forming structure and to rupture in areas that coincide with the apertures in the forming structure. [0079]
  • Such methods of aperturing are known as “hydroformation” and are described in greater detail in commonly assigned U.S. Pat. No. 4,609,518 issued to Curro, et al. on Sept. 2, 1986; U.S. Pat. No. 4,629,643 issued to Curro, et al. on Dec. 16, 1986; U.S. Pat. No. 4,637,819 issued to Ouellette, et al. on Jan. 20, 1987; U.S. Pat. No. 4,681,793 issued to Linman, et al. on Jul. 21, 1987; U.S. Pat. No. 4,695,422 issued to Curro, et al. on Sept. 22, 1987; U.S. Pat. No. 4,778,644 issued to Curro, et al. on Oct. 18, 1988; U.S. Pat. No. 4,839,216 issued to Curro, et al. on Jun. 13, 1989; and U.S. Pat. No. 4,846,821 issued to Lyons, et al. on Jul. 11, 1989, the disclosures of each of said patents being incorporated herein by reference. [0080]
  • As mentioned above, the surface treated web of the present invention may also be formed by methods such as vacuum formation, mechanical methods such as punching, mechanical embossing, flocking, hydrosonics, ultrasonics, delamination of viscous melts or optionally delamination of viscous melts from porous surfaces, printed hair, and brushing. [0081]
  • Vacuum formation is disclosed in U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31, 1984, the disclosure of which is hereby incorporated herein by reference. [0082]
  • Examples of mechanical methods are disclosed in U.S. Pat. No. 4,798,604, issued to Carter on Jan. 17, 1989, U.S. Pat. No. 4,780,352, issued to Palumbo on Oct. 25, 1988, U.S. Pat. No. 3,566,726, issued to Politis on Mar. 2, 1971, U.S. Pat. No. 4,634,440, issued to Widlund, et al. on Jan. 6, 1987, PCT Publication WO 97/40793, issued to Johansson, et al. on Nov. 6, 1997, and European Patent 525,676, issued to Dabi, et al., the disclosures of each of said patents being incorporated herein by reference. [0083]
  • Examples of mechanical embossing are disclosed in European Patents 862,904, issued to Hisashi, et al. on Sep. 9, 1998, 858,792, issued to Tsuji, et al. on Aug. 19, 1998, Japanese Patents 8-260,329, issued to Wataru, et al., 10-131,014, issued to Wataru, et al., and U.S. Pat. No. 5,916,661, issued to Benson, et al. on Jun. 29, 1999, U.S. Pat. No. 5,628,097, issued to Benson, et al. on May 13, 1997, the disclosures of each of said patents being incorporated herein by reference. [0084]
  • Examples of flocking are disclosed in PCT Publications WO 98/42289, issued to Chen, et al. on Oct. 1, 1998, WO 98/36721, issued to Johansson, et al. on Aug. 27, 1998, and European Patent 861,646, issued to Takai, et al. on Sep. 2, 1998, the disclosures of each of said patents being incorporated herein by reference. [0085]
  • Examples of ultrasonics are disclosed in U.S. Pat. No. 5,269,981, issued to Jameson, et al. on Dec. 14, 1993, the disclosure of which is hereby incorporated herein by reference. [0086]
  • Examples of delamination of viscous melts are disclosed in U.S. Pat. No. 3,967,623, issued to Butterworth et al. on Jul. 6, 1976. Examples of delamination of viscous melts from porous surfaces are disclosed in PCT Publication WO 99/06623, issued to Calhoun, et al. on Feb. 11, 1999. Both disclosures of which are hereby incorporated herein by reference. [0087]
  • Examples of printed hair are disclosed in U.S. Pat. No. 5,670,110, issued to Dirk, et al. on Sep. 23, 1997, the disclosure of which is hereby incorporated herein by reference. [0088]
  • Examples of brushing are disclosed in PCT Publication WO 99/06623, issued to Calhoun, et al. on Feb. 11, 1999, the disclosure of which is hereby incorporated herein by reference. [0089]
  • The polymeric film web can be provided with fluid transport apertures using any processes known in the art. Aperturing the web will increase the fluid handling properties of the web and provide the web with a more cloth-like, fiber-like appearance. Examples of such processes include but are not limited to the following: mechanical embossing, stretch rupturing, vacuum forming, hydroforming, hydrocutting, needle punching (solid or hollow), ultrasonics, slitting, ring-rolling, structural elastic-like web, and any combination thereof. [0090]
  • In a preferred embodiment, the fluid transport apertures are provided to the web by mechanically embossing and stretch rupturing the web material. Examples of mechanical embossing are disclosed above. Examples of stretch rupturing are disclosed in PCT Publication WO 97/31601, issued to Hansson on Sep. 4, 1997, and the Benson patents listed above. The disclosures of each of said patents are incorporated herein by reference with respect to aperturing also. [0091]
  • Methods for vacuum formation, hydroforming, needle punching, and ultrasonics are described above. The disclosures of each of said patents are incorporated herein by reference with respect to aperturing also. With respect to ultrasonics, additional methods are disclosed in U.S. Pat. No. 5,879,494, issued to Hoff, et al. on Mar. 9, 1999, U.S. Pat. No. 5,269,981, issued to Jameson, et al. on Dec. 14, 1993, and European Patent 5,355,579, issued to Jameson, et al. on Apr. 7, 1993. The disclosures of each of said patents are incorporated herein by reference. [0092]
  • Methods of hydrocutting are disclosed in U.S. Pat. No. 5,567,736, issued to Turi, et al. on Oct. 22, 1996, and U.S. Pat. No. 5,770,144, issued to James, et al. on Jun. 23, 1998. The disclosures of each of said patents are incorporated herein by reference. [0093]
  • Suitable slitting methods are disclosed in PCT Publication WO 97/31601, issued to Hansson on Sep. 4, 1997, the disclosure of which is hereby incorporated herein by reference. [0094]
  • Suitable processes for ring rolling or “pre-corrugating” are described in U.S. Pat. No. 4,107,364 issued to Sisson on Aug. 15, 1978, U.S. Pat. No. 4,834,741 issued to Sabee on May 30, 1989, U.S. Pat. No. 5,167,897 issued to Weber et al. on Dec. 1, 1992, U.S. Pat. No. 5,156,793 issued to Buell et al. on Oct. 20, 1992, and U.S. Pat. No. 5,143,679 issued to Weber on Sep. 1, 1992. The disclosures of which are incorporated by reference. [0095]
  • Suitable methods of SELF-ing are described in U.S. Pat. No. 5,518,801 issued to Chappell et al. on May 21, 1996. The disclosure of which is incorporated by reference. [0096]
  • Absorbent Articles According to the Present Invention
  • As used herein, the term “absorbent article” refers to devices which absorb and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. The term “disposable” is used herein to describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use, and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). A “unitary” absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a separate holder and pad. Examples of absorbent articles that incorporate the apertured polymeric film web and the multi-ply composite structure of the present invention include disposable articles including sanitary napkins, pantiliners, and diapers as described in pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference. [0097]
  • Test Methods Softness Index Panel Softness Overview
  • A Descriptive Analysis Panel of trained graders is used to compare the tactile softness, defined as fluffy, of a series of test products or topsheet materials. As used herein, fluffy is the attribute that describes the sensation of the nerve endings in the fingertips as they are stimulated by lightly stroking a sample. The feel of 100% cotton flannel represents an extremely soft, fluffy material. [0098]
  • Graders
  • Graders are all female and are selected and trained for their ability to discriminate small differences in tactile softness. As part of this training, each grader identifies a “dominant” (i.e. most sensitive) hand which is used in all evaluations. Graders are monitored on a study to study basis and retrained as needed to minimize drift with time. [0099]
  • Grading and Calibration
  • When the topsheet of sanitary pads are evaluated, the pads are laid flat on the hard countertop surface with the topsheet facing up. When topsheet-only evaluations are performed, a felt sublayer is used to simulate the core. A suitable material is 54 Polyester felt, Rainbow Classic, Royal Blue as is available from Kunin Felt of Hampton, N.H. Other sublayers may give different sensory outcomes. [0100]
  • Graders use the first three fingertips of their dominant hand arched in an upright position so only the fingertips contact the surface of the test sample. Graders use a floating stroke back and forth (5 cycles) across the entire length of the topsheet surface of the test sample. Graders grasp the edge of the test sample with their non-dominant hand using the thumb, forefinger and middle finger flatly against the counter surface to hold the sample in place. Graders are trained and calibrated on reference samples which provide a common sensory experience and demonstrate differences in the range of intensity for fluffiness. Relative intensities are indicated on a 6 inch, 0 to 60, line scale where 0 is defined as not fluffy at all and 60 is identified as very fluffy. [0101]
  • The scale is calibrated with two commercially available sanitary napkin products: Procter and Gamble's Always Ultra with Dri-weave (a vacuum-formed film topsheet) is defined as having a fluffiness score of “10” and Kao's Laurier Soft Mesh Slim Regular (with a nonwoven topsheet) is defined as a “50” on the fluffiness scale. [0102]
  • Apparatus
  • The room designed for sensory evaluations has individual booths for grader separation. The booths have visual barriers that prevent the graders from seeing samples during evaluations. [0103]
  • Method
  • Up to six test samples may be evaluated in any one test period. Samples are presented to each grader in a random order. All samples are marked for direction prior to presentation so all graders evaluate the samples in the same direction. When topsheet-only samples are evaluated, the sample is first spread smoothly on the felt before presentation to the grader. Each sample is only graded one time. The grader grades each sample using the 60 point scale for softness by marking the grade on a linear scale. A minimum of 12 graders evaluate each sample. [0104]
  • Report
  • The average and standard deviation are calculated for each sample tested. Outliers are excluded if they are more than two times the standard deviation away from the average. The “softness index” is the average for each sample excluding any outliers. Known methods of determining statistically significant differences (e.g. analysis of variance, Newman-Keuls Multiple Range Test, etc.) may be used. [0105]
  • Compressibility Index Caliper vs. Z-compression Protocol
  • A. Materials: [0106]
  • 1. Strain gauge (e.g. Ames Co. mechanical caliper gauge (Jeweled Shockless Model #482 Walthan, Mass., USA) capable of measuring to the nearest 0.001 inch and using a foot with area between 1-2 in[0107] 2.
  • 2. Sample with dimensions or area larger than the area of the foot. [0108]
  • B. Protocol: [0109]
  • 1. Place sample under the foot of the strain gauge so that a.) there are no wrinkles or creases in the sample, and b.) the sample edges extend beyond the edges of the foot. All measurements taken at 73° F. [0110]
  • 2. Lower the foot to achieve a pressure of 0.06 psi. [0111]
  • 3. Wait 10 seconds and then record caliper to the nearest 0.001 inch. [0112]
  • 4. Add weight immediately after recording caliper to obtain a pressure of 0.1 psi. [0113]
  • 5. Repeat steps 3 & 4, except add the weight sufficient to obtain pressures of 0.2, 0.5, 0.75 & 1.0 psi. [0114]
  • 6. Repeat steps 1 through 5 for 3 additional sections on the same sample or 3 new samples, do not re-test any of the sections. [0115]
  • Calculations
  • 1. Calculate the “compressibility” for each sample, as used herein, is the % compression at 0.2 psi, by the following equation:[0116]
  • “Compressibility”=[(L 0 −L)/L 0]×100
  • L[0117] 0=caliper at 0.06 psi
  • L=caliper at 0.2 psi [0118]
  • Calculate the “compressibility index” by averaging the “compressibility” of the four samples. [0119]
  • Test Results
  • As can be seen in the Table below, representative apertured polymeric film webs of the present invention are both softer and more compressible than those of prior art. DRI-WEAVE has a particularly plastic-feeling top surface and is not easily compressed. The doubly hydroforned prior art film, while it has much better tactile feel and compressibility, is still not nearly as soft, silky and cloth-like as the webs of the present invention. Thus, the surprising combination of three dimensional surface structures and fluid transport apertures can provide polymeric film webs with aesthetics similar to nonwovens without the undesirable fluid retaining capillary network common to nonwovens. [0120]
    Compressibility
    Softness Index Index
    Topsheet (panel score unit) (%)
    Prior art vacuum formed film (1)  6 10
    Prior art doubly hydroformed film (2) 33 22
    EXAMPLE 2 of present invention 47 44
    EXAMPLE 3 of present invention 41 41
  • EXAMPLES Web Preparation Example
  • An extruded trilayer polymeric film web should be prepared in accordance with pending U.S. application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is hereby incorporated herein by reference. Other embodiments of the present invention include webs extruded with materials exhibiting varying characteristics as described above (i.e., philic/philic, phobic, philic, surface energy gradient, permeability, etc.). [0121]
  • Web Processing Examples
  • The following examples demonstrate the processing of a polymeric film web to provide the web with three dimensional surface structures and fluid transport apertures. The following examples have permanent hydrophilicity according to a preferred embodiment of the present invention. Other embodiments of the present invention webs with varying characteristics. [0122]
  • Example 1
  • A. Three Dimensional Surface Structure Process [0123]
  • The extruded trilayer web comprising a polyethylene layer, a Bynel® 3860 layer and a 50/50 Hytrel® HTR 8171/Hytrel® HTR 8206 layer (80/10/10 layer weight ratio) described above is hydroformed on a 100-mesh screen with holes approximately 7 mil in diameter, under a water pressure of approximately 1,000 pounds per square inch (psi), at a temperature of 160° Fahrenheit (F.), and at a rate of 20 fpm. [0124]
  • The three dimensional surface structures made in this way are cone-shaped microapertures with dimensions of approximately 3-7 mil diameter and 5-7 mil height. [0125]
  • B. Fluid Transport Aperturing Process [0126]
  • The hydroformed web from A. above is fed through the “weakening roller arrangement” (see U.S. Pat. No. 5,628,097—FIGS. 2&3, which is incorporated herein by reference) preferably comprising a patterned calendar roller and the smooth anvil roller. One or both of the rollers may be heated. Pressure between the two rollers may be adjusted to weaken and melt-stabilize the web at a plurality of locations. The web is then passed through a nip formed by the incremental stretching system employing opposed pressure applicators having three-dimensional surfaces which at least to a degree are complimentary to one-another. The incrementally stretching roller has a plurality of teeth and corresponding grooves which extend about the entire circumference of the roller. The web is subjected to tensioning in the CD to cause the weakened melt-stabilized locations to rupture, creating a plurality of apertures coincident with the weakened melt stabilized locations in the web. [0127]
  • Example 2
  • A. Three Dimensional Surface Structure Process and Fluid Transport Aperturing Process [0128]
  • A polymeric film made of polyethylene (1.05 mil thick, 50/50 low density polyethylene/linear low density polyethylene) was processed for both steps A & B as in Example 1 above. [0129]
  • Example 3
  • A. Three Dimensional Surface Structure Process [0130]
  • A polymeric film made of polyethylene (1.05 mil thick, 50/50 low density polyethylene/linear low density polyethylene) was hydroformed and apertured as in Example 1 above. [0131]
  • B. Fluid Transport Aperturing Process [0132]
  • 100 Mesh hydroformed film was placed between the mutually engagable male/female plates (PGP Herringbone #87, Harrington Product Development Center, Cincinnati, Ohio). Mutually engagable plate assembly containing material was loaded into a hydraulic press (e.g. Hydraulic press, Model #6277/93, Scott Industrial Systems Co., Dayton, Ohio). SELFing (SELF: Structural Elastic-Like Film, as taught in U.S. Pat. No. 5,518,801) was then performed by engaging male and female plate until a pressure of 400 psi is reached for approximately 2 seconds. [0133]
  • Example 4
  • A. Three Dimensional Surface Structure Process [0134]
  • A thermoplastic web as described above is abraded as described in Examples 1-4 of PCT Publication WO 99/06623 as cited above to create a fibrillated surface. [0135]
  • B. Fluid Transport Aperturing Process [0136]
  • The web from A. above is apertured as in Example 1. B. above. [0137]
  • Example 5
  • A. Three Dimensional Surface Structure Process [0138]
  • A thermoplastic hydroformed web from Example 1. A. above is subjected to an abrasion step as described in PCT Publication WO 99/06623 as cited above. [0139]
  • B. Fluid Transport Aperturing Process [0140]
  • The web from A. above is apertured using needles according to PCT Publication WO 98/36721 as cited above. [0141]
  • The steps delineated in the above examples may be performed in any order and combination excluding those that are described in the prior art. [0142]
  • As mentioned above, the apertured polymeric film webs described in Examples 1-5 above may also be placed adjacent or joined to a sub-ply to form a multi-ply composite structure. In creating such a structure, the ply may be apertured separately prior to forming the structure or apertured simultaneously to create common fluid communication pathways between the ply. [0143]
  • The disclosures of all patents, patent applications (and any patents which issue thereon, as well as any corresponding published foreign patent applications), and publications mentioned throughout this description are hereby incorporated by reference herein. It is expressly not admitted, however, that any of the documents incorporated by reference herein teach or disclose the present invention. [0144]
  • While various embodiments and/or individual features of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. As will be also be apparent to the skilled practitioner, all combinations of the embodiments and features taught in the foregoing disclosure are possible and can result in preferred executions of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. [0145]

Claims (51)

What is claimed is:
1. An apertured polymeric film web having multiple surfaces and exhibiting a soft and silky tactile impression on at least one of said surfaces, wherein:
said polymeric film web is provided with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces of said polymeric film web;
said polymeric film web is provided with a multiplicity of fluid transport apertures that place at least two of said surfaces in fluid communication with one another; and
said polymeric film web has a softness index greater than 35.
2. An apertured polymeric film web having multiple surfaces and exhibiting a soft and silky tactile impression on at least one of said surfaces, wherein:
said polymeric film web is provided with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces of said polymeric film web;
said polymeric film web is provided with a multiplicity of fluid transport apertures that place at least two of said surfaces in fluid communication with one another; and
said polymeric film web has a compressibility index greater than 25 percent.
3. The polymeric film web of claim 1, wherein said three dimensional surface structures are substantially unaltered relative to their as-made state.
4. The polymeric film web of claim 2, wherein said three dimensional surface structures are substantially unaltered relative to their as-made state.
5. The polymeric film web of claim 1, said web further comprises a top surface and a bottom surface, wherein:
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
6. The polymeric film web of claim 2, said web further comprises a top surface and a bottom surface, wherein:
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
7. The polymeric film web of claim 1, said polymeric film web further comprising a thermoplastic formed film ply comprising at least a first layer and a second layer, wherein:
said first layer is less hydrophilic than said second layer; and
said second layer is permanently hydrophilic.
8. The polymeric film web of claim 2, said polymeric film web further comprising a thermoplastic formed film ply comprising at least a first layer and a second layer, wherein:
said first layer is less hydrophilic than said second layer; and
said second layer is permanently hydrophilic.
9. A method of making an apertured polymeric film web having a softness index greater than 35, the method comprising the steps of:
a) providing at least one thermoplastic material;
b) melting each of said thermoplastic materials;
c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;
d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures; and
e) providing said film with a multiplicity of fluid transport apertures.
10. The method of making an apertured polymeric film web of claim 9, wherein step e is completed prior to step d.
11. A method of making an apertured polymeric film web having a compressibility index greater than 25 percent, the method comprising the steps of:
a) providing at least one thermoplastic material;
b) melting each of said thermoplastic materials;
c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;
d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures; and
e) providing said film with a multiplicity of fluid transport apertures.
12. The method of making an apertured polymeric film web of claim 11, wherein step e is completed prior to step d.
13. A method of making an apertured polymeric film web, the method comprising the steps of:
a) providing at least one thermoplastic material;
b) melting each of said thermoplastic materials;
c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;
d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures using a process selected from the group consisting of vacuum forming, hydroforming, solid needle punching, hollow needle punching, ultrasonics, and hydrosonics; and
e) providing said film with a multiplicity of fluid transport apertures using a process selected from the group consisting of mechanical embossing, stretch rupturing, vacuum forming, solid needle punching, hollow needle punching, ultrasonics, hydrosonics, slitting, ring-rolling, forming structural elastic like film, and sintering.
14. The method of making an apertured polymeric film web in claim 13, wherein:
said process for providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures is selected from the group consisting of vacuum forming, solid needle punching, hollow needle punching, ultrasonics, and hydrosonics; and
said process for providing said film with a multiplicity of fluid transport apertures is hydroforming.
15. The method of making an apertured polymeric film web of claim 13, wherein step e is completed prior to step d.
16. The method of making an apertured polymeric film web of claim 14, wherein step e is completed prior to step d.
17. A multi-ply composite structure comprised of a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply, wherein:
said thermoplastic formed film ply is comprised of the apertured polymeric film web in claim 1; and
said fluid permeable sub-ply is adjacent to said garment facing surface of said thermoplastic formed film ply.
18. A multi-ply composite structure comprised of a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply, wherein:
said thermoplastic formed film ply is comprised of the apertured polymeric film web in claim 2; and
said fluid permeable sub-ply is adjacent to said garment facing surface of said thermoplastic formed film ply.
19. The multi-ply composite structure of claim 17, said thermoplastic formed film ply further comprises:
at least a top surface and a bottom surface, wherein
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
20. The multi-ply composite structure of claim 18, said thermoplastic formed film ply further comprises:
at least a top surface and a bottom surface, wherein
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
21. A multi-ply composite structure comprised of a thermoplastic formed film ply having a body facing surface and a garment facing surface and a sub-ply, wherein:
said body facing surface has a multiplicity of substantially three dimensional surface structures disposed thereon;
said thermoplastic formed film ply is provided with fluid transport apertures to form an apertured thermoplastic formed film ply;
said sub-ply is provided with fluid transport apertures and is adjacent to said garment facing surface of said apertured thermoplastic formed film ply; and
said fluid transport apertures form fluid pathways common to both of said ply.
22. The multi-ply composite structure of claim 21, wherein said sub-ply is comprised of a fluid permeable material.
23. The multi-ply composite structure of claim 21, said apertured thermoplastic formed film ply further comprising:
at least a top surface and a bottom surface, wherein
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
24. A method of making a multi-ply composite, the method comprising the steps of:
a) providing a fluid permeable thermoplastic formed film ply having multiple surfaces with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces;
b) providing a sub-ply having multiple surfaces; and
c) feeding said fluid permeable thermoplastic formed film ply and said sub-ply simultaneously through an aperturing process to form an apertured multi-ply composite structure having fluid transport pathways common to both of said ply.
25. The method of making a multi-ply composite structure in claim 24, wherein said sub-ply is comprised of a fluid permeable material.
26. The method of making a multi-ply composite structure in claim 24, wherein the aperturing process leaves said three dimensional surface structures substantially unaltered relative to their as-made state.
27. The method of making a multi-ply composite structure in claim 24, said thermoplastic formed film ply further comprising:
at least a top surface and a bottom surface, wherein
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
28. The method of making a multi-ply composite structure in claim 24, said thermoplastic formed film ply further comprising:
at least a first layer and a second layer, wherein
said first layer is less hydrophilic than said second layer; and
said second layer is permanently hydrophilic.
29. A method of making a multi-ply composite, the method comprising the steps of:
a) providing a fluid permeable thermoplastic formed film ply having multiple surfaces with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces;
b) providing a fluid permeable sub-ply having multiple surfaces; and
c) laying one surface of said thermoplastic formed film ply adjacent to one surface of said sub-ply to form a multi-ply composite structure.
30. The method of making a multi-ply composite structure in claim 29, said thermoplastic formed film ply further comprising:
at least a top surface and a bottom surface, wherein
said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.
31. The method of making a multi-ply composite structure in claim 29, said thermoplastic formed film ply further comprising:
at least a first layer and a second layer, wherein
said first layer is less hydrophilic than said second layer; and
said second layer is permanently hydrophilic.
32. The apertured polymeric film web of claim 1, wherein said web is suitable for use as a topsheet on an absorbent article and said article is disposable.
33. The apertured polymeric film web of claim 1, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a sanitary napkin or a pantiliner.
34. The apertured polymeric film web of claim 1, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a disposable diaper.
35. The apertured polymeric film web of claim 1, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a tampon.
36. The apertured polymeric film web of claim 2, wherein said web is suitable for use as a topsheet on an absorbent article and said article is disposable.
37. The apertured polymeric film web of claim 2, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a sanitary napkin or a pantiliner.
38. The apertured polymeric film web of claim 2, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a disposable diaper.
39. The apertured polymeric film web of claim 2, wherein said web is suitable for use as a topsheet on an absorbent article and said article is a tampon.
40. The multi-ply composite structure of claim 17, wherein said structure is suitable for use in an absorbent article and said article is disposable.
41. The multi-ply composite structure of claim 17, wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.
42. The multi-ply composite structure of claim 17, wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.
43. The multi-ply composite structure of claim 17, wherein said structure is suitable for use in an absorbent article and said article is a tampon.
44. The multi-ply composite structure of claim 18, wherein said structure is suitable for use in an absorbent article and said article is disposable.
45. The multi-ply composite structure of claim 18, wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.
46. The multi-ply composite structure of claim 18, wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.
47. The multi-ply composite structure of claim 18, wherein said structure is suitable for use in an absorbent article and said article is a tampon.
48. The multi-ply composite structure of claim 21, wherein said structure is suitable for use in an absorbent article and said article is disposable.
49. The multi-ply composite structure of claim 21, wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.
50. The multi-ply composite structure of claim 21, wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.
51. The multi-ply composite structure of claim 21, wherein said structure is suitable for use in an absorbent article and said article is a tampon.
US10/217,911 2000-04-07 2002-08-13 Apertured polymeric film webs and absorbent articles using such webs Abandoned US20030003269A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US10/217,911 US20030003269A1 (en) 2000-04-07 2002-08-13 Apertured polymeric film webs and absorbent articles using such webs
US11/130,877 US9700463B2 (en) 2000-04-07 2005-05-17 Apertured polymeric film webs and absorbent articles using such webs
US12/193,325 US9744080B2 (en) 2000-04-07 2008-08-18 Apertured polymeric film webs and absorbent articles using such webs
US15/584,165 US10124556B2 (en) 2000-04-07 2017-05-16 Apertured polymeric film webs and absorbent articles using such webs
US15/992,647 US10272635B2 (en) 2000-04-07 2018-05-30 Apertured polymeric film webs and absorbent articles using such webs
US15/995,193 US10611119B2 (en) 2000-04-07 2018-06-01 Apertured polymeric film webs and absorbent articles using such webs
US16/007,286 US20180290422A1 (en) 2000-04-07 2018-06-13 Apertured Polymeric Film Webs And Absorbent Articles Using Such Webs
US16/813,804 US10850475B2 (en) 2000-04-07 2020-03-10 Apertured polymeric film webs and absorbent articles using such webs

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US54488600A 2000-04-07 2000-04-07
US10/217,911 US20030003269A1 (en) 2000-04-07 2002-08-13 Apertured polymeric film webs and absorbent articles using such webs

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US54488600A Division 2000-04-07 2000-04-07

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US11/130,877 Continuation US9700463B2 (en) 2000-04-07 2005-05-17 Apertured polymeric film webs and absorbent articles using such webs
US11/130,877 Continuation-In-Part US9700463B2 (en) 2000-04-07 2005-05-17 Apertured polymeric film webs and absorbent articles using such webs

Publications (1)

Publication Number Publication Date
US20030003269A1 true US20030003269A1 (en) 2003-01-02

Family

ID=24174003

Family Applications (8)

Application Number Title Priority Date Filing Date
US10/217,911 Abandoned US20030003269A1 (en) 2000-04-07 2002-08-13 Apertured polymeric film webs and absorbent articles using such webs
US11/130,877 Expired - Lifetime US9700463B2 (en) 2000-04-07 2005-05-17 Apertured polymeric film webs and absorbent articles using such webs
US12/193,325 Expired - Lifetime US9744080B2 (en) 2000-04-07 2008-08-18 Apertured polymeric film webs and absorbent articles using such webs
US15/584,165 Expired - Lifetime US10124556B2 (en) 2000-04-07 2017-05-16 Apertured polymeric film webs and absorbent articles using such webs
US15/992,647 Expired - Fee Related US10272635B2 (en) 2000-04-07 2018-05-30 Apertured polymeric film webs and absorbent articles using such webs
US15/995,193 Expired - Lifetime US10611119B2 (en) 2000-04-07 2018-06-01 Apertured polymeric film webs and absorbent articles using such webs
US16/007,286 Abandoned US20180290422A1 (en) 2000-04-07 2018-06-13 Apertured Polymeric Film Webs And Absorbent Articles Using Such Webs
US16/813,804 Expired - Lifetime US10850475B2 (en) 2000-04-07 2020-03-10 Apertured polymeric film webs and absorbent articles using such webs

Family Applications After (7)

Application Number Title Priority Date Filing Date
US11/130,877 Expired - Lifetime US9700463B2 (en) 2000-04-07 2005-05-17 Apertured polymeric film webs and absorbent articles using such webs
US12/193,325 Expired - Lifetime US9744080B2 (en) 2000-04-07 2008-08-18 Apertured polymeric film webs and absorbent articles using such webs
US15/584,165 Expired - Lifetime US10124556B2 (en) 2000-04-07 2017-05-16 Apertured polymeric film webs and absorbent articles using such webs
US15/992,647 Expired - Fee Related US10272635B2 (en) 2000-04-07 2018-05-30 Apertured polymeric film webs and absorbent articles using such webs
US15/995,193 Expired - Lifetime US10611119B2 (en) 2000-04-07 2018-06-01 Apertured polymeric film webs and absorbent articles using such webs
US16/007,286 Abandoned US20180290422A1 (en) 2000-04-07 2018-06-13 Apertured Polymeric Film Webs And Absorbent Articles Using Such Webs
US16/813,804 Expired - Lifetime US10850475B2 (en) 2000-04-07 2020-03-10 Apertured polymeric film webs and absorbent articles using such webs

Country Status (10)

Country Link
US (8) US20030003269A1 (en)
EP (3) EP1621169B2 (en)
JP (1) JP5122052B2 (en)
KR (1) KR100617328B1 (en)
AU (1) AU2001256989A1 (en)
BR (1) BR0109908B1 (en)
CA (1) CA2403875C (en)
ES (1) ES2509871T3 (en)
MX (1) MXPA02009308A (en)
WO (1) WO2001076842A2 (en)

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030195487A1 (en) * 2000-09-22 2003-10-16 Tredegar Film Products Corporation Absorbent article with enhanced cooling
US20040241389A1 (en) * 2003-03-26 2004-12-02 Chung Tze Wan Pansy Stretchable web
US20050003152A1 (en) * 2003-07-02 2005-01-06 Tredegar Film Products Corporation Flexible form fitting web
US20050214506A1 (en) * 2000-04-07 2005-09-29 Yann-Per Lee Apertured polymeric film webs and absorbent articles using such webs
US20060264860A1 (en) * 2005-05-18 2006-11-23 Theodora Beck Disposable absorbent article having layered containment pockets
US20060293638A1 (en) * 2005-06-23 2006-12-28 Lavon Gary D Disposable absorbent article having doubled side flaps and backsheet strips
US20060293637A1 (en) * 2005-06-22 2006-12-28 The Procter & Gamble Company Disposable absorbent article having dual layer barrier cuff strips
US7323072B2 (en) 2005-04-27 2008-01-29 Kimberly-Clark Worldwide, Inc. Multi-roll bonding and aperturing
US20080208155A1 (en) * 2007-02-22 2008-08-28 Gary Dean Lavon Diaper having abdominal stretch panels
US7737324B2 (en) 2005-11-23 2010-06-15 The Procter & Gamble Company Disposable absorbent article having deployable chassis ears
US7857801B2 (en) 2007-03-23 2010-12-28 The Procter & Gamble Company Diaper having deployable chassis ears and stretch waistband
US20120277701A1 (en) * 2011-04-26 2012-11-01 Keith Joseph Stone Formed Web Comprising Chads
US20160052191A1 (en) * 2014-08-20 2016-02-25 Tredegar Film Products Corporation Formed Films, Methods And Apparatus For Manufacturing Same, And Articles Comprising Same
US9861533B2 (en) 2013-05-08 2018-01-09 The Procter & Gamble Company Apertured nonwoven materials and methods for forming the same
US10076451B2 (en) 2014-11-06 2018-09-18 The Procter & Gamble Company Moiré effect laminates and methods for making the same
US10271999B2 (en) 2014-11-06 2019-04-30 The Procter & Gamble Company Crimped fiber spunbond nonwoven webs/laminate
US10335973B2 (en) * 2015-12-11 2019-07-02 Tredegar Film Products Corporation Hydro-formed film with three-dimensional micro-apertures
US10406775B2 (en) * 2013-10-23 2019-09-10 Pantex International S.P.A. Perforated laminated product and method for producing this product
WO2020041534A1 (en) 2018-08-22 2020-02-27 The Procter & Gamble Company Disposable absorbent article
US10940051B2 (en) 2014-11-06 2021-03-09 The Procter & Gamble Company Absorbent articles with color effects
US11213436B2 (en) 2017-02-16 2022-01-04 The Procter & Gamble Company Substrates having repeating patterns of apertures for absorbent articles
US11918441B2 (en) 2019-04-24 2024-03-05 The Procter & Gamble Company Highly extensible nonwoven webs and absorbent articles having such webs

Families Citing this family (53)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030097103A1 (en) * 2001-11-21 2003-05-22 Horney James Cameron Absorbent article
US7066006B2 (en) 2002-07-02 2006-06-27 Kimberly-Clark Worldwide, Inc. Method of collecting data relating to attributes of personal care articles and compositions
US20040019340A1 (en) * 2002-07-23 2004-01-29 Tredegar Film Products Corporation Absorbent article having a surface energy gradient between the topsheet and the acquisition distribution layer
AU2003297447A1 (en) 2002-12-20 2004-07-22 Tredegar Film Products Corporation Apertured material for use in absorbent articles and method of making same
US8241543B2 (en) 2003-08-07 2012-08-14 The Procter & Gamble Company Method and apparatus for making an apertured web
US20060282376A1 (en) * 2005-06-14 2006-12-14 Goldberg Peter L System and method for automated processing of real estate title commitments
US8277724B2 (en) 2006-03-31 2012-10-02 The Invention Science Fund I, Llc Sterilization methods and systems
US11185604B2 (en) 2006-03-31 2021-11-30 Deep Science Llc Methods and systems for monitoring sterilization status
US20070231193A1 (en) 2006-03-31 2007-10-04 Searete Llc, A Limited Liability Corporation Of The State Of Delaware Sterilization methods and systems
US8114342B2 (en) 2006-03-31 2012-02-14 The Invention Science Fund I, Llc Methods and systems for monitoring sterilization status
US8758679B2 (en) 2006-03-31 2014-06-24 The Invention Science Fund I, Llc Surveying sterilizer methods and systems
US8932535B2 (en) 2006-03-31 2015-01-13 The Invention Science Fund I, Llc Surveying sterilizer methods and systems
US7638090B2 (en) 2006-03-31 2009-12-29 Searete Llc Surveying sterilizer methods and systems
US20100121295A1 (en) * 2006-04-28 2010-05-13 The Procter & Gamble Company Products comprising polymeric webs with nanoparticles
US20070254143A1 (en) * 2006-04-28 2007-11-01 The Procter & Gamble Company Polymeric webs with nanoparticles
US20070254142A1 (en) * 2006-04-28 2007-11-01 Collias Dimitris I Polymeric webs with nanoparticles
US20070264897A1 (en) * 2006-05-15 2007-11-15 The Procter & Gamble Company Polymeric webs with nanoparticles
US7518032B2 (en) * 2006-11-14 2009-04-14 Tredegar Film Products Corporation Three-dimensional apertured film for transmitting dynamically-deposited and statically-retained fluids
EP1946734A1 (en) * 2007-01-15 2008-07-23 RKW AG Rheinische Kunststoffwerke Topsheet and method for its manufacture
BRPI1011701A2 (en) 2009-03-24 2016-03-22 James W Cree embossed textured blankets and manufacturing method
US9849602B2 (en) * 2009-12-18 2017-12-26 Advantage Creation Enterprise Llc Method for making extrusion coated perforated nonwoven web
US8383227B2 (en) 2010-01-28 2013-02-26 Tredegar Film Products Corporation Transfer layer for absorbent article
US9220638B2 (en) 2010-09-10 2015-12-29 The Procter & Gamble Company Deformed web materials
US9067357B2 (en) 2010-09-10 2015-06-30 The Procter & Gamble Company Method for deforming a web
US20120276238A1 (en) 2011-04-26 2012-11-01 John Brian Strube Apparatus for Deforming a Web
US8708687B2 (en) 2011-04-26 2014-04-29 The Procter & Gamble Company Apparatus for making a micro-textured web
US9044353B2 (en) 2011-04-26 2015-06-02 The Procter & Gamble Company Process for making a micro-textured web
US8657596B2 (en) 2011-04-26 2014-02-25 The Procter & Gamble Company Method and apparatus for deforming a web
US8847002B2 (en) 2011-05-19 2014-09-30 Kimberly-Clark Worldwide, Inc. Absorbent article containing apertures arranged in registration with an embossed wave pattern
US9173782B2 (en) 2013-03-28 2015-11-03 Kimberly-Clark Worldwide, Inc. Coordinated apertured and embossed topsheet layer materials, and absorbent articles containing such
WO2015094459A1 (en) 2013-12-20 2015-06-25 The Procter & Gamble Company Method for fabricating absorbent articles
WO2015094460A1 (en) 2013-12-20 2015-06-25 The Procter & Gamble Company Method for fabricating absorbent articles
US10271997B2 (en) 2014-04-08 2019-04-30 The Procter & Gamble Company Absorbent articles having substrates having zonal treatments
JP6386822B2 (en) * 2014-07-14 2018-09-05 株式会社リブドゥコーポレーション Absorbent articles
CN106572923A (en) * 2014-08-06 2017-04-19 宝洁公司 Method for making an apertured web
US20170296396A1 (en) 2016-04-14 2017-10-19 The Procter & Gamble Company Absorbent article manufacturing process incorporating in situ process sensors
US11167522B2 (en) 2016-04-19 2021-11-09 Fitesa Film Products Llc Contoured film with micro-protrusions
TW201821494A (en) * 2016-11-09 2018-06-16 美商比瑞塑料有限公司 Prestretched apertured elastic film with resistance to web breaks
CN110740717B (en) 2017-06-22 2022-07-01 宝洁公司 Laminate web and absorbent article having laminate web
US10813797B2 (en) * 2017-06-22 2020-10-27 The Procter & Gamble Company Laminate webs and absorbent articles having the same
EP3706692B1 (en) 2017-11-06 2024-03-13 The Procter & Gamble Company Method of creating conforming features in an absorbent article
JP2022526920A (en) 2019-03-29 2022-05-27 ザ プロクター アンド ギャンブル カンパニー Fluid control layer for absorbent articles
US20200315859A1 (en) 2019-04-04 2020-10-08 The Procter & Gamble Company Absorbent article having improved comfort
EP3946190B1 (en) 2019-04-04 2024-02-14 The Procter & Gamble Company Absorbent layer for an absorbent article
DE112021004053T5 (en) 2020-07-30 2023-08-03 The Procter & Gamble Company PACKAGING MATERIAL FOR ABSORBENT ARTICLES WITH NATURAL FIBERS
CN115812061A (en) 2020-07-30 2023-03-17 宝洁公司 Absorbent article packaging material with natural fibers
FR3113040A1 (en) 2020-07-30 2022-02-04 The Procter & Gamble Company Packaging material for absorbent articles with natural fibers
FR3115026A1 (en) 2020-10-09 2022-04-15 The Procter & Gamble Company Sealed Packaging Of Absorbent Articles With Natural Fibers
US20220280350A1 (en) 2021-03-08 2022-09-08 The Procter & Gamble Company Absorbent article
GB202400693D0 (en) 2021-07-30 2024-03-06 Procter & Gamble Sealed absorbent article package with natural fibers
WO2023044261A1 (en) 2021-09-14 2023-03-23 The Procter & Gamble Company Collection of absorbent article packages
FR3129667A1 (en) 2021-12-01 2023-06-02 The Procter & Gamble Company Packaging ranges of absorbent articles with natural fibers
WO2023206125A1 (en) 2022-04-27 2023-11-02 The Procter & Gamble Company Fluid management layer for an absorbent article, and an absorbent article containing the same

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4319868A (en) * 1978-12-07 1982-03-16 The Procter & Gamble Company Apparatus for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern roll
US4377544A (en) * 1974-12-10 1983-03-22 Rasmussen O B Manufacture of a textile-like reticular product from thermoplastic film
US4629643A (en) * 1985-05-31 1986-12-16 The Procter & Gamble Company Microapertured polymeric web exhibiting soft and silky tactile impression
US5603707A (en) * 1995-11-28 1997-02-18 The Procter & Gamble Company Absorbent article having a rewet barrier
US5635275A (en) * 1994-08-05 1997-06-03 Tredegar Industries, Inc. Lamination of non-apertured three-dimensional films to apertured three-dimensional films and articles produced therefrom
US5643240A (en) * 1993-12-30 1997-07-01 Kimberly-Clark Corporation Apertured film/nonwoven composite for personal care absorbent articles and the like

Family Cites Families (122)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3566726A (en) 1968-06-13 1971-03-02 Pantasote Co Of New York Inc T Method of making perforated film
US3719736A (en) 1970-10-08 1973-03-06 Gen Foods Corp Method of producing perforated plastic film
US4128679A (en) 1971-11-17 1978-12-05 Firma Carl Freudenberg Soft, non-woven fabrics and process for their manufacture
US3881489A (en) 1973-08-20 1975-05-06 Procter & Gamble Breathable, liquid inpervious backsheet for absorptive devices
US3957414A (en) 1974-10-11 1976-05-18 Ethyl Corporation Apparatus for embossed film manufacture
US3929135A (en) 1974-12-20 1975-12-30 Procter & Gamble Absorptive structure having tapered capillaries
US4285100A (en) 1975-03-31 1981-08-25 Biax Fiberfilm Corporation Apparatus for stretching a non-woven web or an orientable polymeric material
US4107364A (en) 1975-06-06 1978-08-15 The Procter & Gamble Company Random laid bonded continuous filament cloth
US3967623A (en) 1975-06-30 1976-07-06 Johnson & Johnson Disposable absorbent pad
US4152387A (en) 1976-05-21 1979-05-01 Peter Cloeren Method for forming multi-layer laminates
US4197069A (en) 1976-05-21 1980-04-08 Peter Cloeren Variable thickness extrusion die
US4223063A (en) 1979-03-02 1980-09-16 Sabee Reinhardt N Pattern drawing of webs, and product produced thereby
US4342314A (en) 1979-03-05 1982-08-03 The Procter & Gamble Company Resilient plastic web exhibiting fiber-like properties
US4276336A (en) 1979-04-23 1981-06-30 Sabee Products, Inc. Multi-apertured web with incremental orientation in one or more directions
DE3066921D1 (en) * 1979-05-04 1984-04-19 Procter & Gamble Disposable absorbent structure having a textured macroscopically perforated thermoplastic film topsheet
US4327730A (en) * 1979-05-04 1982-05-04 The Proctor & Gamble Company Textured thermoplastic film and product manufactured therefrom
US4324246A (en) 1980-05-12 1982-04-13 The Procter & Gamble Company Disposable absorbent article having a stain resistant topsheet
US4395215A (en) * 1981-02-02 1983-07-26 The Procter & Gamble Company Film forming structure for uniformly debossing and selectively aperturing a resilient plastic web and method for its construction
US4509908A (en) 1981-02-02 1985-04-09 The Procter & Gamble Company Apparatus for uniformly debossing and aperturing a resilient plastic web
US4463045A (en) 1981-03-02 1984-07-31 The Procter & Gamble Company Macroscopically expanded three-dimensional plastic web exhibiting non-glossy visible surface and cloth-like tactile impression
US4614679A (en) 1982-11-29 1986-09-30 The Procter & Gamble Company Disposable absorbent mat structure for removal and retention of wet and dry soil
US4695422A (en) 1984-02-16 1987-09-22 The Procter & Gamble Company Production of formed material by solid-state formation with a high-pressure liquid stream
US4839216A (en) 1984-02-16 1989-06-13 The Procter & Gamble Company Formed material produced by solid-state formation with a high-pressure liquid stream
US4533308A (en) 1984-04-16 1985-08-06 Peter Cloeren Multimanifold extrusion die and coextrusion process
SE449285B (en) 1984-05-15 1987-04-27 Moelnlycke Ab ABSORBING PRODUCT, SUCH AS BLOW, BINDING OR SAR SURFACE
US4681793A (en) 1985-05-31 1987-07-21 The Procter & Gamble Company Non-occluding, liquid-impervious, composite backsheet for absorptive devices
US4588630A (en) 1984-06-13 1986-05-13 Chicopee Apertured fusible fabrics
JPH0664235B2 (en) 1985-03-15 1994-08-22 株式会社リコー Wide-angle lens for copying
US4609518A (en) 1985-05-31 1986-09-02 The Procter & Gamble Company Multi-phase process for debossing and perforating a polymeric web to coincide with the image of one or more three-dimensional forming structures
US4637819A (en) * 1985-05-31 1987-01-20 The Procter & Gamble Company Macroscopically expanded three-dimensional polymeric web for transmitting both dynamically deposited and statically contacted fluids from one surface to the other
DE3521374A1 (en) 1985-06-14 1986-12-18 Unilever N.V., Rotterdam METHOD FOR PRODUCING A FILM COMPOSITE AND THAN MANUFACTURED FILM COMPOSITE
IT1182491B (en) 1985-07-04 1987-10-05 Faricerca Spa COATING STRUCTURE FOR ABSORBENT SANITARY AND SANITARY PRODUCTS AND ABSORBENT PRODUCT PROVIDED WITH SUCH COATING
GB8521254D0 (en) 1985-08-24 1985-10-02 Smith & Nephew Ass Contoured film
US4886632A (en) 1985-09-09 1989-12-12 Kimberly-Clark Corporation Method of perforating a nonwoven web and use of the web as a cover for a feminine pad
US5188625A (en) 1985-09-09 1993-02-23 Kimberly-Clark Corporation Sanitary napkin having a cover formed from a nonwoven web
US4820294A (en) 1986-05-22 1989-04-11 Chicopee Apertured film facing and method of making the same
US4834741A (en) 1987-04-27 1989-05-30 Tuff Spun Products, Inc. Diaper with waist band elastic
US4846821A (en) 1987-08-24 1989-07-11 The Procter & Gamble Company Substantially fluid-impervious microbubbled polymeric web exhibiting low levels of noise when subjected to movement
US4778644A (en) 1987-08-24 1988-10-18 The Procter & Gamble Company Method and apparatus for making substantially fluid-impervious microbubbled polymeric web using high pressure liquid stream
US4859519A (en) 1987-09-03 1989-08-22 Cabe Jr Alex W Method and apparatus for preparing textured apertured film
US5009653A (en) 1988-03-31 1991-04-23 The Procter & Gamble Company Thin, flexible sanitary napkin
US5383869A (en) 1988-03-31 1995-01-24 The Procter & Gamble Company Thin, flexible sanitary napkin
US4950264A (en) 1988-03-31 1990-08-21 The Procter & Gamble Company Thin, flexible sanitary napkin
US5006394A (en) 1988-06-23 1991-04-09 The Procter & Gamble Company Multilayer polymeric film
EP0360929A1 (en) 1988-09-02 1990-04-04 VERATEC, INC. (a Delaware corp.) Fibre-film substrate
US5226992A (en) 1988-09-23 1993-07-13 Kimberly-Clark Corporation Process for forming a composite elastic necked-bonded material
US5158819A (en) 1990-06-29 1992-10-27 The Procter & Gamble Company Polymeric web exhibiting a soft, silky, cloth-like tactile impression and including a contrasting visually discernible pattern having an embossed appearance on at least one surface thereof
US5167897A (en) 1991-02-28 1992-12-01 The Procter & Gamble Company Method for incrementally stretching a zero strain stretch laminate web to impart elasticity thereto
US5143679A (en) 1991-02-28 1992-09-01 The Procter & Gamble Company Method for sequentially stretching zero strain stretch laminate web to impart elasticity thereto without rupturing the web
US5156793A (en) 1991-02-28 1992-10-20 The Procter & Gamble Company Method for incrementally stretching zero strain stretch laminate web in a non-uniform manner to impart a varying degree of elasticity thereto
US5262107A (en) 1991-06-25 1993-11-16 Applied Extrusion Technologies, Inc. Method of making apertured film fabrics
GR1002212B (en) 1991-07-26 1996-03-28 Mcneil Ppc Inc Clean dry facing needled composite.
TW273531B (en) 1991-08-14 1996-04-01 Chicopee Textile-like apertured plastic films
US5269981A (en) 1991-09-30 1993-12-14 Kimberly-Clark Corporation Process for hydrosonically microaperturing
EP0613359A1 (en) 1991-11-19 1994-09-07 The Procter & Gamble Company Absorbent article having a nonwoven and apertured film coversheet
SE501455C2 (en) 1992-05-21 1995-02-20 Moelnlycke Ab Process for manufacturing a material suitable as a topsheet in a disposable absorbent article and such material
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
FI930875A (en) 1992-10-29 1994-04-30 Pfu Ltd Maongsidigt produktionssystem
WO1994009769A1 (en) 1992-11-02 1994-05-11 Buchman Alan L Use of choline in total parenteral nutrition
ES2086111T5 (en) 1992-11-17 2000-06-01 Pantex Srl METHOD AND APPARATUS FOR THE MANUFACTURE OF A MEMBRANE OR A FILM FOR THE COATING OF HYGIENIC PADS OR FOR FILTRATION SYSTEMS OR THE LIKE.
US5494736A (en) 1993-01-29 1996-02-27 Fiberweb North America, Inc. High elongation thermally bonded carded nonwoven fabrics
JP3061507B2 (en) * 1993-03-24 2000-07-10 三井化学株式会社 Surface sheet for body fluid absorbent article, method for producing the same, and apparatus for producing the same
US5368909A (en) 1993-04-02 1994-11-29 The Procter & Gamble Company Fluid-pervious plastic web having improved fluid drainage
US5399174A (en) 1993-04-06 1995-03-21 Kimberly-Clark Corporation Patterned embossed nonwoven fabric, cloth-like liquid barrier material
US5518801A (en) 1993-08-03 1996-05-21 The Procter & Gamble Company Web materials exhibiting elastic-like behavior
US6025050A (en) 1994-06-15 2000-02-15 Bba Nonwovens Simpsonville, Inc. Thermally appertured nonwoven laminates for wipes and coverstock for hygienic articles
US5567501A (en) 1994-06-15 1996-10-22 International Paper Company Thermally apertured nonwoven product
EP0767646B1 (en) 1994-06-30 1999-09-08 The Procter & Gamble Company Fluid pervious web exhibiting a surface energy gradient
JP3563074B2 (en) 1994-06-30 2004-09-08 ザ プロクター アンド ギャンブル カンパニー Fluid transfer web with surface energy gradient
IT1268105B1 (en) 1994-10-07 1997-02-20 P & G Spa COVER STRUCTURE FOR AN ABSORBENT ITEM.
JP3126620B2 (en) 1995-03-22 2001-01-22 花王株式会社 Method and apparatus for producing three-dimensional aperture sheet
US5693037A (en) 1995-04-21 1997-12-02 The Procter & Gamble Company Absorbent articles having improved surfactant-treated hydrophilic topsheets
US5704101A (en) 1995-06-05 1998-01-06 Kimberly-Clark Worldwide, Inc. Creped and/or apertured webs and process for producing the same
EP0749739B1 (en) * 1995-06-19 2000-11-02 The Procter & Gamble Company Perforated dual topsheets for absorbent articles
US5770144A (en) 1995-09-01 1998-06-23 Mcneil-Ppc, Inc. Method of forming improved apertured films by using fluid perforation
US5628097A (en) 1995-09-29 1997-05-13 The Procter & Gamble Company Method for selectively aperturing a nonwoven web
US5626571A (en) 1995-11-30 1997-05-06 The Procter & Gamble Company Absorbent articles having soft, strong nonwoven component
US5670110A (en) 1995-12-21 1997-09-23 The Procter & Gamble Company Method for making three-dimensional macroscopically-expanded webs having improved functional surfaces
SE9600765L (en) 1996-02-28 1997-08-29 Moelnlycke Ab A liquid-permeable surface material for an absorbent article, method for its manufacture
SE510531C2 (en) 1996-05-02 1999-05-31 Sca Hygiene Prod Ab Hollow-casing layer for absorbing articles, as well as ways of making the casing layer
EP0820747A1 (en) * 1996-07-25 1998-01-28 The Procter & Gamble Company Absorbent article with elastic feature
US5879494A (en) 1996-09-23 1999-03-09 Minnesota Mining And Manufacturing Company Method of aperturing thin sheet materials
US5733628A (en) * 1996-10-10 1998-03-31 Tredegar Industries, Inc. Breathable elastic polymeric film laminates
JP3161695B2 (en) 1996-10-18 2001-04-25 花王株式会社 Perforated sheet manufacturing equipment
US5965235A (en) * 1996-11-08 1999-10-12 The Procter & Gamble Co. Three-dimensional, amorphous-patterned, nesting-resistant sheet materials and method and apparatus for making same
JP2001505961A (en) * 1996-12-06 2001-05-08 ウェイアーヒューサー・カンパニー Integrated absorption layer
JP3181924B2 (en) * 1996-12-09 2001-07-03 ザ、プロクター、エンド、ギャンブル、カンパニー Method of forming laminate web
US6015764A (en) 1996-12-27 2000-01-18 Kimberly-Clark Worldwide, Inc. Microporous elastomeric film/nonwoven breathable laminate and method for making the same
JPH10211232A (en) 1997-01-31 1998-08-11 Uni Charm Corp Surface sheet for throw-away body fluid absorbing wear and its manufacture
JP3484037B2 (en) 1997-01-31 2004-01-06 ユニ・チャーム株式会社 Surface sheet for disposable body fluid absorbent articles
SE518133C2 (en) 1997-02-21 2002-08-27 Sca Hygiene Prod Ab Liquid-permeable cover layer for absorbent articles and an absorbent article provided with such cover layer
JP3464587B2 (en) 1997-02-28 2003-11-10 ユニ・チャーム株式会社 Body fluid absorbent articles
US5990377A (en) 1997-03-21 1999-11-23 Kimberly-Clark Worldwide, Inc. Dual-zoned absorbent webs
WO1998042289A1 (en) 1997-03-21 1998-10-01 Kimberly-Clark Worldwide, Inc. Dual-zoned absorbent webs
US6605332B2 (en) 1997-07-29 2003-08-12 3M Innovative Properties Company Unitary polymer substrate having napped surface of frayed end microfibers
DE29720192U1 (en) 1997-11-14 1999-03-25 Kuesters Eduard Maschf Calender for treating a web
JP3423725B2 (en) * 1997-12-15 2003-07-07 ザ、プロクター、エンド、ギャンブル、カンパニー Soft flexible web
US6599612B1 (en) * 1997-12-15 2003-07-29 The Procter & Gamble Company Process of forming a perforated web
JPH11239587A (en) 1998-02-25 1999-09-07 Mitsui Chem Inc Top sheet material for absorptive object
EP0955159A1 (en) 1998-04-28 1999-11-10 The Procter & Gamble Company Method for forming apertured laminate web
EP0953324A1 (en) 1998-04-28 1999-11-03 The Procter & Gamble Company Apertured laminate web
US6228462B1 (en) 1998-05-15 2001-05-08 The Procter & Gamble Company Multilayer compression-resistant apertured web
US6410823B1 (en) 1998-06-30 2002-06-25 Kimberly-Clark Worldwide, Inc. Apertured film covers with localized wettability and method for making the same
DE19838507C2 (en) 1998-08-25 2002-04-25 Borealis Gmbh Schwechat Mannsw Extrusion coated nonwoven webs
EP0995413A1 (en) 1998-10-16 2000-04-26 The Procter & Gamble Company Method for forming an apertured web
US6353149B1 (en) 1999-04-08 2002-03-05 The Procter & Gamble Company Fast blooming surfactants for use in fluid transport webs
US6461716B1 (en) 1999-06-24 2002-10-08 The Procter & Gamble Company Apertured webs having permanent hydrophilicity and absorbent articles using such webs
US7037569B2 (en) 1999-12-21 2006-05-02 The Procter & Gamble Company Laminate web comprising an apertured layer and method for manufacturing thereof
US6286145B1 (en) 1999-12-22 2001-09-11 Kimberly-Clark Worldwide, Inc. Breathable composite barrier fabric and protective garments made thereof
DE10008827A1 (en) 2000-02-25 2001-09-06 Bp Chemicals Plastec Gmbh Laminate for hygiene and medical purposes comprises a fiber layer on a polymer film whose perforations are freely exposed on the fiber layer side
AU2001256989A1 (en) * 2000-04-07 2001-10-23 The Procter And Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US6537930B1 (en) 2000-05-18 2003-03-25 Tredegar Film Products Corporation Three-dimensional highly elastic film/non-woven composite
US6700036B2 (en) 2000-09-22 2004-03-02 Tredegar Film Products Corporation Acquisition distribution layer having void volumes for an absorbent article
US6610904B1 (en) 2000-09-22 2003-08-26 Tredegar Film Products Corporation Acquisition distribution layer having void volumes for an absorbent article
JP3739288B2 (en) 2001-02-21 2006-01-25 ユニ・チャーム株式会社 Liquid absorbing sheet
US6582798B2 (en) 2001-06-06 2003-06-24 Tredegar Film Products Corporation Vacuum formed film topsheets having a silky tactile impression
US6837956B2 (en) * 2001-11-30 2005-01-04 Kimberly-Clark Worldwide, Inc. System for aperturing and coaperturing webs and web assemblies
CN100393293C (en) 2001-12-03 2008-06-11 屈德加薄膜产品股份有限公司 Apertured nonwoven composites and method for making
US7166094B2 (en) 2002-05-28 2007-01-23 Tyco Healthcare Retail Services Ag Multiple layer absorbent article
US20040005457A1 (en) 2002-07-03 2004-01-08 Kimberly-Clark Worldwide, Inc. Methods of improving the softness of fibers and nonwoven webs and fibers and nonwoven webs having improved softness
AU2003297447A1 (en) * 2002-12-20 2004-07-22 Tredegar Film Products Corporation Apertured material for use in absorbent articles and method of making same
EP1712667B1 (en) 2005-04-11 2011-01-05 Pantex International S.p.A. Method for producing a nonwoven fabric and a product obtained with said method

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4377544A (en) * 1974-12-10 1983-03-22 Rasmussen O B Manufacture of a textile-like reticular product from thermoplastic film
US4319868A (en) * 1978-12-07 1982-03-16 The Procter & Gamble Company Apparatus for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern roll
US4629643A (en) * 1985-05-31 1986-12-16 The Procter & Gamble Company Microapertured polymeric web exhibiting soft and silky tactile impression
US5643240A (en) * 1993-12-30 1997-07-01 Kimberly-Clark Corporation Apertured film/nonwoven composite for personal care absorbent articles and the like
US5635275A (en) * 1994-08-05 1997-06-03 Tredegar Industries, Inc. Lamination of non-apertured three-dimensional films to apertured three-dimensional films and articles produced therefrom
US5603707A (en) * 1995-11-28 1997-02-18 The Procter & Gamble Company Absorbent article having a rewet barrier

Cited By (54)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10124556B2 (en) 2000-04-07 2018-11-13 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US20050214506A1 (en) * 2000-04-07 2005-09-29 Yann-Per Lee Apertured polymeric film webs and absorbent articles using such webs
US9700463B2 (en) 2000-04-07 2017-07-11 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US9744080B2 (en) 2000-04-07 2017-08-29 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US20090026651A1 (en) * 2000-04-07 2009-01-29 Yann-Per Lee Apertured polymeric film webs and absorbent articles using such webs
US10611119B2 (en) 2000-04-07 2020-04-07 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US10850475B2 (en) 2000-04-07 2020-12-01 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US10272635B2 (en) 2000-04-07 2019-04-30 The Procter & Gamble Company Apertured polymeric film webs and absorbent articles using such webs
US20030195487A1 (en) * 2000-09-22 2003-10-16 Tredegar Film Products Corporation Absorbent article with enhanced cooling
US20040241389A1 (en) * 2003-03-26 2004-12-02 Chung Tze Wan Pansy Stretchable web
US20080063837A1 (en) * 2003-03-26 2008-03-13 Tredegar Film Products Corporation Stretchable web
US8057879B2 (en) 2003-03-26 2011-11-15 Tredegar Film Products Corporation Stretchable web
WO2004096472A1 (en) * 2003-04-24 2004-11-11 Tredegar Film Products Corporation Absorbent article with enhanced cooling
US20050003152A1 (en) * 2003-07-02 2005-01-06 Tredegar Film Products Corporation Flexible form fitting web
US7323072B2 (en) 2005-04-27 2008-01-29 Kimberly-Clark Worldwide, Inc. Multi-roll bonding and aperturing
US20060264860A1 (en) * 2005-05-18 2006-11-23 Theodora Beck Disposable absorbent article having layered containment pockets
US7763004B2 (en) 2005-05-18 2010-07-27 The Procter & Gamble Company Disposable absorbent article having layered containment pockets
US20100125263A1 (en) * 2005-06-22 2010-05-20 Gary Dean Lavon Disposable absorbent article having dual layer barrier cuff strips
US7695463B2 (en) 2005-06-22 2010-04-13 The Procter & Gamble Company Disposable absorbent article having dual layer barrier cuff strips
US20060293637A1 (en) * 2005-06-22 2006-12-28 The Procter & Gamble Company Disposable absorbent article having dual layer barrier cuff strips
US20060293638A1 (en) * 2005-06-23 2006-12-28 Lavon Gary D Disposable absorbent article having doubled side flaps and backsheet strips
US7737324B2 (en) 2005-11-23 2010-06-15 The Procter & Gamble Company Disposable absorbent article having deployable chassis ears
US20080208155A1 (en) * 2007-02-22 2008-08-28 Gary Dean Lavon Diaper having abdominal stretch panels
US7857801B2 (en) 2007-03-23 2010-12-28 The Procter & Gamble Company Diaper having deployable chassis ears and stretch waistband
US9724245B2 (en) * 2011-04-26 2017-08-08 The Procter & Gamble Company Formed web comprising chads
US20120277701A1 (en) * 2011-04-26 2012-11-01 Keith Joseph Stone Formed Web Comprising Chads
US9861533B2 (en) 2013-05-08 2018-01-09 The Procter & Gamble Company Apertured nonwoven materials and methods for forming the same
US10406775B2 (en) * 2013-10-23 2019-09-10 Pantex International S.P.A. Perforated laminated product and method for producing this product
US20160052191A1 (en) * 2014-08-20 2016-02-25 Tredegar Film Products Corporation Formed Films, Methods And Apparatus For Manufacturing Same, And Articles Comprising Same
US11202725B2 (en) 2014-11-06 2021-12-21 The Procter & Gamble Company Crimped fiber spunbond nonwoven webs / laminates
US11491057B2 (en) 2014-11-06 2022-11-08 The Procter & Gamble Company Crimped fiber spunbond nonwoven webs / laminates
US10357410B2 (en) 2014-11-06 2019-07-23 The Procter & Gamble Company Pre-strained laminates and methods for making the same
US11813150B2 (en) 2014-11-06 2023-11-14 The Procter & Gamble Company Patterned apertured webs
US11766367B2 (en) 2014-11-06 2023-09-26 The Procter & Gamble Company Patterned apertured webs
US10583050B2 (en) 2014-11-06 2020-03-10 The Procter & Gamble Company Patterned apertured webs and methods for making the same
US10272000B2 (en) 2014-11-06 2019-04-30 The Procter & Gamble Company Patterned apertured webs and methods for making the same
US11696857B2 (en) 2014-11-06 2023-07-11 The Procter & Gamble Company Absorbent articles with color effects
US10646381B2 (en) 2014-11-06 2020-05-12 The Procter & Gamble Company Crimped fiber spunbond nonwoven webs / laminates
US10667962B2 (en) 2014-11-06 2020-06-02 The Procter & Gamble Company Patterned apertured webs
US10786401B2 (en) 2014-11-06 2020-09-29 The Procter & Gamble Company Apertured topsheets and methods for making the same
US10271999B2 (en) 2014-11-06 2019-04-30 The Procter & Gamble Company Crimped fiber spunbond nonwoven webs/laminate
US10940051B2 (en) 2014-11-06 2021-03-09 The Procter & Gamble Company Absorbent articles with color effects
US10973705B2 (en) 2014-11-06 2021-04-13 The Procter & Gamble Company Apertured webs and methods for making the same
US11090202B2 (en) 2014-11-06 2021-08-17 The Procter & Gamble Company Apertured webs and methods for making the same
US11135103B2 (en) 2014-11-06 2021-10-05 The Procter & Gamble Company Apertured webs and methods for making the same
US10076451B2 (en) 2014-11-06 2018-09-18 The Procter & Gamble Company Moiré effect laminates and methods for making the same
US11633311B2 (en) 2014-11-06 2023-04-25 The Procter & Gamble Company Patterned apertured webs
US11324645B2 (en) 2014-11-06 2022-05-10 The Procter & Gamble Company Garment-facing laminates and methods for making the same
US10350119B2 (en) 2014-11-06 2019-07-16 The Procter & Gamble Company Pre-strained laminates and methods for making the same
US10618191B2 (en) 2015-12-11 2020-04-14 Tredgar Film Products Corporation Hydro-formed film with three-dimensional micro-apertures
US10335973B2 (en) * 2015-12-11 2019-07-02 Tredegar Film Products Corporation Hydro-formed film with three-dimensional micro-apertures
US11213436B2 (en) 2017-02-16 2022-01-04 The Procter & Gamble Company Substrates having repeating patterns of apertures for absorbent articles
WO2020041534A1 (en) 2018-08-22 2020-02-27 The Procter & Gamble Company Disposable absorbent article
US11918441B2 (en) 2019-04-24 2024-03-05 The Procter & Gamble Company Highly extensible nonwoven webs and absorbent articles having such webs

Also Published As

Publication number Publication date
EP1621169A3 (en) 2007-01-03
US20090026651A1 (en) 2009-01-29
US20180281342A1 (en) 2018-10-04
CA2403875C (en) 2007-08-21
US20200207054A1 (en) 2020-07-02
JP2003530243A (en) 2003-10-14
US20180272650A1 (en) 2018-09-27
US10124556B2 (en) 2018-11-13
US9744080B2 (en) 2017-08-29
KR100617328B1 (en) 2006-08-30
US10272635B2 (en) 2019-04-30
ES2509871T3 (en) 2014-10-20
EP2807995A1 (en) 2014-12-03
EP1621169A2 (en) 2006-02-01
WO2001076842A2 (en) 2001-10-18
AU2001256989A1 (en) 2001-10-23
EP2807995B1 (en) 2020-07-15
EP1621169B2 (en) 2017-09-13
CA2403875A1 (en) 2001-10-18
JP5122052B2 (en) 2013-01-16
US20170296395A1 (en) 2017-10-19
BR0109908B1 (en) 2012-06-26
EP1621169B1 (en) 2014-07-23
KR20020084297A (en) 2002-11-04
BR0109908A (en) 2003-07-22
US20050214506A1 (en) 2005-09-29
US10611119B2 (en) 2020-04-07
US10850475B2 (en) 2020-12-01
US20180290422A1 (en) 2018-10-11
WO2001076842A3 (en) 2002-03-28
US9700463B2 (en) 2017-07-11
EP1267780A2 (en) 2003-01-02
MXPA02009308A (en) 2004-09-06

Similar Documents

Publication Publication Date Title
EP1621169B1 (en) Apertured polymeric film webs and absorbent articles using such webs
JP4519319B2 (en) Multilayer compression resistant perforated web
US6461716B1 (en) Apertured webs having permanent hydrophilicity and absorbent articles using such webs
US5792412A (en) Apertured films having durable wettability and processes for marking them
US20210267820A1 (en) Formed films and absorbent articles including same
WO2021096512A1 (en) Formed films and absorbent articles including same
MXPA00011261A (en) Multilayer compression resistant apertured web
WO2001076524A1 (en) Textured, microapertured webs and absorbent articles using such webs
MXPA99002370A (en) Apertured films having durable wettability and processes for making them

Legal Events

Date Code Title Description
STCB Information on status: application discontinuation

Free format text: EXPRESSLY ABANDONED -- DURING EXAMINATION