Method for making a fibrous laminated web

This invention relates to a method of making a fibrous laminated material wherein a first fibrous layer comprising a plurality of staple fibers or continuous filaments of a thermoplastic material and a second fibrous layer comprising a plurality of staple fibers or continuous filaments of two or more thermoplastic or other materials are bonded together in a spaced apart bonding pattern having apertures formed therein to form a fibrous laminate having improved liquid distribution and management properties as well as enhanced comfort and softness when placed in contact with human skin.

BACKGROUND OF THE INVENTION 
This invention generally relates to fibrous web laminates suitable for use 
in articles used to absorb, distribute and retain body liquids, such as 
disposable diapers, sanitary napkins, incontinence garments and the like, 
and to a method and apparatus for making same. More specifically, this 
invention relates to a nonwoven laminated material having improved liquid 
distribution and management and air circulation properties as well as 
enhanced comfort and softness when placed in contact with human skin. 
Nonwoven materials, such as spunbonded webs and carded webs, have been used 
as bodyside liners in disposable absorbent articles. Typically, very open, 
porous liner structures have been employed to allow liquid to pass through 
them rapidly, thereby keeping the wearer's skin separate from the wetted 
absorbent core underneath the liner. Also, other layers of material, such 
as those constructed with thick, lofty fabric structures, have been 
interposed between the liner and absorbent pad for the purpose of reducing 
flowback. 
U.S. Pat. No. 4,761,322 to Raley discloses a fibrous web laminate wherein a 
fibrous layer having a soft texture is laminated with a contiguous layer 
having a greater structural integrity such that the soft texture layer may 
be utilized as a skin-contacting surface and the contiguous layer thereto 
may provide mechanical strength and integrity to the laminate. The 
laminate of this patent includes a first fibrous layer, which is pattern 
bonded in a first spaced-apart bonding pattern, formed, for example, by 
passing the first layer through the nip formed by a first heated pattern 
roll and a smooth roll, and a second fibrous layer, which is pattern 
bonded in a second spaced-apart bonding pattern, formed, for example, by 
passing the first and second layers through the nip formed by a second 
heated pattern roll and a smooth roll. The second bonding pattern further 
produces bonds between the first and second layers, while the first 
bonding pattern does not. 
U.S. Pat. No. 4,392,862 to Marsan et al. discloses an absorptive device 
including a facing element, a support element, an absorbent core and a 
backsheet. The facing element is a fluid permeable, unbonded, carded web 
of hydrophobic, thermoplastic fibers. The facing element is bonded in 
spaced apart bonding regions to a fluid permeable support element of 
nonwoven polyester or monofilament scrim. 
U.S. Pat. No. 4,088,726 to Cumbers discloses a method of making nonwoven 
fabrics wherein a nonwoven web of thermally bondable material is passed 
through a nip between co-operating calender rolls, at least one of which 
is heated, with one calender roll having a surface pattern consisting of 
continuous lands and the other calender roll having a surface pattern 
consisting of lands that are isolated projections and the centroids of 
area of those projections concurrently in the nip being disposed at 
differing distances from the longitudinal axis of the nearest continuous 
land surface so that lands that oppose each other in the nip overlap to 
different extents. 
Notwithstanding the development of nonwoven materials of the types 
described above, the need remains for a nonwoven material that can provide 
improved liquid intake and distribution as well as air circulation when 
used as a body contacting layer in a disposable absorbent article, 
resulting in greater surface dryness and comfort for the wearer's skin. 
There also is a need for a nonwoven material that exhibits improved 
softness and comfort when placed in contact with the wearer's skin. 
SUMMARY OF THE INVENTION 
This invention relates to a nonwoven laminated material wherein a first 
nonwoven layer comprising a plurality of staple fibers or continuous 
filaments of a thermoplastic material, and a second nonwoven layer 
comprising a plurality of staple fibers or continuous filaments of two or 
more thermoplastic materials are bonded together in a spaced apart bonding 
pattern having apertures formed therein to form a nonwoven laminate having 
improved liquid distribution and management properties as well as enhanced 
comfort and softness when placed in contact with human skin. Also 
disclosed are a method and apparatus for making such a nonwoven laminate.

DETAILED DESCRIPTION 
The present invention comprehends a laminated fibrous fabric or material 
having a first fibrous layer comprising a plurality of staple fibers or 
continuous filaments of one or more thermoplastic materials and a second 
fibrous layer comprising a plurality of staple fibers or continuous 
filaments of two or more thermoplastic materials. The first layer and 
second layer, which can be nonwoven webs, are formed into a fibrous 
laminate by a spaced apart bonding pattern, such as by thermal bonding 
between a pair of heated embossing or bonding rolls having raised bonding 
patterns on the outer surfaces thereof. This spaced apart bonding pattern 
provides high structural integrity between the first and second layers 
without compromising the flexibility and soft surface texture of the first 
layer or the loftiness of the resulting fibrous laminate. Apertures are 
formed in the spaced apart bonding areas to enhance liquid distribution 
and air circulation through the respective layers of the fibrous laminate. 
The fibrous laminate formed in accordance with the present invention 
exhibits improved liquid intake and distribution and air circulation 
characteristics, resulting in greater surface dryness and comfort when 
placed against human skin. The fibrous laminate of this invention further 
provides a lofty, pillowed structure that exhibits improved softness and 
cushiony feel to the user. Other attributes and advantages of the present 
invention will be apparent from the ensuing disclosure and appended 
claims. 
As used herein, the terms "nonwoven web" and "nonwoven layer" mean a 
fibrous web or layer having a structure of individual fibers or filaments 
that are interlaid in a random pattern. Nonwoven webs have been formed in 
the past, as known to those of ordinary skill in the art, by a variety of 
processes, such as, for example, meltblowing, spunbonding, air-laying, 
wet-laying, dry-laying, dry staple and carded web processes. While 
nonwoven webs can be used in practicing the present invention, the 
invention is not to be considered limited to nonwoven materials and other 
suitable fibrous structures may be employed. 
The fibrous laminated material of this invention will be described herein 
in connection with its use in disposable absorbent articles, however, it 
should be understood that potential applications of this invention need 
not be limited to such disposable absorbent articles. As used herein, the 
term "disposable absorbent article" means an article that is used to 
absorb and retain body exudates and is intended to be discarded after a 
limited period of use. Such articles can be placed against or in close 
proximity to the body of the wearer to absorb and retain various exudates 
discharged from the body. 
Referring now to FIG. 1, a perspective partial sectional view of an 
embodiment of the present invention is shown. The nonwoven material 10 
comprises a first nonwoven layer 12 and a second nonwoven layer 22. The 
first layer 12 has an upper surface 14 and a lower surface 16 and the 
second layer 22 has an upper surface 24 and a lower surface 26. In the 
embodiment shown, a plurality of thermal fusion bonds in a spaced apart 
bonding pattern 18 extend through the thickness of the nonwoven material 
10 to thermally fuse or bond fibers of first layer 12 with fibers of 
second layer 22 at the interface 20 therebetween. Bonding of the first and 
second layers is substantially limited to the bonding regions 18. That is, 
in the areas 19 of the first and second layers outside of the bonding 
pattern 18, the fibers of the respective layers are only lightly bonded to 
one another by fiber fusing from thermal energy. Thus, the bonding regions 
18 are separated or "spaced apart" by lightly bonded areas 19. Also as 
shown in this embodiment, apertures 30 are formed within the bonding areas 
18 to improve the liquid distribution rate and air circulation of the 
nonwoven material 10. 
The respective first and second fibrous layers of the present invention may 
be formed by any suitable natural or synthetic fibers in any appropriate 
structure, although in the embodiments shown in the accompanying drawings, 
these fibers are formed into nonwoven layers. In general, each nonwoven 
layer of the present invention can be prepared from noncontinuous fibers, 
continuous filaments or a combination thereof. The method of producing 
each layer in the embodiment shown employs dry staple processes, or more 
specifically, carded web techniques, as known to those of ordinary skill 
in the art. While carded web techniques can be advantageously employed in 
forming the respective layers of the present invention, spunbonding, 
meltblowing, air-laying and other techniques known to those of ordinary 
skill in the art that produce noncontinuous fibers and continuous 
filaments are also considered within the scope of this invention. Carded 
webs suitable for use in the practice of the present invention can have 
the fibers in an aligned or an unaligned configuration. Conventional 
carding machines, as known to those of ordinary skill in the art, can be 
employed in producing the respective layers of the present invention. 
Commercially available thermoplastic polymeric materials can be 
advantageously employed in both layers of the present invention. Examples 
of such polymers, by way of illustration only, include polyolefins, 
polyamides, polyesters and the like. The fibers may have any suitable 
morphology and may include hollow or core fibers, shaped fibers, 
bicomponent fibers or high absorbent particle impregnated fibers. 
In the embodiment shown in FIG. 1, the first nonwoven layer 12 of the 
nonwoven fabric 10 is a bonded carded web made of thermoplastic 
polypropylene fibers. The second nonwoven layer 22 of the nonwoven fabric 
is a substantially unbonded or unbonded carded web made of a blend of 
polypropylene and polyester fibers. By "substantially unbonded" as used 
herein is meant a web with fibers that are sufficiently bonded together, 
by known bonding processes, for handling the web, but insufficiently 
bonded to provide the needed strength and integrity for the end-use 
application. By "unbonded" as used herein is meant a web with fibers that 
are not mechanically, thermally nor chemically bonded together. 
The ratio of different thermoplastic fibers in the second layer 22 can be 
varied as appropriate for the intended end-use application of the nonwoven 
material. For example, the ratio of polypropylene to polyester fibers by 
total weight of the second layer 22 can range from about 70:30 to about 
25:75, with about 40:60 being the ratio for the embodiment shown. 
It is an important advantage of the present invention that certain 
materials that might not have optimum properties in a nonwoven web for 
various reasons may be used in the present invention in combination with a 
web made from one or more different materials to produce a better set of 
properties. For example, an unbonded or substantially unbonded nonwoven 
layer of polypropylene and polyester fibers may be considered too soft and 
weak for certain nonwoven web applications. However, in following the 
teachings of the present invention, a nonwoven layer made of an 
appropriate blend of polypropylene and polyester fibers can be bonded to a 
stronger nonwoven web, such as a bonded layer of polypropylene fibers, to 
thereby make a more desirable nonwoven laminate. 
The fiber sizes, basis weights and densities of the fibrous layers 
comprising the nonwoven fabric 10 of the present invention also can be 
readily varied depending on the intended use of the web. For example, in 
one application of the present invention, the nonwoven material can be 
used as a body facing layer for a disposable absorbent article having an 
absorbent core placed between the liner and an outer cover. Such 
disposable articles include, by way of illustration only, diapers, 
training pants, sanitary napkins, incontinence garments and the like. For 
this application, the polypropylene fibers of the first layer 12 can be as 
fine as about 1.0 denier (12.5 .mu.m in diameter) to as coarse as about 
3.0 denier (21.6 .mu.m) and have a crimped fiber length of from about 1.25 
in. (31.75 mm) to about 2.5 in. (63.5 mm), although it is desireable for 
the user's comfort that the fibers be from about 2 denier (17.6 .mu.m) to 
about 2.2 denier (18.5 .mu.m) and have a crimped fiber length of about 1.5 
in (38.1 mm). (It is known in the art that crimping is a function of fiber 
type, diameter and density.) The finer fiber size of the polypropylene 
fibers in the first layer 12, which in this application comes into contact 
with human skin and functions as a liner layer, yields a softer surface 
texture for the first layer 12. The polypropylene fibers in the second 
layer 22 can, but need not, be identical to the polypropylene fibers in 
the first layer 12. The polyester fibers in the second layer can be from 
about 3 denier (17.5 .mu.m) to about 9 denier (30.4 .mu.m) and have a 
crimped fiber length of from about 1.25 in. (31.75 mm) to about 3 in. 
(76.2 mm), with polyester fibers of 6 denier (24.8 .mu.m) having a crimped 
fiber length of about 2 in. (50.8 mm) being suitable. While not wishing to 
be bound by any particular theory, it is currently believed that the use 
of different fibers enhances the liquid wicking and distribution 
properties of the second layer 22. The fibers in the first layer 12, which 
have the same diameters, tend to form similarly sized pores in a single 
plane, while the fibers in the second layer 22, which have different 
diameters, tend to form pores of varying sizes in multiple planes. The 
differing pore sizes in multiple planes in second layer 22 are believed to 
enhance wicking of liquid throughout the second layer 22 and liquid intake 
into and distribution through the second layer 22. It is further currently 
believed that the resiliency of the polyester fibers is a contributing 
factor to the improved liquid management and air circulation 
characteristics of the nonwoven laminate of this invention. Consequently, 
in this application, the second layer 22 functions as a surge layer or 
temporary reservoir for the liquid passing through the nonwoven material 
10 into the absorbent core of an absorbent article. 
The nonwoven material 10 of this invention can have a basis weight from 
about 25 g/m.sup.2 (0.7 oz/yd.sup.2) to about 78 g/m.sup.2 (2.3 
oz./yd.sup.2), a thickness of from about 0.03 in. (0.76 mm) to about 0.08 
in. (2.03 mm) and a density of from about 0.020 g/cc to about 0.050 g/cc. 
Density is determined using the following equation: 
##EQU1## 
For example, in the embodiment shown, the basis weight for the nonwoven 
web 10 can range from about 47 g/m.sup.2 (1.4 oz/yd.sup.2) to about 58 
g/m.sup.2 (1.7 oz/yd.sup.2), the thickness can range from about 0.04 in. 
(1.02 mm) to about 0.06 in. (1.52 mm) and the density can range from about 
0.030 g/cc to about 0.045 g/cc. 
The basis weight of the nonwoven material 10 was measured using a device 
that measures the weight of a sample of the nonwoven material. Each sample 
measured no less than 4 in.sup.2 (2580 mm.sup.2). Each sample was cut, 
smoothed to eliminate folds or wrinkles, and weighed on an analytical 
balance to the nearest 0.01 g. The basis weight then was calculated by 
dividing the sample weight by the sample area. 
The thickness of the nonwoven material 10 was measured using a device that 
applies a constant loading pressure of 0.05 psi (35.15 kg/m.sup.2) to a 
sample of the nonwoven material. Each sample measured at least 5.times.5 
in. (127.times.127 mm). Each sample was cut out, smoothed to eliminate 
folds or wrinkles, placed under a circular plexiglass platen (foot) having 
a 3 in. (76.2 mm.) diameter, centered as much as possible, and the platen 
then was lowered onto the specimen. The thickness of each sample was 
recorded to the nearest 0.001 in. (0.0254 mm). 
Although in alternative embodiments, the basis weight and density of the 
first layer 12 prior to bonding to the second layer 22 can vary in 
relation to that of the second layer 22, the embodiment shown includes a 
first layer 12 having a lower basis weight and a higher density than the 
second layer 22. The basis weight for the first layer can range from about 
0.4 oz/yd.sup.2 (16 g/m.sup.2) to about 0.8 oz/yd.sup.2 (28 g/m.sup.2), 
with about 0.5 oz/yd.sup.2 (18 g/m.sup.2) to about 0.6 oz/yd.sup.2 (22 
g/m.sup.2) being desireable, and the basis weight for the second layer can 
range from about 0.7 oz/yd.sup.2 (24 g/m.sup.2) to about 1.02 oz/yd.sup.2 
(35 g/m.sup.2), with about 0.9 oz/yd.sup.2 (32 g/m.sup.2) being 
desireable. The density for the first layer can range from about 0.050 
g/cc to about 0.065 g/cc, with about 0.055 g/cc being desireable, and the 
density for the second layer can range from about 0.024 g/cc to about 
0.045 g/cc, with about 0.035 g/cc being desireable. 
Referring now to FIG. 2, a cross-sectional view of the embodiment of the 
nonwoven material 10 of the present invention described above is shown, 
comprising a first nonwoven layer 12 and a second nonwoven layer 22. A 
series of bonds forming a spaced apart bonding pattern 18 extend through 
the thicknesses of the respective layers and bond the first layer 12 to 
the second layer 22 at the interface 20 in the bonding regions 18. The 
manner of forming the spaced apart bonding pattern 18 now will be 
described. 
The spaced apart bonding regions 18 may be produced by any suitable method 
of bonding the respective first and second layers to one another at the 
interface 20 therebetween that yields a nonwoven material 10 having the 
liquid management, air circulation and other properties described herein. 
Thermal bonding, which includes the use of a pair of heated embossing 
rolls, is considered a useful method of forming the bonding pattern 18, as 
described in greater detail hereinbelow. 
The present invention contemplates bonding of the respective layers in 
various sequences. For example, the first layer 12 may be formed and 
bonded in a first operation, with the second layer 22 formed in a second 
operation and then bonded to the first layer 12 in yet a further 
operation. Alternatively, the first layer 12 may be formed in a first 
operation, the second layer 22 formed in a second operation, and the 
respective layers bonded together in still another separate operation 
which simultaneously bonds the fibers in the first layer 12 to one 
another. The thermoplastic fibers of second layer 22, which are initially 
unbonded or substantially unbonded, do have a degree of thermal bonding 
when formed into the nonwoven laminated material 10, as further described 
below. 
In the embodiment shown, the fibers of the first layer 12 have a greater 
extent of bonding relative to the fibers of the second layer 22. For 
example, first layer 12 may be thermobonded by passing the layer 12 
between a pair of bonding rolls of conventional construction (i.e., an 
engraving roll and a smooth roll) heated to a temperature of between 
270.degree. F. (132.degree. C.) and 300.degree. F. (149.degree. C.), with 
275.degree. F. (135.degree. C.) to 285.degree. F. (141.degree. C.) being 
desireable. The appropriate temperature for bonding layer 12 using thermal 
bonding rolls will vary depending upon the rotational surface speeds and 
diameters of the bonding rolls and the thermoplastic fibers used. The 
first layer 12 may alternatively be bonded by other known bonding 
processes, such as by pattern adhesive bonding, needling or hydro or 
airjet entangling of the fibers. In this embodiment, the first layer 12 
has a higher density than the second layer 22. In this way, the first 
layer 12, which has greater structural integrity and mechanical strength 
than the second layer 22, can provide a base substrate for the second 
layer 22. 
The degree of bonding of the first layer 12 to the second layer 22 may be 
controlled in the spaced apart bonding region 18 by altering the percent 
bond area, which refers to the surface area of the interface between the 
respective layers that is occupied by bonds within the bonding regions. 
Thus, as shown in FIGS. 1 and 2, the interface 20 of the first layer 12 
and second layer 22 has a spaced apart pattern of bonds 18 disposed across 
its surface and the ratio of the surface area occupied by the bonding 
regions 18 to the total area of the surface of the interface 20 is the 
percent bond area for the interface 20. In the embodiment shown, the 
percent bond area of the nonwoven laminate can range from about 1% to 
about 6%, with about 2% to about 4% being desireable. While a hexagonal 
(honeycomb-like) bonding pattern is shown in this embodiment, the present 
invention encompasses other geometric, non-geometric, repeating and 
non-repeating bonding patterns, which are suitable for incorporation into 
the nonwoven material of the present invention. 
FIG. 3 is a schematic diagram of the apparatus used for forming the 
above-described embodiment of the nonwoven laminated material of the 
present invention. As stated above, conventional carding machines, such as 
described in U.S. Pat. Nos. 3,604,062 and 3,604,475, can be employed in 
producing the respective layers of the present invention. As shown, the 
first carding machine 42 lays down the first layer 12 on a moving belt 40, 
while the second carding machine 52 lays down the second layer 22 on top 
of the first layer 12. In this way, first layer 12 acts as a base 
substrate for second layer 22 as the two layers pass through the forming 
process. 
Optionally, the two layers may be passed through a pair of compacting 
rollers that slightly compact the fibrous webs to thereby increase the 
integrity of the webs and to aid in further processing. One or both of the 
layers also may be passed through apparatus that orients the fibers in the 
web to optimize material strength in the machine direction (MD) and cross 
direction (CD). As used herein, machine direction (MD) refers to the 
direction in which the web was laid down (from left to right in FIG. 3) 
and cross direction (CD) refers to the axis perpendicular to the direction 
in which the web was laid down. MD strength for the nonwoven laminate of 
this invention must be sufficiently high (at least about 900 g/in. (354 
g/cm) to about 2700 g/in. (1062 g/cm), with at least about 1300 g/in. (512 
g/cm) being desireable) so that the nonwoven webs will not be broken 
during high speed manufacturing processes used for producing disposable 
absorbent articles, such as diapers. 
The two nonwoven layers next pass through the two bonding rolls 60 and 70. 
In the embodiment shown in FIGS. 3 and 3a, both bonding rolls are heated 
and have raised (male) bonding patterns on the outer surfaces thereof. The 
lower roll 60 has a spaced apart bonding pattern 62 on its surface, while 
the upper roll 70 has raised bonding points 72 on its surface. In 
alternative embodiments, the positions of the bonding rolls can be 
reversed. It is a feature of this invention, therefore, that thermal 
bonding rolls having different male or raised bonding patterns on each of 
the outer surfaces thereof are employed to create a spaced apart bonding 
pattern for bonding together the respective layers of the nonwoven 
material. 
As the two nonwoven layers 12 and 22 pass between these two heated rolls 60 
and 70, each layer becomes stabilized by the formation of discrete 
compacted bonding areas 18 of thermally induced fiber bonds that extend 
through a major portion of the thickness of each nonwoven layer. The 
thickness of the compacted or bonded regions 18, which may vary depending 
upon the thicknesses of the respective layers 12 and 22, can range from 
about 50 .mu.m to about 150 .mu.m, with about 70 .mu.m to about 110 .mu.m 
being used in the embodiment shown herein. The compacted bonded areas of 
nonwoven material 10 are distributed in a bonding pattern 18 formed by the 
points of contact between the raised bonding patterns on the two heated 
rolls 60 and 70, with lightly bonded fiber spans 19 therebetween. 
Apertures 30 are formed in the bonded areas 18 formed by the points of 
contact between the raised patterns on the heated bonding rolls 60 and 70, 
as described in greater detail below. While the exact size and shape of 
the apertures 30 are not considered critical by the inventor (see FIGS. 5 
and 6), apertures having average diameters ranging from about 8 .mu.m to 
about 580 .mu.m or more can be advantageously employed in the present 
invention, with aperture average diameters from about 29 .mu.m to about 
277 .mu.m being desireable. As shown in FIGS. 5 and 6, the apertures 30 
are substantially free of fibers throughout the thickness of the nonwoven 
laminated material 10 and provide a non-tortuous pathway for liquid to 
pass through the nonwoven material 10. The apertures 30, consequently, 
allow rapid liquid intake through the first layer 12 into the second layer 
22 and finally into the absorbent core of an absorbent article. It has 
been observed that liquid primarily flows away from the point of contact 
with the nonwoven material 10 along the apertured bonding regions 18, 
which act as channels for the liquid. The apertures 30 are to be 
distinguished from the pores formed between fibers in layers 12 and 22, 
which are not sufficiently large nor non-tortuous to allow such rapid 
liquid intake and distribution. Consequently, a nonwoven fabric 10 is 
shown having spaced apart bonded areas 18 with lightly bonded areas 19 
therebetween and apertures 30 formed in the bonded areas 18. 
Two parameters of concern in regard to the specific combination of raised 
patterns on the bonding rolls that are used are the size of the raised 
bonding areas of the bonding rolls and the distance or spacing separating 
the bonding areas. These two parameters together affect the percentage of 
area on the nonwoven material 10 that becomes bonded, as described above. 
It is important that the percent bond area be great enough to insure 
sufficient integrity of the web for its intended use. On the other hand, 
it is important that the percent bond area not be too great, as a higher 
percent bond area usually produces a web with reduced softness. The 
percent bond area of the lower roll 60 (the ratio of the surface area of 
the raised bonding pattern 62 to the total area of the outer surface of 
lower roll 60) of this embodiment can range from about 9% to about 20%, 
with about 18% to about 19.5% being desireable. The percent bond area of 
the upper roll 70 (the ratio of the surface area of the raised bonding 
points 72 to the total area of the outer surface of lower roll 70) of this 
embodiment can range from about 10% to about 30%, with about 11% to about 
20% being desireable. As noted above, the percent bond area of the 
nonwoven laminate 10, which is the mathematical product of the percent 
bond areas of the upper roll 70 and lower roll 60, can range from about 1% 
to about 6%, with about 2% to about 4% being desireable. 
It is further important that the raised bonding patterns of the two bonding 
rolls be combined to optimize the number of apertures within the bonded 
areas. In the embodiment shown in FIGS. 3a, 3b and 3c, the width of the 
raised bonding pattern 62 on the outer surface 64 of the lower roll 60 can 
range from about 0.04 in. (1.0 mm.) to about 0.08 in. (2.0 mm.), with a 
width of about 0.07 in. (1.8 mm.) being desireable, and the width at the 
base 66 of the raised bonding pattern 62 can range from about 0.06 in. 
(1.6 mm) to about 0.12 in. (3.1 mm), with about 0.11 in. (2.8 mm) being 
desireable. The raised bonding pattern 62 of the lower roll 60 in this 
embodiment has an engraving depth of about 0.04 in. (1.0 mm), which is the 
distance between the outer surface 64 and base 66 of the raised bonding 
pattern 62. The individual hexagons 68 of the raised bonding pattern 62 of 
lower roll 60 can have a repeating width W of from about 0.65 in. (16.50 
mm) to about 0.68 in. (17.33 mm), a repeating height H of from about 1.10 
in. (28 mm) to about 1.18 in. (30 mm), and a pitch P of about 0.65 in. 
(16.50 mm) to about 0.68 in. (17.33 mm) at a pitch angle of from about 
45.degree. to about 60.degree.. 
Still referring to FIGS. 3a, 3b and 3c, the width of the raised bonding 
points 72 on the outer surface 74 of the upper roll 70 can range from 
about 0.028 in. (0.70 mm) to about 0.031 in. (0.80 mm), with a width of 
about 0.030 (0.75 mm) being suitable. As is conventional in the art, the 
width at the base 76 of the raised bonding points 72 is slightly greater 
than the width on the outer surface 74. The raised bonding points 72 of 
the upper roll 70 can have an engraving depth of about 0.026 in. (0.65 
mm). The individual raised bonding points 72 in this embodiment are 
arranged at about 218.0 bonding points/in.sup.2 (33.8 bonding 
points/cm.sup.2) and have a repeating width W' of about 0.094 in. (2.4 mm) 
to about 0,118 in. (3.0 mm), a repeating height H' of about 0.068 in. 
(1.72 mm), and a pitch P' of about 0.068 in. (1.72 mm) at a pitch angle of 
from about 30.degree. to about 45.degree.. While in the embodiment shown, 
the outer surface 74 of the raised bonding points 72 is in the form of a 
square, other geometric and non-geometric shapes may be employed as the 
raised bonding points 72 of upper roll 70. 
The inventor has observed in optimizing the nonwoven material 10 of the 
present invention, the following factors are interrelated: 
1) Temperature of bonding rolls 60 and 70; 
2) Line speed of the forming process; 
3) Nip pressure between the bonding rolls; 
4) Diameter of the bonding rolls; and 
5) Types of materials used in forming layers 12 and 22. 
That is, modifying one or more of the above factors tends to affect the 
remaining factors as well. For example, an increase in the line speed of 
the forming process results in the layers of the nonwoven laminate being 
in contact with the bonding rolls for a shorter period of time. 
Consequently, the temperature of the bonding rolls may have to be 
increased to achieve the required degree of bonding of the two layers, 
thereby compensating for the change in line speed. 
As noted above, an important factor relating to the bonding of the two 
layers is the temperature at which the bonding rolls 60 and 70 are 
maintained. Naturally, temperatures below a certain point for each polymer 
will not effect any bonding, while temperatures above another point will 
melt too much of the web. Also, its has been observed that the temperature 
of the bonding rolls can affect both the tensile strength and softness of 
the nonwoven laminate produced. In particular, within a certain range, 
higher temperatures will produce a web with higher tensile strength. 
However, these same higher temperatures can produce a web with decreased 
softness. This is likely due to a higher and lower degree of bonding that 
occurs within this range of temperatures. That is, the higher temperatures 
likely result in more and stronger interfilament bonding that is 
beneficial to tensile strength and somewhat detrimental to softness. In 
addition, higher temperatures likely result in a less lofty, pillowed 
structure, as the thermoplastic fibers experience more shrinkage, 
adversely affecting the softness and cushiony feel of the nonwoven 
material 10. 
It has further been observed that the temperature of the rolls can affect 
the formation of apertures in the bonded areas of the web. While the 
apertures formed in the bonded areas are not solely thermally produced, 
thermal bonding allows the respective layers to be compressed to a 
sufficient degree that mechanical aperturing may occur, as further 
described below. 
In the embodiment shown, the bonding temperature for lower roll 60 can 
range from about 260.degree. F. (127.degree. C.) to about 285.degree. F. 
(141.degree. C.), with a temperature of about 265.degree. F. (129.degree. 
C.) to about 275.degree. F. (135.degree. C.) being desireable, and the 
bonding temperature for upper roll 70 can range from about 270.degree. F. 
(132.degree. C.) to about 320.degree. F. (160.degree. C.), with a 
temperature of about 290.degree. F. (143.degree. C.) to about 315.degree. 
F. (157.degree. C.) being desireable. It is important that the bonding 
roll that contacts the first nonwoven layer 12, which in this embodiment 
is lower bonding roll 60, have a lower temperature than the bonding roll 
that contacts the second nonwoven layer 22, which in this embodiment is 
upper roll 70, such that the softness of the first layer 12 is not 
significantly reduced, while the thermoplastic fibers in the second layer 
22 are sufficiently heated to thermally fuse with the thermoplastic fibers 
in the first layer 12. So long as the temperature of bonding roll 60 is 
maintained at a slightly lower temperature than the temperature at which 
the first layer 12 is bonded, assuming all other operating parameters are 
constant for the forming process described above, the softness of layer 12 
will not change significantly. 
Another important factor relating to the bonding of the two layers as well 
as the formation of apertures in the bonding regions is the line speed at 
which the respective bonding rolls are operated. In the embodiments shown, 
the rolls can operate at line speeds ranging from about 65 feet/min. (20 
m/min.) to about 328 feet/min. (100 m/min.) or more. It has further been 
observed that aperture formation within the bonding regions can be 
significantly improved by employing different rotational surface speeds 
for the two bonding rolls. The difference in rotational surface speeds can 
differ from about 4% to about 20%, with about 5% to about 15% being 
conveniently employed. Either bonding roll may be employed with a higher 
rotational speed than the other bonding roll. While not wishing to be 
bound by any particular theory, it is believed that aperture formation is 
improved by operating the bonding rolls at different rotational speeds 
because the shearing forces tangential to the bonding roll surfaces in the 
thermally produced compacted bonding areas tear (mechanical aperturing) 
the nonwoven materials at the points of contact between the raised bonding 
patterns of the bonding rolls. 
Another important factor relating to the bonding of the two layers is the 
diameter of each bonding roll. While in the embodiment shown (and in the 
ensuing Examples), the bonding rolls each are about 12 inches (305 mm) in 
diameter, bonding rolls having smaller or larger diameters are suitable 
for producing the nonwoven laminate of the present invention. Moreover, 
the diameters of the bonding rolls need not be identical. 
Another important factor relating to the bonding of the two layers and 
aperture formation within the bonding regions is the nip pressure between 
the bonding rolls. In the embodiment shown, the bonding rolls produce a 
nip pressure of from about 60 pli (10 kg/lcm) to about 400 pli (67 
kg/lcm). It is likely that higher nip pressures will result in a less 
lofty, pillowed structure, adversely affecting the softness 
characteristics of the nonwoven material 10. 
In the embodiment shown, after the layers 12 and 22 of nonwoven laminated 
material 10 are bonded by bonding rolls 60 and 70, nonwoven material 10 is 
wound on a take up roll (winder) 78. Alternatively, it may be desirable to 
design this apparatus to connect with a fabrication line for the end 
product. Higher tension on the take up roll 78 or fabrication line is 
another factor that is likely to adversely affect the loftiness of the 
nonwoven material 10 of this invention. 
FIG. 4 is a cross-sectional view through a disposable diaper 100 including 
the nonwoven material 80 of the present invention positioned on the side 
of the diaper that will be placed next to the infant's body. In the 
embodiment shown, the nonwoven material 80 forms a body facing outer layer 
12 comprising a bonded carded web formed of polypropylene fibers and an 
inner "surge" layer 22 comprising a substantially unbonded or unbonded 
carded web formed of a blend of polypropylene and polyester fibers as 
described above. The diaper further includes a liquid-permeable bodyside 
liner 82 formed, for example, of nonwoven spunbond or bonded carded web 
material, an absorbent core 84 formed, for example, of a blend of 
hydrophilic cellulosic woodpulp fluff and highly absorbent gelling 
particles (e.g., superabsorbents), a tissue layer 92 surrounding at least 
a portion of absorbent core 84, and a flexible, liquid-impermeable outer 
cover 86 formed, for example, of thin polyethylene film. As used herein, 
the term "superabsorbent" refers to a material, natural or synthetic, 
capable of absorbing or gelling at least about 10 times its weight in 
liquid. 
In the embodiment shown, the nonwoven material 80, which overlies liner 82, 
is substantially coextensive with the width of absorbent core 84, while 
the total area of liner 82 is substantially coextensive with the total 
area of outer cover 86. Alternatively, the nonwoven material 80 may be 
arranged to be generally coextensive with the outer cover 86. In other 
configurations, nonwoven material 80 may have a width that is less than 
the minimum width of absorbent core 84. In various optional 
configurations, the length of nonwoven material 80 may be equal to or less 
than the length of outer cover 86, although in the illustrated embodiment, 
the lengths of nonwoven material 80 and outer cover 86 are substantially 
equal. 
As further shown in FIG. 4, nonwoven material 80 is positioned between two 
optional containment flaps 88 attached to the bodyside surface of liner 
82. Suitable constructions and arrangements for containment flaps are 
described, for example, in U.S. Pat. No. 4,704,116, issued Nov. 3, 1987, 
to K. Enloe, the disclosure of which is hereby incorporated by reference. 
Elastic members 90, which may optionally be included in the absorbent 
article, are disposed adjacent each longitudinal edge of diaper 100. 
Elastic members 90 are arranged to draw and hold the lateral, side margins 
of diaper 100 against the legs of the wearer. Additionally, elastic 
members (not shown) also may be disposed adjacent either or both of the 
end edges of diaper 100 to provide an elasticized waistband. 
Nonwoven material 80 is connected to or otherwise associated with bodyside 
liner 82 or outer cover 86 in an operable manner. As used herein, the term 
"associated" encompasses configurations where nonwoven material 80 is 
directly joined to bodyside liner 82 by affixing marginal areas or 
intermediate areas of nonwoven material 80 directly to liner 82, and 
configurations where nonwoven material 80 is joined to outer cover 86, 
either directly or by affixing nonwoven material 80 to intermediate 
components that in turn are affixed to outer cover 86. Nonwoven material 
80 may be affixed directly to bodyside liner 82 or outer cover 86 by 
attachment means (not shown) such as adhesive, sonic bonds, thermal bonds 
or any other attachment means known to those of ordinary skill in the art. 
It is readily apparent that such attachment means may also be used to 
interconnect and assemble together the other component parts of the diaper 
100. Fastening means (not shown) of known construction may also be 
optionally incorporated in the diaper construction shown. 
While a particular configuration of the component parts of diaper 100 is 
shown in FIG. 4, these components may be assembled into a variety of 
well-known diaper configurations. It should be further recognized, 
however, that in disposable absorbent articles other than diapers, 
individual components may be optional, depending upon their intended end 
uses. 
An important property of any bodyside liner material is its softness. In 
particular, it is important for the liner to be both extremely pliable as 
well as soft to the touch in consideration of the infant's comfort. The 
present inventor has observed that the body facing layer 12 of the 
nonwoven material 80 of the present invention exhibits excellent softness 
characteristics. 
Another important property of a nonwoven liner and nonwoven fabrics in 
general is tensile strength, i.e., the resistance to tearing, and percent 
elongation prior to tearing. These properties have been measured by the 
present inventor on a device, such as the Instron Model TM 1000 (Instron 
Corp. having offices in Canton Mass.), that grips a sample (about 
1.times.6 in. (25.4.times.1524 mm)) of a nonwoven fabric in a pair of jaws 
extending the entire width of the sample, and then pulls it apart at a 
constant rate of extension. The force needed to rupture the fabric is 
recorded as the tensile strength and the length of the fabric before 
rupture as compared to the original length provides the percent elongation 
value. These tests can be performed either with the fabric oriented in the 
jaws so that the force is applied in the machine direction, MD, or with 
the fabric oriented so that the force is applied in the cross direction, 
CD. It was observed that the nonwoven materials made in accordance with 
the present invention, several examples of which are discussed below, 
exhibited sufficient tensile strength and percent elongation properties. 
Yet another property that is particularly important for a liner of an 
absorbent article, such as a disposable diaper, is the wettability of the 
liner. Depending upon the design of the absorbent article, it is usually 
desirable to have the liner be at least partially wettable in order to 
facilitate passage of liquid through to the absorbent core. In addition, 
it is even more desirable to provide a wettability gradient in the liner 
whereby liquid can be wicked away from the wearer for increased comfort 
and skin health. In particular, it is desireable to provide, as in the 
present invention, a body facing layer 12 that is less wettable than the 
"surge" layer 22, i.e., the layer closest to the absorbent material. In 
this way, liquid flows more easily through to the absorbent core material 
than it flows back to the wearer. 
Many of the polymers that are suitable to make nonwoven webs are 
hydrophobic. Specifically, polyolefin fibers are completely hydrophobic. 
As a result, it is desirable for nonwoven webs made with these polymers to 
impart a desired level of wettability and hydrophilicity. It is known in 
the art that wettability of hydrophobic fibers, such as polypropylene, can 
be increased by the application of water-soluble finishes, typically 
ranging from about 0.3% to about 0.6%, to the surfaces of such hydrophobic 
fibers for improving the liquid management properties of such fibers in 
their end-use applications. In the embodiment described herein, the 
polypropylene fibers employed can be made wettable by treating the fibers 
with water-soluble finishes before being formed into nonwoven layers 12 
and 22. Another contributing factor in producing the described wettability 
gradient is the blending of polyester fibers in a desired amount with the 
polypropylene fibers forming the second nonwoven layer 22. As described 
above, the differing pore sizes resulting from using the coarser, more 
resilient polyester fibers in a homogeneous blend of polypropylene and 
polyester fibers in nonwoven layer 22, produce the required wettability 
gradient between first layer 12 and second layer 22. 
The following examples are provided to give a more detailed understanding 
of the invention. The particular compositions, proportions, materials and 
parameters are exemplary and are not intended to specifically limit the 
scope of the present invention. 
EXAMPLES 
Example 1 
A first layer was formed of 100% polypropylene (PP-196 manufactured by 
Hercules, Inc. having offices in Wilmington, Del.) by blending on a 
conventional carding machine as described above. The first layer had a 
basis weight of about 18 g/m.sup.2 (0.5 oz/yd.sup.2). A second layer was 
formed of 60% polyester (SD-10 manufactured by Sam Yang having offices in 
Seoul, South Korea) and 40% PP-196 polypropylene by blending on a 
conventional carding machine. The second layer had a basis weight of about 
32 g/m.sup.2 (0.9 oz/yd.sup.2). The first and second layers were 
thermobonded together by heated bonding rolls as shown in FIGS. 3 and 3a., 
with the bonding roll contacting the first layer maintained at a 
temperature of about 272.degree. F. (133.degree. C.) and the bonding roll 
contacting the second layer maintained at a temperature of about 
315.degree. F. (157.degree. C.) The line speed for the bonding rolls was 
about 80 ft/min. (24 m/min.) and the nip pressure between the bonding 
rolls was about 300 pli. The thermobonding process yielded a nonwoven 
laminated material having a spaced apart bonding pattern with apertures 
formed within the bonding regions and a percent bond area of about 2%. 
Example 2 
A first layer was formed of 100% PP-196 polypropylene by blending on a 
conventional carding machine as described above. The first layer had a 
basis weight of about 18 g/m.sup.2 (0.5 oz/yd.sup.2). A second layer was 
formed of 60% polyester (PET-295 manufactured by Hoechst Celanese having 
offices in Greenville, S.C.) and 40% PP-196 polypropylene by blending on a 
conventional carding machine. The second layer had a basis weight of about 
32 g/m.sup.2 (0.9 oz/yd.sup.2). The first and second layers were 
thermobonded together by heated bonding rolls as shown in FIGS. 3 and 3a., 
with the bonding roll contacting the first layer maintained at a 
temperature of about 272.degree. F. (133.degree. C.) and the bonding roll 
contacting the second layer maintained at a temperature of about 
315.degree. F. (157.degree. C.) The line speed for the bonding rolls was 
about 80 ft/min. (24 m/min.) and the nip pressure between the bonding 
rolls was about 300 pli. The thermobonding process yielded a nonwoven 
laminated material having a spaced apart bonding pattern with apertures 
formed within the bonding regions and a percent bond area of about 2%. 
Example 3 
A first layer was formed of 100% polypropylene fibers (PT110-20 supplied by 
Lohmann GmbH & Co. KG having offices in Neuwied, Germany). The first layer 
had a basis weight of about 20 g/m.sup.2 (0.5 oz/yd.sup.2). A second layer 
was formed of 60% polyester (PET-292 manufactured by Hoechst/AG having 
offices in Frankfurt, Germany) and 40% polypropylene (PP-71 "SOFT-71" 
manufactured by Danaklon A/S, Inc. having offices in Varde, Denmark) by 
blending on a conventional carding machine as described above. The second 
layer had a basis weight of about 32 g/m.sup.2 (0.9 oz/yd.sup.2). The 
first and second layer were thermobonded together by heated bonding rolls 
as shown in FIGS. 3 and 3a., with the bonding roll contacting the first 
layer maintained at a temperature of about 272.degree. F. (133.degree. C.) 
and the bonding roll contacting the second layer maintained at a 
temperature of about 315.degree. F. (157.degree. C.) The line speed for 
the bonding rolls was about 80 ft/min. (24 m/min.) and the nip pressure 
between the bonding rolls was about 300 pli. The thermobonding process 
yielded a nonwoven laminated material having a spaced apart bonding 
pattern with apertures formed within the bonding regions and a percent 
bond area of about 2%. 
Example 4 
A first layer was formed of 100% PP-71 polypropylene using a conventional 
spunbonding forming process. The first layer had a basis weight of about 
22 g/m.sup.2 (0.6 oz/yd.sup.2). A second layer was formed of 60% polyester 
PET-292 and 40% PP-71 polypropylene by blending on a conventional carding 
machine. The second layer had a basis weight of about 32 g/m.sup.2 (0.9 
oz/yd.sup.2). The first and second layer were thermobonded together by 
heated bonding rolls as shown in FIGS. 3 and 3a., with the bonding roll 
contacting the first layer maintained at a temperature of about 
272.degree. F. (133.degree. C.) and the bonding roll contacting the second 
layer maintained at a temperature of about 315.degree. F. (157.degree. C) 
The line speed for the bonding rolls was about 80 ft/min. (24 m/min.) and 
the nip pressure between the bonding rolls was about 300 pli. The 
thermobonding process yielded a nonwoven laminated material having a 
spaced apart bonding pattern with apertures formed within the bonding 
regions and a percent bond area of about 2%. 
Example 5 
A first layer was formed of 100% polypropylene (75% PP-196 and 25% PP-190, 
both manufactured by Hercules, Inc. having offices in Wilmington, Del.) by 
blending on a conventional carding machine as described above. The first 
layer had a basis weight of about 18 g/m.sup.2 (0.5 oz/yd.sup.2). A second 
layer was formed of 60% PET-292 polyester and 40% PP-71 polypropylene by 
blending on a conventional carding machine. The second layer had a basis 
weight of about 32 g/m.sup.2 (0.9 oz/yd.sup.2). The first and second layer 
were thermobonded together by heated bonding rolls as shown in FIGS. 3 and 
3a., with the bonding roll contacting the first layer maintained at a 
temperature of about 272.degree. F. (133.degree. C.) and the bonding roll 
contacting the second layer maintained at a temperature of about 
315.degree. F. (157.degree. C.) The line speed for the bonding rolls was 
about 80 ft/min. (24 m/min.) and the nip pressure between the bonding 
rolls was about 300 pli. The thermobonding process yielded a nonwoven 
laminated material having a spaced apart bonding pattern with apertures 
formed within the bonding regions and a percent bond area of about 2%. 
Example 6 
A first layer was formed of 100% PP-196 polypropylene by blending on a 
conventional carding machine as described above. The first layer had a 
basis weight of about 18 g/m.sup.2 (0.5 oz/yd.sup.2). A second layer was 
formed of 60% PET-295 polyester and 40% PP-196 polypropylene by blending 
on a conventional carding machine. The second layer had a basis weight of 
about 32 g/m.sup.2 (0.9 oz/yd.sup.2). The first and second layers were 
thermobonded together by heated bonding rolls as shown in FIGS. 3 and 3a., 
with the bonding roll contacting the first layer maintained at a 
temperature of about 272.degree. F. (133.degree. C.) and the bonding roll 
contacting the second layer maintained at a temperature of about 
315.degree. F. (157.degree. C.) The line speed for the bonding rolls was 
about 80 ft/min. (24 m/min.) and the nip pressure between the bonding 
rolls was about 300 pli. The thermobonding process yielded a nonwoven 
laminated material having a spaced apart bonding pattern with apertures 
formed within the bonding regions and a percent bond area of about 2%. 
The resultant nonwoven laminated materials of the above examples had the 
properties set forth in the following table: 
TABLE I 
______________________________________ 
Basis Tensile % 
Weight Thickness 
Density 
(g/in.) Elongation 
Example 
(g/m.sup.2) 
(in.) (g/cc) 
MD CD MD 
______________________________________ 
1 49.0 0.046 0.041 1578.0 
196.0 33.2 
2 52.0 0.046 0.044 1585.0 
198.0 32.0 
3 51.0 0.048 0.042 2672.0 
402.0 29.2 
4 56.5 0.051 0.043 1439.0 
382.0 26.1 
5 51.2 0.057 0.034 1509.0 
228.0 39.6 
6 51.5 0.058 0.035 1610.0 
263.0 37.3 
______________________________________ 
For the purposes of the present disclosure, the following test procedures 
can be used to determine particular parameters of the nonwoven material 10 
of the present invention. 
The Fluid Intake and Flowback Evaluation (FIFE) test has been designed to 
measure the absorbency/penetration time, flowback amount and amount of 
liquid retention in the liner of a disposable absorbent article. The 
absorbency/penetration time (in seconds) is measured by using a stopwatch 
and visually determining the length of time required to absorb simulated 
urine voidings. The flowback test measures, in grams, the amount of liquid 
that emerges from the "user side" of the absorbent article after it has 
absorbed each of three liquid insults and pressure has been applied. 
The apparatus shown in FIGS. 7 and 8 is used for this test. A sample diaper 
to be tested, as shown in FIG. 4 and shown in phantom at 102 in FIG. 7, is 
weighed to the nearest 0.1 g. The sample 102 is prepared by cutting the 
leg and waist elastic members and containment flap elastics (not shown) 
along their length in order to allow the sample to lie flat. Sample 
dimensions, weight and density profiles of the sample 102 and composition 
of the absorbent core must be appropriately controlled to obtain valid 
results. Data reported herein were obtained from 12 in..times.12 in. (305 
mm..times.305 mm.) rectangular samples including the nonwoven materials 10 
described above in Examples 4, 5 and 6 and absorbent cores containing 
about 10 grams of woodpulp fluff and about 12 grams of superabsorbent 
material, such as DOW DRYTECH 835 or an equivalent thereof. 
The sample 102 is placed flat and smooth under an 880 g. cylinder plate 
assembly 104 such that the cylinder 106, which has a 5.1 cm i.d., ends up 
in a designated location 108. For example, the designated location 108 can 
range from about 41/2 inches (114.3 mm.) to about 53/4 inches (146.1 mm.) 
from the edge of the sample 102, depending upon the size (e.g., small (s), 
medium (m), large (l) or extra large (xl)) of the absorbent article to be 
tested. Under the sample 102 is a raised platform 110 that is 1/2 inch 
(12.7 mm.) high (d).times.6 inches (152.4 mm.) long (e).times.3 inches 
(76.2 mm.) wide (f). Also, the cylinder 106 extends a distance (g) of 
about 1/32 inch (0.8 mm.) below the cylinder plate assembly 104. 
Funnel 112 on top of cylinder 106 is perpendicular to the sample 102 and 
centered on the designated location 108. A specified amount of synthetic 
urine (e.g., 50 ml, 80 ml or 100 ml for small, medium and large or extra 
large diapers, respectively), is poured through the funnel 112. (An 
example of a suitable synthetic urine is Item No. K-C 399105, available 
from PPG Industries having offices in Appleton, Wis.) The time elapsing 
between the first liquid contact with the sample 102 and the time when 
liquid no longer is visible on the surface of the sample 102 is measured 
with a stop watch. One minute after the initial liquid insult is imbibed, 
a second insult of the same size is introduced. The time to imbibe the 
second insult of liquid is measured as for the first insult. 
Referring now to FIGS. 9 and 10, one minute after the second insult is 
imbibed, the sample 102 is placed on a vacuum apparatus 114 and covered 
with blotter paper 116 together with liquid impervious latex sheeting 118. 
A 35,000 dyne/cm.sup.2 (about 0.5 psi) vacuum pressure then is applied to 
suck the impervious latex sheeting 118 onto the blotter 116 and sample 102 
for two minutes. After the pressure is released, the wet blotter paper 116 
then is weighed. The increase in weight (in grams) of the blotter paper 
116 represents the flowback. 
Within one minute after the pressure is released from the sample 102, a 
third liquid insult is introduced and timed as described above. The liquid 
intake time then is the number of seconds for the prescribed amount of 
liquid (80 ml for the results described herein) to enter the sample 102. 
Samples 102 including the nonwoven laminated materials of the above 
Examples 4, 5 and 6 had the flowback and liquid intake time values set 
forth in the following table: 
TABLE II 
______________________________________ 
FIFE Liquid 
FIFE 
Intake Time 
Flowback 
Example (seconds) (grams) 
______________________________________ 
4 33 7.1 
5 34 1.9 
6 30 3.2 
______________________________________ 
While the Fluid Intake and Flowback Evaluation test results are indicated 
above for several specific Examples, absorbent articles incorporating the 
nonwoven material 10 described herein can have liquid intake times ranging 
from about 11 seconds to about 38 seconds and flowback values ranging from 
about 1.0 gram to about 9.0 grams. 
It is contemplated that the nonwoven material 10 constructed in accordance 
with the present invention will be tailored and adjusted by those of 
ordinary skill in the art to accommodate various levels of performance 
demand imparted during actual use. For example, mild urinary incontinence 
and menstrual flow pads involve different delivery rates, volumes and 
timing than infant urine insults. Moreover, the liquid in the surge can 
vary in terms of the liquid viscosity, surface tension, temperature and 
other physical properties that could affect the performance of the 
nonwoven material 10 in the various actual product end usages. 
Accordingly, while this invention has been described by reference to the 
above embodiments and examples, it will be understood that this invention 
is capable of further modifications. This application is, therefore, 
intended to cover any variations, uses or adaptations of the invention 
following the general principles thereof, and including such departures 
from the present disclosure as come within known or customary practice in 
the art to which this invention pertains and fall within the limits of the 
appended claims.