Patent Publication Number: US-7713683-B2

Title: Apparatus and method for making a forming structure

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of pending U.S. Ser. No. 10/402,396, filed on Mar. 28, 2003 now U.S. Pat. No. 7,303,861, which is a continuation-in-part of pending U.S. Ser. No. 10/324,181, filed on Dec. 20, 2002. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a forming structure for making a polymeric web exhibiting a soft and silky tactile impression on at least one surface. More particularly, the present invention relates forming structure for making a three-dimensional polymeric web exhibiting a soft and silky tactile impression that can be used as a body-facing topsheet in disposable absorbent. 
     BACKGROUND OF THE INVENTION 
     It is extremely desirable to construct disposable articles, such as absorptive devices, including sanitary napkins, pantyliners, interlabial devices, diapers, training pants, incontinent devices, wound dressings and the like, with a soft cloth-like surface feel to the user&#39;s skin at any anticipated points of contact. Likewise, it has long been known in the disposable articles art to construct absorptive devices that present a dry surface feel to the user, especially during use. By having a soft, cloth-like body-facing surface that retains a dry surface feel during use, an absorptive device gives improved wearing comfort, and minimizes the development of undesirable skin conditions due to prolonged exposure to moisture absorbed within the absorptive device. 
     While woven and non-woven fibrous webs are often employed as body-facing topsheets for absorptive devices because of their pleasant surface feel, macroscopically expanded, three dimensional, apertured polymeric webs such as the commercially successful DRI-WEAVE™ topsheet marketed by Procter &amp; Gamble Company have also been utilized. One viable polymeric web of this type is disclosed in U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3, 1982. Such webs have been shown to exhibit desirable fluid transport and fluid retaining characteristics. Desirable fluid transport characteristics allow the topsheet to acquire fluids, such as urine or menses, and pass to fluid into the absorptive article. Once absorbed into the absorptive article, the fluid retaining feature of the topsheet preferably prevents rewet, i.e., the movement of fluid back through the topsheet. Rewet can be a result of at least two causes: (1) squeezing out of the absorbed fluid due to pressure on the absorptive article; and/or (2) wetness entrapped within or on the topsheet. Preferably, both properties, fluid acquisition and fluid retention, are maximized. Said differently, preferably a topsheet will exhibit high rates of fluid acquisition, and low levels of rewet. 
     Other macroscopically expanded, three dimensional, apertured polymeric webs are known. For example, U.S. Pat. No. 4,463,045 issued to Ahr et al. on Jul. 31, 1984 discloses a macroscopically expanded three-dimensional polymeric web that exhibits a substantially non-glossy visible surface and cloth-like tactile impression. Ahr et al. teaches the criteria which must be met with respect to the regularly spaced pattern of surface aberrations in order to diffusely reflect incident light and thereby eliminate gloss. Ahr, et al teaches that the surface aberrations in the web should exhibit an average amplitude of at least about 0.2 mils (i.e., 0.0002 inches), and most preferably at least about 0.3 mils (i.e., 0.0003 inches) for a more clothlike or fiberlike tactile impression in the resultant web. Despite its advancements in eliminating gloss, the structure of the surface aberrations of the web in Ahr, et al. can lack desired softness. As recognized in the art, for example is U.S. Pat. No. 4,629,643, issued to Curro et al. (discussed below), the lack of desired softness is believed to be due to the structure of each aberration, which can be described as having the properties of an “arch” that behaves as a discrete structural unit, resisting deflection. This lack of sufficient deflection detracts from the softness impression experienced by the user&#39;s skin. 
     One proposed solution to improve the softness impression to the web of Ahr et al., was disclosed in the aforementioned U.S. Pat. No. 4,629,643 (Curro, et al. &#39;643) Curro, et al. &#39;643 discloses a microapertured polymeric web exhibiting a fine scale pattern of discrete surface aberrations. Each of these surface aberrations have a maximum amplitude and, unlike the web structure disclosed in Ahr, et al. at least one microaperature is provided that is substantially coincidental with the maximum amplitude of each surface aberration. The forming of microapertures at the maximum amplitude of each surface aberration provides a volcano-like cusp with petal shaped edges. It is believed that the resultant web surface that is in contact with the human skin is of smaller total area and is less resistant to compressive and shear forces than the unapertured “arch-like” structures taught by Ahr et al. 
     Although the microapertured film of Curro, et al. &#39;643 imparts superior tactile impression to the skin of the user, it has some drawbacks related to certain fluid handling properties when used as a topsheet in absorbent articles. For example, it has been found that a web as disclosed in Curro, et al. &#39;643, when used as a topsheet on a sanitary pad can permit an unacceptably high amount of rewet, i.e., fluid that returns back to the skin-facing surface of the topsheet after initially having passed through the topsheet to be absorbed by the sanitary napkin. In particular, it appears that a web according to Curro &#39;643 can be more susceptible to rewet under pressure. This is because when such a product is used as a topsheet in a catamenial product, for example, absorbed fluid can be urged back out of the product through the many microapertures of the topsheet. It appears that each of the microapertures in the structure of Curro, et al. &#39;643 can provide a pathway for fluid to escape from an underlying absorbent core in an absorbent article under the pressure of normal wearing conditions. These pathways in the web structures therefore cause decreased fluid retention and increased rewet in the absorbent structures. 
     Attempts at alleviating the shortcoming of Curro &#39;643, i.e., attempts to both maximize softness and reduce rewet, can be found, for example, in U.S. Pat. No. 6,228,462 issued to Lee, et al., on May 8, 2001. Lee discloses a compression resistant web comprising rigid polymers. The compression resistance of the rigid polymers helps reduce rewet, but the rigid polymers utilized tend to decrease the softness of the web. 
     Furthermore, the hydroforming processes disclosed in Curro, et al. &#39;643 and Lee &#39;462 for making macroscopically expanded, three dimensional, apertured polymeric webs results in a formed film that must be dried after hydroforming. Due to the many interstices of the microapertures that can retain water, drying commercial quantities of these webs consumes significant amounts of energy, and can require significant capital investments in drying equipment. One example of an approach to effectively dry such webs is disclosed in U.S. Pat. No. 4,465,422 issued Sep. 22, 1987 to Curro, et al. 
     One further drawback associated with the webs disclosed in Curro &#39;643 and Lee &#39;462 when used as topsheets on sanitary napkins is the tendency of the microapertures to entrap fluid, such as menses. The entrapment can be in the microapertures themselves and/or between adjacent microapertures. Fluid so entrapped remains at or near the surface of the web, and can, therefore be in contact with the wearer&#39;s skin for prolonged periods of time. This contact negatively affects the skin health of the wearer and causes the topsheet to not have a clean appearance post-use. 
     Another attempt at making a soft, three-dimensional, macroscopically-expanded web having an improved functional surface is U.S. Pat. No. 5,670,110, issued to Dirk, et al. on Sep. 23, 1997. The web of Dirk et al. utilizes fibrils achieved via a screen printing roll. However, screen printing is a relatively slow process for making commercial webs for consumer articles. 
     Accordingly, it would be beneficial to have an improved formed film web that has superior tactile impression and superior fluid handling properties. 
     Additionally, it would be beneficial to have a formed film web that has superior tactile impression and provides for superior fluid retention and rewet characteristics. 
     Additionally, it would be beneficial to have a formed film web that has superior tactile impression and provides for superior cleanliness for hygiene articles. 
     Additionally, it would be beneficial to have an improved process for making a formed film web that has superior tactile impression and provides for superior fluid retention and rewet characteristics. 
     Finally, it would be beneficial to have an improved apparatus and method of making a forming structure for forming a formed film web that has superior tactile impression and provides for superior fluid retention and rewet characteristics. 
     SUMMARY OF THE INVENTION 
     A method for making a forming structure having columnar protrusions extending therefrom, the method comprising the steps of:
         a) providing a forming unit;   b) providing a backing film;   c) providing a foraminous element;   d) juxtaposing the foraminous element and the backing film with respect to the forming unit so that the backing film is interposed between the foraminous element and the forming unit;   e) providing a liquid photosensitive resin;   f) applying a coating of the liquid photosensitive resin to the foraminous element;   g) juxtaposing in contacting relationship with the coating of photosensitive resin a first transparent mask;   h) controlling a first thickness between the backing film and the first mask of the coating to a preselected value;   i) exposing the liquid photosensitive resin to light having an activating wavelength through the first mask thereby inducing partial curing of the photosensitive resin to form a monolithic slab of partially-cured photosensitive resin;   j) removing the first mask;   k) repeating steps (a)-(j) one time with a different, second mask replacing the first mask in steps (g)-(h) and a second thickness in step (h), the second thickness being defined between the backing film and the second mask and being greater than the first thickness, and, in step (i) inducing partial curing of a plurality of protrusions on the monolithic slab such that they are joined to and integral with the monolithic slab, and removing the second mask in step (j);   l) immersing the foraminous element and partially cured resin thereon in an oxygen-free environment;   m) exposing the foraminous element and partially cured resin thereon to light having an activating wavelength to fully cure the partially cured resin, resulting in the forming structure having columnar protrusions extending therefrom.
 
The method can further comprise the step of laser etching a plurality of apertures through the forming structure to form an apertured forming structure.
       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which: 
         FIG. 1  is an enlarged, partially segmented, perspective illustration of a prior art polymeric web of the type generally disclosed in commonly assigned U.S. Pat. No. 4,342,314. 
         FIG. 2  is an enlarged, partially segmented, perspective illustration of a prior art polymeric web of the type generally disclosed in commonly assigned U.S. Pat. No. 4,629,643. 
         FIG. 3  is an enlarged, partially segmented, perspective illustration of a polymeric web made on a forming structure of the present invention. 
         FIG. 4  is a further enlarged, partial view of a portion of the web shown in  FIG. 3  illustrating in greater detail certain features of the polymeric web of the present invention. 
         FIG. 5  is a cross-sectional depiction of a cross section taken along Section  5 - 5  of  FIG. 4 . 
         FIG. 6  is a plan view of representative aperture shapes projected in the plane of the first surface of a polymeric web of the present invention. 
         FIG. 7  is a top plan view of a sanitary napkin with portions cut away to more clearly show the construction of a catamenial device of the present invention. 
         FIG. 8  is a cross-sectional view of the sanitary napkin taken along Section  8 - 8  of  FIG. 7 . 
         FIG. 9  is a simplified schematic illustration of a single phase forming process of the present invention. 
         FIG. 10  is an enlarged, partially segmented, perspective illustration of a forming structure of the present invention. 
         FIG. 11  is a further enlarged, partial view of a portion of the forming structure shown in  FIG. 10 . 
         FIG. 12  is a further enlarged partial view of a portion of the forming structure shown in  FIG. 11 . 
         FIG. 13  is a photomicrograph of one embodiment of a forming structure of the present invention. 
         FIG. 14  is an enlarged view of a portion of the forming structure of  FIG. 13 . 
         FIG. 15  is a photomicrograph of another embodiment of a forming structure of the present invention. 
         FIG. 16  is an enlarged view of a portion of a forming structure similar to that shown in  FIG. 15 . 
         FIG. 17  is a photomicrograph of a portion of a web made on a forming structure of the present invention. 
         FIG. 18  is an enlarged view of a portion of the web shown in  FIG. 17 . 
         FIG. 19  is a photomicrograph of a portion of a web made on a forming structure of the present invention. 
         FIG. 20  is an enlarged view of a portion of a web made on a forming structure of the present invention. 
         FIG. 21  is a plan view of a forming structure of the present invention. 
         FIG. 22  is a cross-sectional view of the forming structure shown in  FIG. 21 . 
         FIG. 23  is a schematic representation of a method from making a forming structure of the present invention. 
         FIG. 24  is a photomicrograph showing an enlarged portion of a forming structure of the present invention. 
         FIG. 25  is a photomicrograph showing a further enlarged portion of the forming structure shown in  FIG. 24 . 
         FIG. 26  is a photomicrograph showing in cross section an enlarged portion of the forming structure shown in  FIG. 24 . 
         FIG. 27  is a representation of a first mask used in a process for making a forming structure of the present invention. 
         FIG. 28  is a representation of a second mask used in a process for making a forming structure of the present invention. 
         FIG. 29  is a simplified schematic illustration of a process for making a web using a belted forming structure of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is an enlarged, partially segmented perspective illustration of a prior art macroscopically-expanded, three-dimensional, fluid pervious polymeric web  40  formed generally in accordance with the aforementioned U.S. Pat. No. 4,342,314. Webs of this type have been found to be highly suitable for use as a topsheet in absorbent articles such as sanitary napkins, pantyliners, interlabial devices, and the like. The fluid pervious web  40  exhibits a plurality of macroscopic surface aberrations that can be apertures, such as primary apertures  41 . Primary apertures  41  are formed by a multiplicity of interconnecting members, such as fiber like elements, e.g.,  42 ,  43 ,  44 ,  45  and  46 , that are interconnected to one another to define a continuous first surface  50  of the web  40 . Each fiber like element has a base portion, e.g., base portion  51 , located in plane  52  of first surface  50 . Each base portion has a sidewall portion, e.g., sidewall portion  53 , attached to each longitudinal edge thereof. The sidewall portions extend generally in the direction of a discontinuous second surface  55  of web  40 . The intersecting sidewall portions are interconnected to one another intermediate the first and second surfaces of the web, and terminate substantially concurrently with one another in the plane  56  of the second surface  55 . In some embodiments, the base portion  51  may have surface aberrations  58  in accordance with the aforementioned Ahr &#39;045 patent. 
     As used herein, the term “macroscopically expanded” refers to the structure of a web formed from a precursor web or film, e.g., a planar web, that has been caused to conform to the surface of a three-dimensional forming structure so that both sides, or surfaces, of the precursor web are permanently altered due to at least partial conformance of the precursor web to the three-dimensional pattern of the forming structure. Such macroscopically-expanded webs are typically caused to conform to the surface of the forming structure by embossing (i.e., when the forming structure exhibits a pattern comprised primarily of male projections), by debossing (i.e., when the forming structure exhibits a pattern comprised primarily of female depressions, or apertures), or by a combination of both. 
     As used herein, the term “macroscopic” refers to structural features or elements that are readily visible and distinctly discernable to a human having 20/20 vision when the perpendicular distance between the viewer&#39;s eye and the web is about 12 inches. Conversely, the term “microscopic” is utilized to refer to structural features or elements that are not readily visible and distinctly discernable to a human having 20/20 vision when the perpendicular distance between the viewer&#39;s eye and the plane of the web is about 12 inches. In general, as used herein, the primary apertures of a web disclosed herein are macroscopic, and surface aberrations, such as hair-like fibrils as disclosed more fully below are considered microscopic. 
     The term “planar” as used herein to refers to the overall condition of a precursor web or film when viewed by the naked eye on a macroscopic scale, prior to permanently deforming the web into a three-dimensional formed film. In this context, extruded films prior to post-extrusion processing and films that do not exhibit significant degree of permanent macroscopic three-dimensionality, e.g., deformation out of the plane of the film, would generally be described as planar. 
     As utilized herein, the term “interconnecting members” refers to some or all of the elements of a web, e.g., web  40  in  FIG. 1 , portions of which serve to define the primary apertures by a continuous network. As can be appreciated from the description of  FIG. 1  and the present invention herein, the interconnecting members, e.g., fiber like elements  42 ,  43 ,  44 ,  45 , and  46 , are inherently continuous, with contiguous interconnecting elements blending into one another in mutually adjoining transition portions. Individual interconnecting members can be best described with reference to  FIG. 1  as those portions of the web disposed between any two adjacent primary apertures, originating in the first surface and extending into the second surface. On the first surface of the web the interconnecting members collectively form a continuous network, or pattern, the continuous network of interconnecting members defining the primary apertures, and on the second surface of the web interconnecting sidewalls of the interconnecting members collectively form a discontinuous pattern of secondary apertures. Interconnecting members are described more generally below with reference to  FIG. 6 . 
     In a three-dimensional, macroscopically-expanded web, the interconnecting members may be described as channel-like. Their two dimensional cross-section may also be described as “U-shaped”, as in the aforementioned Radel &#39;314 patent, or “upwardly concave-shaped”, as disclosed in U.S. Pat. No. 5,514,105, issued on May 7, 1996 to Goodman, Jr., et al. “Upwardly-concave-shaped” as used herein, and as represented in  FIG. 1 , describes the orientation of the channel-like shape of the interconnecting members with relation to the surfaces of the web, with a base portion  51  generally in the first surface  50 , and the legs, e.g., sidewall portions  53 , of the channel extending from the base portion  51  in the direction of the second surface  55 , with the channel opening being substantially in the second surface  55 . In general, for a plane cutting through the web, e.g., web  40 , orthogonal to the plane, e.g., plane  52 , of the first surface  50  and intersecting any two adjacent primary apertures, e.g., apertures  41 , the resulting cross-section of an interconnecting member disposed therein will exhibit a generally upwardly concave shape that may be substantially U-shaped. 
     The term “continuous” when used herein to describe the first surface of a macroscopically-expanded, three-dimensional formed film web, refers to the uninterrupted character of the first surface generally in the plane of the first surface. Thus, any point on the first surface can be reached from any other point on the first surface without substantially leaving the first surface. Conversely, as utilized herein, the term “discontinuous” when used to describe the second surface of a three-dimensionally formed film web refers to the interrupted character of the second surface generally in the plane of the second surface. Thus, any point on the second surface cannot necessarily be reached from any other point on the second surface without substantially leaving the second surface in the plane of the second surface. 
       FIG. 2  shows an enlarged, partially segmented, perspective illustration of a portion of another prior art polymeric microapertured web  110  formed generally in accordance with the aforementioned Curro &#39;643 patent. The microapertured surface aberrations  120  can be formed by a hydroforming process in which a high-pressure liquid jet is utilized to force the web to conform to a three-dimensional support member. As shown, ruptures which coincide substantially with the maximum amplitude of each micropertured surface aberration  120  result in the formation of a volcano-shaped aperture  125  having relatively thin, irregularly shaped petals  126  about its periphery. The relatively thin, petal-shaped edges of the aperture of such a web provide for increased softness impression on the skin of a user when compared, for example, to the web of Ahr &#39;045. It is believed that this softness impression is due to the relative lack of resistance to compression and shear afforded by the surface aberrations having volcano-shaped apertures. 
     As mentioned above, although the microapertured film of Curro &#39;643 imparts a superior tactile impression of softness, it can also permit undesirable rewet when used as a topsheet on a disposable absorbent article. The web of the present invention solves this problem by providing for softness via surface aberrations that exhibit low resistance to compression and shear, comparable to the web of Curro &#39;643, and yet do not permit fluid flow via microapertures. Therefore, one benefit of the web of the present invention is superior softness together with minimal rewet when used as a topsheet on a disposable absorbent article, such as a sanitary napkin. 
       FIG. 3  is an enlarged, partially segmented perspective illustration of a fluid pervious, macroscopically-expanded, three-dimensional polymeric web  80  of the present invention. The geometric configuration of the macroscopic surface aberrations, e.g., primary apertures  71 , of the polymeric web can be generally similar to that of the prior art web  40  illustrated in  FIG. 1 . Primary apertures  71  may be referred to as “apertures” or “macroapertures” herein, and refer to openings in the web that permit fluid communication between a first surface  90  of web  80  and a second surface  85  of web  80 . The primary apertures  71  of the web shown in  FIG. 3  are defined in the plane  102  of first surface  90  by a continuous network of interconnecting members, e.g., members  91 ,  92 ,  93 ,  94 , and  95  interconnected to one another. The shape of primary apertures  71  as projected in the plane of the first surface  90  may be in the shape of polygons, e.g., squares, hexagons, etc., in an ordered or random pattern. In a preferred embodiment primary apertures  71  are in the shape of modified ovals, and in one embodiment primary apertures  71  are in the general shape of a tear drop. Polymer web  80  exhibits a plurality of surface aberrations  220  in the form of hair-like fibrils  225 , described more fully below. 
     In a three-dimensional, microapertured polymeric web  80  of the present invention, each interconnecting member comprises a base portion, e.g., base portion  81 , located generally in plane  102 , and each base portion has sidewall portions, e.g., sidewall portions  83  extending from each longitudinal edge thereof. Sidewall portions  83  extend generally in the direction of the second surface  85  of the web  80  and join to sidewalls of adjoining interconnecting members intermediate the first and second surfaces,  90  and  85 , respectively, and terminate substantially concurrently with one another to define secondary apertures, e.g., secondary apertures  72  in the plane  106  of second surface  85 . 
       FIG. 6  is a plan view of representative primary aperture shapes projected in the plane of the first surface of an alternative embodiment of a three-dimensional, macroapertured polymer web of the present invention. While a repeating pattern of uniform shapes, for example a tessellating pattern, is preferred, the shape of primary apertures, e.g., apertures  71 , may be generally circular, polygonal, or mixed, and may be arrayed in an ordered pattern or in a random pattern. 
     As shown in  FIG. 6  the interconnecting members, e.g., interconnecting members  97  and  98 , are each inherently continuous, with contiguous interconnecting elements blending into one another in mutually adjoining transition zones or portions, e.g., portions  87 . In general transition portions are defined by the largest circle that can be inscribed tangent to any three adjacent apertures. It is understood that for certain patterns of apertures the inscribed circle of the transition portions may be tangent to more than three adjacent apertures. For illustrative purposes, interconnecting members may be thought of as beginning or ending substantially at the centers of the transition portions, such as interconnecting members  97  and  98 . Interconnecting members need not be linear, but may be curvilinear. The sidewalls of the interconnecting members can be described as interconnecting to the sidewalls of adjacent, contiguous interconnecting members. Exclusive of portions of the transition zones and portions including hair-like fibrils, as disclosed below, cross-sections of interconnecting members transverse to the longitudinal centerline between the beginning and end of the interconnecting member may be generally described as U-shape. However, the transverse cross-section need not be uniform or U-shaped along the entire length of the interconnecting member, and for certain primary aperture configurations it may not be uniform along most of its length. In particular, in transition zones or portions interconnecting members blend into contiguous interconnecting members and transverse cross-sections in the transition zones or portions may exhibit substantially non-uniform U-shapes, or no discernible U-shape. 
       FIG. 4  is a further enlarged, partial view of the three-dimensional polymeric web  80  shown in  FIG. 3 . The three-dimensional polymeric web  80  comprises a polymer film  120 , i.e., the precursor film, which can be a single layer of extruded polymer or a multilayer coextruded or laminate film. As shown in  FIG. 4 , film  120  is a two layer laminate comprising a first layer  101  and a second layer  103 . Laminate materials may be coextruded, as is known in the art for making laminate films, including films comprising skin layers. While it is presently preferred that, as shown in  FIG. 4 , the polymeric layers, e.g., layers  101  and  103 , terminate substantially concurrently in the plane of the second surface  106  it is not presently believed to be essential that they do so. One or more layers may extend further toward the second surface than the other(s). 
       FIG. 4  shows a plurality of surface aberrations  220  in the form of hair-like fibrils  225 . The hair-like fibrils are formed as protruded extensions of the polymeric web  80 , generally on the first surface  90  thereof. The number, size, and distribution of hair-like fibrils  225  on polymeric web  80  can be predetermined based on desired skin feel. For applications as a topsheet in disposable absorbent articles, it is preferred that hair-like fibrils  225  protrude only from the base portion  81  in first surface  90  of polymeric web  80 , as shown in  FIGS. 3 and 4 . Therefore, when web  80  is used as a topsheet in a disposable absorbent article, the web can be oriented such that the hair-like fibrils  225  are skin contacting for superior softness impression, and yet, the hair-like fibrils  225  do not obstruct fluid flow through macroapertures  71 . Moreover, having hair-like fibrils  225  with closed distal portions  226  results in reduced rewet, i.e., reduced amounts of fluid being re-introduced to the surface of the topsheet after having been first passed through the topsheet to underlying absorbent layers. 
     As shown in cross-section  FIG. 5 , hair-like fibrils  225  can be described as protruding from first surface  90  of web  80 . As such, hair-like fibrils  225  can be described as being integral with film  120 , and formed by permanent local plastic deformation of film  120 . Hair-like fibrils can be described as having a side wall  227  defining an open proximal portion  229  and a closed distal portion  226 . Hair-like fibrils  225  have a height h measured from a minimum amplitude A min  between adjacent fibrils to a maximum amplitude A max  at the closed distal portion  226 . Hair-like fibrils have a diameter d, which for a generally cylindrical structure is the outside diameter at a lateral cross-section. By “lateral” is meant generally parallel to the plane of the first surface  102 . For non-uniform lateral cross-sections, and/or non-cylindrical structures of hair-like fibrils, diameter d is measured as the average lateral cross-sectional dimension at ½ the height h of the fibril, as shown in  FIG. 5 . Thus, for each hair-like fibril  225 , an aspect ratio, defined as h/d, can be determined. Hair-like fibrils  225  can have an aspect ratio h/d of at least 0.5. The aspect ratio can be 1, or 1.5 and is preferably at least about 2. 
     In general, because the actual height h of any individual hair-like fibril  225  can be difficult to determine, and because the actual height may vary, an average height h avg  of a plurality of hair-like fibrils can be determined by determining an average minimum amplitude A min  and an average maximum amplitude A max  over a predetermined area of web  80 . Likewise, for varying cross-sectional dimensions, an average dimension d avg  can be determined for a plurality of hair-like fibrils  225 . Such amplitude and other dimensional measurements can be made by any method known in the art, such as by computer aided scanning microscopy and data processing. Therefore, an average aspect ratio AR avg  of the hair-like fibrils  225  for a predetermined portion of the web can be expressed as h avg /d avg . 
     The dimensions h and d for hair-like fibrils  225  can be indirectly determined based on the known dimensions of a forming structure, as disclosed more fully below. For example, for a forming structure made according to predetermined dimensions of male protrusions, e.g., protrusions  2250  shown in  FIG. 11  below, on which hair-like fibrils  225  are to be formed can have known dimensions. If precursor film  120  is fully and permanently deformed over protrusions  2250 , then h and d can be calculated from these known dimensions, taking into account the thickness of the precursor film  120 , including predicted and/or observed web thinning. If the precursor film  120  is not fully formed over protrusions  2250 , then the height h of hair-like pillars will be less than the corresponding height of the protrusions  2250 . 
     In one embodiment the diameter of hair-like fibrils  225  is constant or decreases with increasing amplitude (amplitude increases to a maximum at closed distal end  226 ). As shown in  FIG. 5 , for example, the diameter, or average lateral cross-sectional dimension, of hair-like fibrils  225  can be a maximum at proximal portion  229  and the lateral cross-sectional dimension steadily decreases to distal end  226 . This structure is believed to be necessary to ensure the polymeric web  80  can be readily removed from the forming structure  350 , as more fully described below with respect to  FIG. 10 . 
     As shown in  FIG. 5 , some thinning of precursor web  120  can occur due to the relatively deep drawing required to form high aspect ratio hair-like fibrils  225 . For example, thinning can be observed at or near closed distal ends  226 . By “observed” is meant that the thinning is distinct when viewed in magnified cross-section. Such thinning can be beneficial as the thinned portions offer little resistance to compression or shear when touched by a person&#39;s skin. For example, when a person touches the polymeric web  80  on the side exhibiting hair-like fibrils  225 , the finger tips first contact closed distal ends  226  of hair-like fibrils  225 . Due to the high aspect ratio of hair-like fibrils  225 , and, it is believed, to the wall thinning of the film at or near the distal ends  226 , the hair-like fibrils offer little resistance to the compression or shear imposed on the web by the person&#39;s fingers. This lack of resistance is registered as a feeling of softness, much like the feeling of a velour fabric. In fact, it has been found that polymeric webs of the present invention can provide for a feeling of softness equal to or greater than that of prior art polymeric webs, such as the web disclosed in Curro &#39;643. 
     It should be noted that a fluid impermeable web having only the hair-like fibrils as disclosed herein, and not having macroscopic apertures, can offer softness for any application in which fluid permeability is not required. Thus, in one embodiment of the present invention, the invention can be described as a polymeric web  80  exhibiting a soft and silky tactile impression on at least one surface thereof, the silky feeling surface of the web  80  exhibiting a pattern of discrete hair-like fibrils  225 , each of the hair-like fibrils  225  being a protruded extension of the web surface and having a side wall  227  defining an open proximal portion  229  and a closed distal portion  226 , the hair-like fibrils maximum lateral cross-sectional dimension at or near said open proximal portion, exhibiting a cross-sectional diameter d of between about 50 microns (about 0.002 inch) to about 76 microns (about 0.003 inch), and can be at least 100 microns (0.004 inches) 130 microns (0.005 inches). The hair-like fibrils can have an aspect ratio from 0.5 to 3. 
     For disposable absorbent articles, where a topsheet having a fluid permeable, three-dimensional structure is desired, the invention can be described as a polymeric web  80  exhibiting a soft and silky tactile impression on at least one surface  90  thereof, the silky feeling surface  90  of the web exhibiting a pattern of discrete hair-like fibrils  225 , each of the hair-like fibrils  225  being a protruded extension of the web surface  90  and having a side wall  227  defining an open proximal portion  229  and a closed distal portion  226 , the hair-like fibrils exhibiting an average cross-sectional diameter d of between 50 microns (0.002 inches) 130 microns (0.005 inches), and an aspect ratio from at least 0.5, 1, 1.5, 2, or 3 and wherein the web  80  further exhibits a macroscopically expanded, three-dimensional pattern of macroscopic surface aberrations, e.g., primary apertures  71  superposed thereon, the macroscopic surface aberrations  71  being oppositely oriented from the hair-like fibrils  225 , that is, the primary apertures extend from a first surface  90  to a second surface  85  of polymeric web  80 . 
     The “area density” of the hair-like fibrils  225 , which is the number of hair-like fibrils  225  per unit area of first surface  90 , can be optimized for use in absorbent articles. In general, the center-to-center spacing can be optimized for adequate tactile impression, while at the same time minimizing fiber-to-fiber entrapment of fluid. Currently, it is believed that a center-to-center spacing of about 100 microns to 250 microns (about 0.004 inch to about 0.010 inch) is optimal for use in sanitary napkins. Minimizing entrapment of menses between fibers improves the surface cleanliness of the sanitary napkin, which, in turn improves the cleanliness and skin health of the wearer. 
     In one embodiment, “superposed thereon” means that the polymeric web appears generally as shown in  FIG. 3 , wherein the pattern of discrete hair-like fibrils  225  is disposed on the land areas  81  of the interconnecting members only, i.e., only on the first surface  90  of web  80 . However, conceptually, it is contemplated that “superposed thereon” could also cover an embodiment (not shown) in which the pattern of discrete hair-like fibrils  225  extends into macroapertures  71 , for example on side walls  83  of the interconnecting members. In other embodiments, hair-like fibrils  225  are disposed only in certain predetermined regions of web  80 . For example, a topsheet for a sanitary napkin can have a central region having hair-like fibrils  225 , and the remainder of the topsheet being free from hair-like fibrils  225 . 
     Precursor web  120  can be any polymeric film having sufficient material properties to be formed into the web of the present invention by the hydroforming process described herein. That is, precursor web  120  must have sufficient yield properties such that the precursor web  120  can be strained without rupture to an extent to produce hair-like fibrils  225  and, in the case of a three-dimensional, macroscopically-apertured, formed film, rupture to form macroapertures  71 . As disclosed more fully below, process conditions such as temperature can be varied for a given polymer to permit it to stretch with or without rupture to form the web of the present invention. In general, therefore, it has been found that preferred starting materials to be used as the precursor web  120  for producing the web  80  of the present invention exhibit a low yield and high-elongation characteristics. In addition, the starting films preferably strain harden. Examples of films suitable for use as the precursor web  120  in the present invention include films of low density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and blends of linear low-density polyethylene and low density polyethylene (LDPE/LLDPE). 
     Precursor web  120  must also be sufficiently deformable and have sufficient ductility for use as a polymeric web of the present invention. The term “deformable” as used herein describes a material which, when stretched beyond its elastic limit, will substantially retain its newly formed conformation. 
     One material found suitable for use as a precursor web  120  of the present invention is DOWLEX 2045A polyethylene resin, available from The Dow Chemical Company, Midland, Mich., USA. A film of this material having a thickness of 20 microns can have a tensile yield of at least 12 MPa; an ultimate tensile of at least 53 MPa; an ultimate elongation of at least 635%; and a tensile modulus (2% Secant) of at least 210 MPa (each of the above measures determined according to ASTM D 882). 
     Precursor web  120  can be a laminate of two or more webs, and can be a co-extruded laminate. For example, precursor web  120  can comprise two layers as shown in  FIG. 4 , and precursor web  120  can comprise three layers, wherein the inner most layer is referred to as a core layer, and the two outermost layers are referred to as skin layers. In one embodiment precursor web  120  comprises a three layer coextruded laminate having an overall thickness of about 25 microns (0.001 in.), with the core layer having a thickness of about 18 microns (0.0007 in.); and each skin layer having a thickness of about 3.5 microns (0.00015 in.). In general, for use as a topsheet in sanitary napkins, precursor web  120  should have an overall thickness (sometimes referred to as caliper) of at least about 10 microns and less than about 100 microns. The thickness of precursor web  120  can be about 15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, or 60 microns. In general, the ability to form high area density (or low average center-to-center spacing C) hair-like fibrils  225  on web  80  is limited by the thickness of precursor web  120 . For example, it is believed that the center-to-center spacing C of two adjacent hair-like fibrils  225  should be greater than twice the thickness of precursor web  120  to permit adequate and complete three-dimensional web formation between adjacent protrusions  2250  of forming structure  350  as disclosed more fully below. 
     The precursor web  120  preferably comprises a surfactant. In a three layer laminate, the core layer can comprise a surfactant while the outer layers are initially devoid of surfactants. Preferred surfactants include those from non-ionic families such as: alcohol ethoxylates, alkylphenol ethoxylates, carboxylic acid esters, glycerol esters, polyoxyethylene esters of fatty acids, polyoxyethylene esters of aliphatic carboxylic acids related to abietic acid, anhydrosorbitol esters, etyhoxylated anhydrosorbitol esters, ethoxylated natural fats, oils, and waxes, glycol esters of fatty acids, carboxylic amides, diethanolamine condensates, and polyalkyleneoxide block copolymers. Molecular weights of surfactants selected for the present invention may range from about 200 grams per mole to about 10,000 grams per mole. Preferred surfactants have a molecular weight from about 300 to about 1,000 grams per mole. 
     The surfactant level initially blended into precursor web  120  (or optionally the core layer in a three layer laminate) can be as much as 10 percent by weight of the total multilayer structure. Surfactants in the preferred molecular weight range (300-1,000 grams/mole) can be added at lower levels, generally at or below about 5 weight percent of the total multilayer structure. 
     The precursor web  120  can also comprise titanium dioxide in the polymer blend. Titanium dioxide can provide for greater opacity of the finished web  80 . Titanium dioxide can be added at up to about 10 percent by weight to low density polyethylene for blending into the precursor web  120  material. 
     Other additives, such as particulate material, e.g., calcium carbonate (CaCO 3 ), particulate skin treatments or protectants, or odor-absorbing actives, e.g., zeolites, can be added in one or more layers of precursor web  120 . In some embodiments, webs  80  comprising particulate matter, when used in skin-contacting applications, can permit actives to contact the skin in a very direct and efficient manner. Specifically, in some embodiments, formation of hair-like fibrils  225  can expose particulate matter at or near the distal ends thereof. Therefore, actives such as skin care agents can be localized at or near distal ends  226  to permit direct skin contact with such skin care agents when the web  80  is used in skin contacting applications. 
     The precursor web  120  can be processed using conventional procedures for producing multilayer films on conventional coextruded film-making equipment. Where layers comprising blends are required, pellets of the above described components can be first dry blended and then melt mixed in the extruder feeding that layer. Alternatively, if insufficient mixing occurs in the extruder, the pellets can be first dry blended and then melt mixed in a pre-compounding extruder followed by repelletization prior to film extrusion. Suitable methods for making precursor web  120  are disclosed in U.S. Pat. No. 5,520,875, issued to Wnuk et al. on May 28, 1996 and U.S. Pat. No. 6,228,462, issued to Lee et al. on May 8, 2001; both patents the disclosure of which is incorporated herein by reference. 
     A fluid pervious polymeric web of the present invention can be utilized as a topsheet on a catamenial device, such as a sanitary napkin. For example, a polymeric web  80  of the present invention exhibiting a macroscopically expanded, three-dimensional pattern of macroscopic surface aberrations in the form of primary apertures  71  combines softness properties with excellent fluid rewet properties (i.e., reduced fluid rewet compared to previous webs, such as the web of Curro &#39;643). 
       FIG. 7  is a top plan view of a sanitary napkin  20  with portions cut away to more clearly show the construction of the napkin  20 , including topsheet  22 , which can comprise a polymeric web  80  of the present invention. It should be understood that the polymeric web  80  of the present invention can also be utilized in other absorbent articles such as pantyliners, interlabial devices, diapers, training pants, incontinent devices, wound dressings and the like. It also should be understood, that the present invention is not limited to the particular type or configuration of the sanitary napkin  20  shown in  FIG. 7 , which is simply a representative non-limiting example. 
     As shown in  FIG. 8 , the sanitary napkin  20  has two surfaces, a body-facing surface  20   a  and an opposed garment-facing surface  20   b . The body-facing surface  20   a  is intended to be worn adjacent to the body of the wearer. The garment-facing surface  20   b  is intended to be placed adjacent to the wearer&#39;s undergarments when the sanitary napkin  20  is worn. 
     The sanitary napkin  20  has two centerlines, a longitudinal centerline “l” and a transverse centerline “t”. The term “longitudinal”, as used herein, refers to a line, axis or direction in the plane of the sanitary napkin  20  that is generally aligned with (e.g., approximately parallel to) a vertical plane which bisects a standing wearer into left and right body halves when the sanitary napkin  20  is worn. The terms “transverse” or “lateral” as used herein, are interchangeable, and refer to a line, axis or direction which lies within the plane of the sanitary napkin  20  that is generally perpendicular to the longitudinal direction. 
     As shown in  FIG. 7 , the sanitary napkin  20  comprises a liquid pervious topsheet  22 , which can comprise web  80  of the present invention, a liquid impervious backsheet  23  joined with the liquid pervious topsheet  22 , and an absorbent core  24  positioned between the liquid pervious topsheet  22  and the liquid impervious backsheet  23 .  FIG. 7  also shows that the sanitary napkin  20  has a periphery  30  which is defined by the outer edges of the sanitary napkin  20  in which the longitudinal edges (or “side edges”) are designated  31  and the end edges (or “ends”) are designated  32 . 
     Sanitary napkin  20  preferably includes optional sideflaps or “wings”  34  that can be folded around the crotch portion of the wearer&#39;s panties. The side flaps  34  can serve a number of purposes, including, but not limited to protecting the wearer&#39;s panties from soiling and keeping the sanitary napkin secured to the wearer&#39;s panties. 
       FIG. 8  is a cross-sectional view of the sanitary napkin taken along section line  8 - 8  of  FIG. 7 . As can be seen in  FIG. 8 , the sanitary napkin  20  preferably includes adhesive fastening means  36  for attaching the sanitary napkin  20  to the undergarment of the wearer. Removable release liners  37  cover the adhesive fastening means  36  to keep the adhesive from sticking to a surface other than the crotch portion of the undergarment prior to use. In addition to having a longitudinal direction and a transverse direction, the sanitary napkin  20  also has a “z” direction or axis, which is the direction proceeding down through the liquid pervious topsheet  22  and into whatever fluid storage core  24  that may be provided. A continuous path between the liquid pervious topsheet  22  and underlying layer or layers of the articles herein permits fluid to be drawn in the “z” direction and away from the topsheet of the article into its ultimate storage layer. In some embodiments, the continuous path will have a gradient of increasing capillary attraction, which facilitates fluid flow down into the storage medium. 
     In  FIG. 9  there is shown single-phase web process for debossing and drying (if necessary) a continuous polymeric web  80  of the present invention. By single-phase is meant that the process uses only one three-dimensional forming structure. By continuous is meant to distinguish the described process from a batch process in which individual, discrete samples of web are made, often referred to as hand sheets. While it is recognized that webs of the present invention can be batch-processed using the structures described for the continuous process, a continuous process is the preferred method for commercially making a polymeric web of the present invention. Further, while the process described with respect to  FIG. 9  is primarily designed to form macroscopically-expanded webs having hair-like fibrils  225  and primary apertures, e.g., apertures  71  of web  80 , it is believed that a hydroforming process can be utilized to form a web having only hair-like fibrils by suitably modifying the forming structure to have only protrusions  2250 . 
     Polymeric web  80  of the present invention can be formed by a hydroforming process on a single three-dimensional forming structure  350  and can also be annealed and/or dried on the forming structure  350  prior to rewinding the web into roll stock for further processing. The three-dimensional structures of a polymeric web, e.g., polymeric web  80  shown in  FIG. 4 , are formed by forcing the web to conform to the forming structure  350 , which rotates about stationary forming drum  518 . Forming structure  350  is described more fully below, but, in general, it is a three-dimensional form to which the precursor web  120  is forced to conform. 
     Precursor web  120  can be extruded and chilled immediately prior to being fed directly onto the surface of forming structure  350 , or it can be fed from a supply roll, as shown by supply roll  501  in  FIG. 9 . In some embodiments it is preferred that the temperature of the precursor web  120  be elevated sufficiently to soften it and make it more conformable to the forming structure  350 . The temperature of precursor web  120  can be elevated by applying hot air or steam to the web or by passing the web through heated nip rolls, prior to subjecting it to the forming process. 
     In the process described in  FIG. 9 , precursor web  120  is fed in a substantially planar condition in the machine direction (MD) from a supply roll  501  onto the surface of forming structure  350 . Forming structure  350  rotates at a speed such that the tangential surface velocity of the forming structure  350  substantially matches that of the linear velocity of precursor web  120  in the machine direction, so that during the hydroforming process the web is substantially stationary relative to forming structure  350 . 
     Once precursor web  120  is adjacent to and being “carried on”, so to speak, the forming structure  350 , precursor web  120  is directed over stationary vacuum chamber  520  which is interior to forming drum  518 . Although the hydroforming process described herein can be accomplished to some degree without vacuum chambers, in general, vacuum chambers aid in better three-dimensional web formation as well as liquid removal. As precursor web  120  passes over vacuum chamber  520 , the outwardly-exposed surface of precursor web  120  is impinged upon by a liquid jet  540  discharged from high pressure liquid jet nozzle  535  between a pair of stationary liquid baffles  525  and  530  which served to help localize splashing liquid. The effect of the liquid jet  540  is to cause the precursor web to conform to forming structure  350 . As precursor web conforms to forming structure  350 , both the hair-like fibrils  225  and the primary apertures  71  can be formed. As primary apertures  71  form, vacuum from vacuum chamber  520  aids in removing excess liquid from the web, and, in some cases aids in forming precursor web  120  to forming structure  350 . As precursor web  120  is passed under the influence of high pressure liquid jet  540 , it is permanently deformed to conform to the forming structure  350 , thereby being formed into three-dimensional, macroscopically-expanded polymeric web  80  of the present invention. 
     In the process described with reference to  FIG. 9 , a single liquid jet  540  is described as forming both the hair-like fibrils  225  and the primary apertures  71 . In another embodiment, additional liquid (or fluid) jets can be used to form the three-dimensional web structures in multiple stages. For example, a first fluid, such as water, can impinge precursor web  120  to form macroapertures  71  in a first stage, and following the first stage, a second fluid, such as hot water or air (optionally in combination with a vacuum chamber) can impinge the partially-formed web to further form the hair-like fibrils  225  in a second stage. 
     In the process described in  FIG. 9 , liquid jets  540  and/or drying means  590  can be replaced by re-heat means. Re-heat means refers to means for directing streams of heated gases, such as air, such that the heated air, alone or in combination with vacuum from vacuum chambers  520  or  555 , is sufficient to cause precursor web  120  to conform to forming structure  350 . Re-heat means are known in the art, for example as disclosed in U.S. Pat. No. 4,806,303 issued to Bianco et al. In general, a re-heat means comprises an air blower and a heater as well as a nozzle to direct forced, heated air onto the surface of a web. In one embodiment the air exiting the nozzle can be between 220 and 305 degrees centigrade and the precursor web  120  can be moved under or across the heated air stream at about 25 meters per minute. In one embodiment vacuum can be maintained at about 365 mm Hg. In embodiments where re-heat means replaces liquid jets  540 , drying means  590  are not necessary, but can be utilized if desired, for example as annealing means or further forming means. 
     Without being bound by theory, it is believed that by adjusting the precursor web properties, the vacuum dwell time, i.e., the time precursor web is adjacent vacuum chambers  520  and/or  555 , and/or the level of vacuum, i.e., partial pressure, it is possible to form web  80  on the apparatus shown in  FIG. 9  in a cast process without using any liquid jets  540 . That is, by suitably adjusting the precursor web properties, e.g., thickness, material, temperature, vacuum alone is sufficient to form a web  80  that conforms to forming structure  350 . In a cast process precursor web  120  is extruded directly onto the surface of forming structure  350  such that web  80  formation can occur prior to cooling of precursor web  120 . 
     In general, therefore, one fluid (e.g., water or air) or more than one fluid (e.g., water, air) can be directed to impinge on, and do energetic work on, precursor web  120  in one or more stages. It is believed that, for thermoplastic precursor webs  120 , as the temperature of the precursor web approaches its melting point, it more easily stretches without rupture to form over protrusions  2250  of forming structure  350 . However, for forming macroapertures it is more desirable to have relatively high strain rates and relatively rapid rupture, and for forming hair-like fibrils it is more desirable to have relatively low strain rates and no rupture. Accordingly, in a two-stage forming process, the temperature of the impinging fluid at first and/or second stages can be adjusted independently, depending on the dwell time over which each impingement acts and the temperature of the precursor web  120  to form both macroapertures  71  and high aspect ratio hair-like fibrils  225  independently. 
     For making webs suitable for use as a topsheet in a disposable absorbent article, precursor web  120  can be a polyolefinic film from about 10 microns to about 100 microns in total thickness. For such precursor webs  120 , high pressure liquid jet  540  is typically water at a temperature from about 15-95 degrees C., operated at a pressure in the range of about 200 psig to about 1200 psig and a water flow rate in the range of about 18 liters (4 gallons) per minute to about 62 liters (14 gallons) per minute per 25.4 cross-machine direction (CD) mm (1 inch) of width of the precursor web  120 . 
     After passing beyond the high pressure liquid jet  540 , (or jets, as discussed above), polymeric web  80  of the present invention can be dried while still on forming structure  350 . For example, as shown in  FIG. 9 , polymeric web  80  can be directed, while still on forming structure  350 , under the influence of drying means  590 . Drying means  590  can be any of means for removing, or driving off liquids from polymeric webs, such as radiant heat drying, convective drying, ultrasonic drying, high velocity air knife drying, and the like. In general, a drying medium  600  can be utilized, such as heated air, ultrasonic waves, and the like. A stationary vacuum chamber  555  can be utilized to aid in drying by means of a partial pressure inside forming drum  518 . Drying means  590  can be designed to drive liquid off of polymeric web  80  and into vacuum chamber  555 . Baffles  570  and  580  can be utilized to locally contain any liquid that gets removed and does not enter vacuum chamber  555 . Baffles  570  and  580  can also serve to localize and direct heat or heated air used for drying. 
     Using a heated drying medium  600  has an additional benefit for making webs  80  of the present invention. Prior art macroscopically-expanded, three-dimensional polymeric webs, such as the webs disclosed in the aforementioned Curro &#39;643, are dried in a separate process after being removed form their respective forming structures. These webs are typically wound onto a roll for storage until needed for web processing of disposable articles, for example. One problem associated with prior art webs is the compression setting that occurs during winding and storage. Without being bound by theory, it is believed that three-dimensional polyethylene webs can experience a secondary crystallization over time which “locks in” the collapsed, wound state of the web. It has been found that by first annealing three-dimensional polymeric webs by subjecting them to elevated temperatures for a sufficient time, this observed compression set is reduced or prevented altogether. In general, however, it is difficult to subject prior art webs to the requisite temperatures due to the relatively fragile structure. That is, if a prior art web is subjected to annealing temperatures, the web tends to lose the three-dimensional structure formed on the forming structure. For this reason, therefore, drying the web while still on the forming structure provides a significant processing benefit by permitting processing with sufficiently high annealing temperatures to anneal the web, while at the same time drying it. The annealing temperature will vary depending on the time of drying, the polymer used and the thickness of the web, but, in general, for polyolefinic webs, a drying/annealing temperature of between about 50-250 degrees C. is sufficient. 
     After polymeric web  80  passes the drying (or drying/annealing) stage of the process it can be removed from the forming structure  350  about roller  610  and is thereafter rewound or fed directly to subsequent converting operations. 
     A forming structure of the present invention, such as forming structure  350  referred to with respect to  FIG. 9 , is necessary for making a web of the present invention. The forming structure is sometimes referred to as a forming screen.  FIG. 10  shows a portion of a forming structure of the present invention  350  in partial perspective view. The forming structure  350  exhibits a plurality of forming structure apertures  710  defined by forming structure interconnecting members  910 . Forming structure apertures  710  permit fluid communication between opposing surfaces, that is, between forming structure first surface  900  in the plane of the first surface  1020  and forming structure second surface  850  in the plane of the second surface  1060 . Forming structure sidewall portions  830  extend generally between the forming structure first surface  900  and forming structure second surface  850 . Protrusions  2200  extend from forming structure first surface  900  to form generally columnar, pillar-like forms. 
     A comparison of  FIG. 10  with  FIG. 3  shows the general correspondence of forming structure  350  with polymeric web  80  of the present invention. That is, the three-dimensional protrusions  2250  and depressions (e.g., apertures  710 ) of forming structure  350  have a one-to-one correspondence to the hair-like fibrils  225  and primary apertures  71 , respectively, of polymeric web  80 . The one-to-one correspondence is necessary to the extent that the forming structure  350  determines the overall dimensions of the polymeric web  80  of the present invention. However, the distance between plane of the first surface  102  and plane of the second surface  106  of the polymeric web  80  need not be the same as the distance between the plane of the first surface  1020  and the plane of the second surface  1060  of forming structure  350 . This is because the distance “T” for polymeric web  80 , as shown in  FIG. 5 , is not dependent upon the actual thickness of forming structure  350 , the thickness being the perpendicular distance between the plane of the first surface  1020  and the plane of the second surface  1060  of forming structure  350 . 
       FIG. 11  is a further enlarged, partial perspective view of the forming structure  350  shown in  FIG. 10 , and compares with the similar view of polymeric web  80  in  FIG. 4 . Protrusions  2250  can be made by methods described below to extend from first surface  900  to a distal end  2260 . As shown in the further enlarged view of  FIG. 12 , protrusions  2250  can have a height hp measured from a minimum amplitude measured from first surface  900  between adjacent protrusions to distal end  2260 . Protrusion height hp can be at least about 50 microns (about 0.002 inch) and can be at least about 76 microns (about 0.003 inch), and can be at least about 152 microns (about 0.006 inch), and can be at least about 250 microns (about 0.010 inch), and can be at least about 381 microns (about 0.015 inch). Protrusions  2250  have a diameter dp, which for a generally cylindrical structure is the outside diameter. For non-uniform cross-sections, and/or non-cylindrical structures of protrusions  2250 , diameter dp is measured as the average cross-sectional dimension of protrusions at ½ the height hp of the protrusions  2250 , as shown in  FIG. 12 . Protrusion diameter dp can be about 50 microns (about 0.002 inch), and can be at least about 66 microns, and can be about 76 microns (about 0.003 inch), and can be at least about 127 microns (about 0.005 inch). Thus, for each protrusion  2250 , a protrusion aspect ratio, defined as hp/dp, can be determined. Protrusions  2250  can have an aspect ratio hp/dp of at least 1, and as high as 3 or more. The aspect ratio can be at least about 5 and can be about 6. In one embodiment, protrusions had a substantially uniform diameter of about 66 microns over a height of about 105 microns, for an aspect ratio of about 1.6. The protrusions  2250  can have a center-to-center spacing Cp between two adjacent protrusions  2250  of between about 100 microns (about 0.004 inch) to about 250 microns (about 0.010 inch). In one embodiment the center-to-center spacing was 179 microns. In general, it is believed that the actual distance between two adjacent protrusions  2250  (i.e., a “side-to-side” dimension) should be greater than twice the thickness t of precursor web  120  to ensure adequate deformation of precursor web  120  between adjacent protrusions  2250 . 
     In general, because the actual height hp of each individual protrusion  2250  may vary, an average height hp avg  of a plurality of protrusions  2250  can be determined by determining a protrusion average minimum amplitude Ap min  and a protrusion average maximum amplitude Ap max  over a predetermined area of forming structure  350 . Likewise, for varying cross-sectional dimensions, an average protrusion diameter dp avg  can be determined for a plurality of protrusions  2250 . Such amplitude and other dimensional measurements can be made by any method known in the art, such as by computer aided scanning microscopy and related data processing. Therefore, an average aspect ratio of the protrusions  2250 , ARp avg  for a predetermined portion of the forming structure  350  can be expressed as hp avg /dp avg . The dimensions hp and dp for protrusions  2250  can be indirectly determined based on the known specifications for making forming structure  350 , as disclosed more fully below. 
     In one embodiment the diameter of protrusions  2250  is constant or decreases with increasing amplitude. As shown in  FIG. 12 , for example, the diameter, or largest lateral cross-sectional dimension, of protrusions  2250  is a maximum near first surface  900  and steadily decreases to distal end  2260 . This structure is believed to be necessary to ensure that the polymeric web  80  can be readily removed from the forming structure  350 . 
     Forming structure  350  can be made of any material that can be formed to have protrusions  2250  having the necessary dimensions to make a web of the present invention, is dimensionally stable over process temperature ranges experienced by forming structure  350 , has a tensile modulus of at least about 5 MPa, more preferably at least about 10 MPa, more preferably at least about 30 MPa more preferably at least about 100-200 MPa, and more preferably at least about 400 MPa, a yield strength of at least about 2 MPa, more preferably at least about 5 MPa more preferably at least about 10 MPa, more preferably at least about 15 MPa, and a strain at break of at least about 1%, preferably at least about 5%, more preferably at least about 10%. It has been found that relatively tall, high aspect ratio protrusions form better webs as the modulus of the material of the forming structure increases, as long as it has sufficient strain at break (i.e., not too brittle) so as not to break. For modulus and yield strength data, values can be determined by testing according to known methods, and can be tested at standard TAPPI conditions at a strain rate of 100%/minute. 
     Dimensional stability with respect to thermal expansion is necessary only for commercial processes as described with respect to  FIG. 9 , because for some process conditions the forming structure  350 /forming drum  518  interface can be compromised if the forming structure  350  expands or contracts more than the forming drum  518 . For batch processing of polymeric webs of the present invention dimensional stability is not a requirement. However, for all commercial processes it is necessary that the forming structure be made of a material suitable for the processing temperature ranges. Process temperature ranges are affected by process conditions including the temperature of the fluid jet, e.g., liquid jet  540 , and the temperature of forming structure  350 , which can be heated, for example. In general, for polyolefinic webs, including laminated, co-extruded films for use in webs for disposable absorbent articles (i.e., films having a thickness, t, of about 10-100 microns), a water temperature of between 15 degrees C. and 95 degrees C. can be used. The drying/annealing air temperature can be 250 degrees C. or less. In general, process temperatures can be varied throughout a wide range and still make the polymeric web  80  of the present invention. However, the temperature ranges can be varied to make polymeric web  80  at optimal rates depending on film thickness, film type, and line speed. 
     In a preferred embodiment, protrusions  2250  are made integrally with forming structure  350 . That is, the forming structure is made as an integrated structure, either by removing material or by building up material. For example, forming structure  350  having the required relatively small scale protrusions  2250  can be made by local selective removal of material, such as by chemical etching, mechanical etching, or by ablating by use of high-energy sources such as electrical-discharge machines (EDM) or lasers. 
     Acid etching of steel structures as disclosed in the aforementioned Ahr &#39;045 patent, is believed to be only capable of making protrusions having an aspect ratio of 1 or less. Without being bound by theory it is believed that acid etching steel in small, incremental steps may be result in the high aspect ratios preferred in a forming structure of the present invention, but it is expected that the resulting protrusion(s) would be severly undercut to have “mushroom” shaped profiles. It is not currently known by the inventors of the present invention how one might acid etch steel as taught in Ahr &#39;045 to form the generally cylindrical protrusions  2250  of the present invention having the requisite aspect ratio. Likewise, forming protrusions on steel by electroplating is believed to result in “mushroom” shaped protrusions. In both instances, i.e., acid etching and electroplating, the mushroom shape is expected due to the nature of the material removal/deposition. Material would not be removed/deposited only in a general aligned, e.g., vertical manner. Therefore, it is currently known to make metal forming structures  350  only by use of electrical-discharge machines (EDM) or lasers. 
     A portion of a prototype forming structure  350  made of steel and having protrusions  2250  made by a conventional EDM process is shown in  FIGS. 13 and 14 .  FIG. 13  is a photomicrograph of a forming structure  350  and  FIG. 14  is a further enlarged view the forming structure of  FIG. 13 . As shown in  FIG. 13 , a steel forming structure has been subjected to an EDM process to form integral protrusions  2250  having distal ends  2260 . The forming structure  350  shown in  FIGS. 13 and 14  has depressions  710  generally similarly shaped to those shown in  FIG. 3 . However, as can be seen in  FIGS. 13 and 14 , the structure is less than ideal for making topsheets for absorbent articles because of the geometrical constraints of both the forming structure  350  prior to the EDM process, and the EDM process itself. Specifically, as can be seen, first surface  900  of forming structure interconnecting members  910  is only one protrusion “wide”. Also, as can be seen in  FIG. 13 , due to the geometrical constraints of the process of EDM, gaps between protrusions  2250  can result. For example, gap  901  in  FIG. 13  resulted from the EDM wire being oriented slightly off parallel from the respective forming structure interconnecting members  910  shown. Therefore, for commercially successful production of webs suitable for topsheets in disposable absorbent articles, the forming structure shown in  FIG. 13  may not be acceptable. However, it is clear that suitably shaped protrusions  2250  having the required aspect ratios can be formed. The protrusions  2250  of the forming structure shown in  FIG. 13  have an average height hp avg  of about 275 microns (0.011 inch), and an average diameter of about dp avg  of about 100 microns (0.004 inch), defining an average aspect ratio of ARp avg  of about 2.7. (Note that the forming screen shown in  FIGS. 13 and 14  is a prototype, and has been processed by EDM on both sides. In practice, it is only necessary to form protrusions on one side.) 
     In another method of making forming structure  350 , a base material susceptible to laser modification is laser “etched” to selectively remove material to form protrusions  2250  and forming structure apertures  710 . By “susceptible to laser modification” means that the material can be selectively removed by laser light in a controlled manner, recognizing that the wavelength of light used in the laser process, as well as the power level, may need to be matched to the material (or vice-versa) for optimum results. Currently known materials susceptible to laser modification include thermoplastics such as polypropylene, acetal resins such as DELRIN® from DuPont, Wilmington Del., USA, thermosets such as crosslinked polyesters, or epoxies, or even metals such as aluminum or stainless steel. Optionally, thermoplastic and thermoset materials can be filled with particulate or fiber fillers to increase compatibility with lasers of certain wavelengths of light and/or to improve modulus or toughness to make more durable protrusions  2250 . For example, it has been found that certain polymers, such as PEEK, can be laser machined to higher resolution and at higher speeds by uniformly filling the polymer with sufficient amounts of hollow carbon nanotube fibers. 
     One method of making forming structure  350  includes the steps of: a) providing partially-cured slabs of curable resinous material; b) providing a support structure; c) providing a laser-etching means; d) laying up in a layered and partially-overlapping relationship the partially-cured slabs of curable resinous material; e) fully curing the partially-cured slabs of curable resinous material to form a unitary, cured forming structure having an outer-facing surface; and f) laser etching the outer-facing surface to form thereon a plurality of protrusions  2250 . 
     In one embodiment a forming structure can be laser machined in a continuous process. For example, a polymeric material such as DELRIN® can be provided in a cylindrical form as a base material having a central longitudinal axis, an outer surface, and an inner surface, the outer surface and inner surface defining a thickness of the base material. A moveable laser source can be directed generally orthogonal to the outer surface. The moveable laser source can be moveable in a direction parallel to the central longitudinal axis of the base material. The cylindrical base material can be rotated about the central longitudinal axis while the laser source machines, or etches, the outer surface of the base material to remove selected portions of the base material in a pattern that defines a plurality of protrusions. Each protrusion can be the generally columnar and pillar-like protrusions  2250 , as disclosed herein. By moving the laser source parallel to the longitudinal axis of the cylindrical base material as the cylindrical base material rotates, the relative movements, i.e., rotation and laser movement, can be synchronized such that upon each complete rotation of cylindrical base material a predetermined pattern of protrusions can be formed in a continuous process similar to “threads” of a screw. 
       FIG. 15  is a photomicrograph of laser-etched embodiment of a forming structure  350  of the present invention.  FIG. 16  is an enlarged view of another, but similar, forming structure  350  of the present invention. The forming structures  350  shown in  FIGS. 15 and 16  are made by first forming a polymer layer having formed therein depressions  710 , which as shown are generally “teardrop” shaped and would make generally teardrop shaped primary apertures  71  in web  80  of the present invention. The depressions  710  can be formed, for example, by laser etching the depressions first. The polymer layer having depressions  710  therein can also be formed by radiating a liquid photosensitive resin such as a UV-light-curable polymer, through an appropriate masking layer on an underlying support layer (not shown) such as a foraminous woven backing. Suitable polymer layers, support layers, masking layers and UV-curing processes are well known in the art of making paper-making belts and are disclosed in U.S. Pat. No. 5,334,289 issued to Trokhan et al., on Aug. 2, 1994; and U.S. Pat. No. 4,529,480 issued to Trokhan on Jul. 16, 1985; and U.S. Pat. No. 6,010,598 issued to Boutilier et al. on Jan. 4, 2000, each of these patents, being hereby incorporated herein by reference for the teaching of structures, resins and curing techniques. As disclosed in the Boutilier &#39;598 patent, for example, one suitable liquid photosensitive resin composition is comprised of four components: a prepolymer; monomers; photoinitiator and antioxidants. A preferred liquid photosensitive resin is Merigraph L-055 available from MacDermid Imaging Technology, Inc. of Wilmington, Del. 
     After the polymer layer is cured to have depressions  710  the polymer layer is laser etched to form protrusions  2250  having distal ends  2260 . Laser etching can be achieved by known laser techniques, selecting wavelength, power, and time parameters as necessary to produce the desired protrusion dimensions. In the forming structure of  FIG. 16 , protrusions have an average height hp of 250 microns and an average diameter dp of 85 microns (at ½ height hp) and an aspect ratio arp of about 2.9. 
     Therefore, as disclosed above, in one embodiment, depressions  710  can be made in one manner, and the protrusions in another, by a separate process. For example, depressions  710  can be preformed in a forming structure “blank” that is subsequently laser machined, i.e., etched, to have protrusions formed on the land areas between depressions  710 . In one embodiment, forming structure  350  formed as a cured polymer on a support layer can be used as is, with the support layer being a part of forming structure  350 . However, in another embodiment, the cured polymer can be removed from the support layer and used alone. In this case, it may be desirable to only partially cure the polymer, remove the support layer  903  and finish fully curing the polymer material. 
     A web  80  made on the forming structure shown in  FIG. 15  is shown in the photomicrographs of  FIGS. 17 and 18 .  FIG. 17  is a photomicrograph of a portion of web  80  showing hair-like fibrils  225  and aperture  71 .  FIG. 18  is a further enlarged view of web  80  showing in more detail hair-like fibrils  225  having closed distal ends  226 . The precursor web  120  for the web  80  shown in  FIGS. 17 and 18  was made from a 25 micron (0.001 inch) thick Dowlex 2045A precursor film  120 . 
       FIGS. 19 and 20  show greatly enlarged portions of webs  80  made in batch processes on the forming structure shown in  FIGS. 13 and 14  to more closely show details of hair-like fibrils  225 . The polymer webs  80  shown in  FIGS. 19 and 20  have primary apertures  71  (not shown) generally in a pentahexagon shape, each having a projected area in the first surface  90  of about 1.4 square millimeters. The spacing between primary apertures  71  is such that the open area primary apertures  71  as projected in the first surface  90  is up to 65% of total surface area. The web  80  exhibits about 4,650 hair-like fibrils  225  per square centimeter of first surface  90  area (about 30,000 hair-like fibrils  225  per square inch). This concentration of hair-like fibrils  225  is referred to as the “density” or “area density” of hair-like fibrils  225 , and represents the number of hair-like fibrils per unit area of first surface  90 , as opposed to total area of polymer web  80 . Thus, the regions of polymer web  80  corresponding to primary apertures  71  do not contribute to the area when calculating density. In general, the density is determined by the average center-to-center spacing of the protrusions  2250  on forming structure  350 , which is about 150 microns (0.006 inch) for the forming structure shown in  FIGS. 13 and 14 . 
     It is believed that a polymer web  80  of the present invention suitable for use as a topsheet on a disposable absorbent article (e.g., a sanitary napkin) should have a density of hair-like fibrils  225  of at least about 1550 per square centimeter (about 10,000 per square inch). The density of hair-like fibrils  225  can be about 2325 per square centimeter (about 15,000 per square inch), and can be about 3100 per square centimeter (about 20,000 per square inch) and can be about 3875 per square centimeter (about 25,000 per square inch). Since for some webs it may be difficult to determine exactly where first surface  90  begins and ends, density can be approximated by taking total area of a predetermined portion of polymer web  80  and subtracting out the area of primary apertures  71  as projected in the first surface  90  of that predetermined portion. The area of primary apertures  71  can be based on the projected area of the depressions  710  of forming structure  350 . By “projected area” is meant the area of a surface if it were projected onto a plane parallel to that surface, and can be imagined by analogy, for example, as an “ink stamp” of the surface. 
       FIG. 19  is a photomicrograph of a web  80  made from a 25 micron (0.001 inch) DOWLEX® 2045A precursor film  120 . As shown, the web  80  of  FIG. 19  comprises discrete hair-like fibrils  225 , each of the hair-like fibrils  225  being a protruded extension of first surface  90 . Each of the hair-like fibrils  225  has a side wall  227  defining an open portion  229  (as shown in  FIG. 5 ) and a closed distal portion  226 . The hair-like fibrils  225  shown have a height of about 211 microns, and a diameter at ½ their height of about 142 microns, resulting in an aspect ratio of about 1.5. 
     The web  80  of  FIG. 20  comprises discrete hair-like fibrils  225 , each of the hair-like fibrils  225  being a protruded extension of first surface  90 . Each of the hair-like fibrils  225  has a side wall  227  defining an open portion  229  (as shown in  FIG. 5 ) and a closed distal portion  226 . The hair-like fibrils  225  shown in  FIG. 20  have an aspect ratio AR of at least 1. 
     The difference between the webs  80  shown in  FIGS. 19 and 20  is that the precursor film  120  used to make the polymeric web  80  shown in  FIG. 20  was a coextruded four layer polyethylene film comprising calcium carbonate in one of the outermost layers. Specifically, the calcium carbonate was added into the polymer melt for the polymer that forms the first surface of web  80  after formation of hair-like fibrils  225 . The four layers comprised polyethylene in the follow order: (1) ExxonMobil NTX-137 at about 42 volume percent; (2) ExxonMobil Exact 4151 at about 16 volume percent; (3) ExxonMobil Exact 4049 at about 32 volume percent; and (4) a mixture of 57 weight percent Ampacet 10847 with calcium carbonate blended in as a master batch and 43 weight percent ExxonMobil LD 129, this mixture at a volume percent of about 10 percent. The precursor film  120  had a starting thickness of about 25 microns (0.001 inch). 
     One interesting and unexpected result of using a CaCO 3 /PE blend for a skin layer of precursor film  120  is the formation of regions of roughened outer surfaces  228  at or near the distal end  226  of hair-like fibrils  225  as can be seen on the web shown in  FIG. 20 . These regions of relatively greater surface roughness  228 , which have less surface smoothness than the surrounding surfaces, such as first surface  90 , provide for a more cloth-like appearance due to its inherent low gloss, and an even greater soft and silky tactile impression. Without being bound by theory, it is believed that the relatively roughened surface texture of the distal ends of hair-like fibrils  225  gives greater texture that is experienced as softness to the skin of a person touching the surface. Without being bound by theory, it is believed that the formation of roughened outer surfaces at or near the distal end  226  of hair-like fibrils  225  is a result of deep drawing precursor web having therein particulate matter. It appears that possibly the particulate matter, in this case CaCO 3 , causes stress concentrations in the film blend that give rise to surface discontinuities. At the points of maximum strain, i.e., at the point of maximum draw of hair-like fibrils  225 , the surface of the film (i.e., precursor film  120 ) breaks up, exposing particulate matter on the surface of the hair-like fibrils  225 . 
     Therefore, in one embodiment polymer web  80  can be described as having hair-like fibrils  225  in which at least a portion near the distal end  226  thereof exhibits regions of relatively greater surface roughness  228  than the remaining portions. By using different additive particulate matter, the regions of relatively greater surface roughness  228  can provide for other benefits. For example, particulate skin treatments or protectants or odor-absorbing actives can be used. Importantly, webs  80  comprising particulate matter permit actives to be delivered to the skin of a wearer of an article using web  80  in a very direct and efficient manner. 
     In general, it is believed that any non-diffusing ingredient (particulate and non-particulate) blended into the melt of a polymer of precursor web  120  can be exposed upon strain of the polymer near the distal end of hair-like fibrils  225 . Specifically, actives such as skin care agents can be localized substantially at or near distal ends  226  which can be the primary skin contact surfaces for web  80 . Other known methods of imparting localized strain to polymeric films can also serve to expose non-diffusing ingredients in layers. For example, embossing, ring rolling, thermovacuum forming, and other known processes can provide for localized rupture and exposure of active ingredients of polymer films. 
     Other methods of making forming structure  350  include building up the structure by way of localized electroplating, 3-D deposition processes, or photoresist techniques. One 3-D deposition process is a sintering process. Sintering is similar to stereo lithography in which layers of powdered metal are built up to produce a final work piece. However, it is believed that sintering processes may be limited in resolution. Photoresist techniques include forming a three dimensional structure by use of an appropriate mask over a liquid photosensitive resin, such as the UV-curable polymer disclosed above. UV curing is effective at curing only the portions of a liquid resin exposed to UV light from a UV light source. The remaining (uncured) portions of the liquid resin can then be washed off, leaving behind only the cured portions. The liquid resin UV-curable polymer can be placed on a tray, for example, to a desired depth or thickness and appropriately masked and UV light-cured to selectively cure the portions to be protrusions  2250  and to not cure the portions that will be the apertures  710 . 
     In another embodiment, a flexible polymeric forming structure  350  as shown in  FIGS. 21 and 22  can be formed from the polymerization of a UV-curable polymer on an air-permeable backing screen  430 . First surface  900  defines apertures  710  which, in the illustrated embodiment are hexagons in a bilaterally staggered array. It is to be understood that, as before, a variety of shapes and orientations of apertures  710  can be used.  FIG. 22  illustrates a cross sectional view of that portion of forming structure  350  shown in  FIG. 28  as taken along line  22 - 22 . Machine direction reinforcing strands  420  and cross direction reinforcing strands  410  are shown in both  FIGS. 21 and 22 . Together machine direction reinforcing strands  420  and cross direction reinforcing strands  410  combine to form a foraminous woven element  430 . One purpose of the reinforcing strands is to strengthen the flexible polymeric forming structure  350 . As shown, reinforcing strands  410  and  420  can be round and can be provided as a square weave fabric around which the UV-curable resin has cured. Any convenient filament size in any convenient weave can be used, although, in general, the more open the weave the better. A more open weave generally results in better air flow through the apertures  710 . Better air flow results in better, i.e., more economical, hydroforming when forming structure  350  is used to form a polymeric web, such as polymeric web  80 . In one embodiment forming structure  350   430  is a metal screen, such as is commonly used on household doors and windows. In one embodiment the metal screen is an 18×16 mesh bright aluminum screening having a filament diameter for both machine direction filaments  420  and cross direction filaments  410  of 0.24 mm, available as Hanover Wire Cloth from Star Brand Screening, Hanover, Pa., USA, having. 
     As shown in  FIGS. 21 and 22 , protrusions  2250  extend from first surface  900  and have distal ends  2260  that are generally rounded in shape. In another embodiment, as shown in the photomicrograph of  FIG. 26 , the distal ends can be generally flattened into a plateau. The forming structure shown in  FIG. 26  is a flexible polymeric forming structure formed by a two-stage process of polymerizing a UV-curable resin. 
     One two-stage method for making flexible polymeric forming structure  350 , such as the forming structure shown in  FIGS. 24-26 , is described with reference to  FIG. 23 . The method described herein makes forming structures  350  having a combination of relatively large openings, i.e., depressions  710 , and relatively fine protrusions, i.e., protrusions  2250 . In the preferred embodiment illustrated in  FIG. 23 , the method described herein makes continuous belted forming structures  351 . In broad outline, the method involves using a photosensitive resin to construct in and about a foraminous element a solid, polymeric framework which delineates the preselected patterns of the relatively large depressions  710  and relatively fine protrusions  2250  of forming structure  350  (or belted forming structure  351 ). More particularly, the method comprises a two stage resin casting process including the steps of:
         a. Applying a backing film to the working surface of a forming unit;   b. Juxtaposing a foraminous element to the backing film so that the backing film is interposed between the foraminous element and the forming unit;   c. Applying a coating of liquid photosensitive resin to the surfaces of the foraminous element;   d. Controlling the thickness of the coating to a preselected value;   e. Juxtaposing in contacting relationship with the coating of photosensitive resin a mask comprising both opaque and transparent regions where the opaque regions define a preselected pattern corresponding to depressions  710 ;   f. Exposing the liquid photosensitive resin to light having an activating wavelength through the mask thereby inducing at least partial curing of the photosensitive resin in those regions which are in register with the transparent regions of the mask; and   g. Removing from the composite foraminous element/partially cured resin substantially all the uncured liquid photosensitive resin;   h. Repeating one time steps a-g with a different controlled thickness (e.g., a greater thickness, such as a thickness corresponding to hf 2  in  FIG. 22 ) in step (d) and a different mask in step (e), the mask in step (e) comprising both opaque and transparent regions where the transparent regions define a preselected pattern corresponding to protrusions  2250 ;   i. Immersing the foraminous element/cured resin in an oxygen-free environment such as a water bath or other aqueous solution;   j. Exposing the foraminous element/partially cured resin to light having an activating wavelength through the mask thereby inducing full curing of the photosensitive resin, resulting in the finished belted forming structure.       

     The exact apparatus (or equipment) used in the practice of the present invention is immaterial so long as it can, in fact, be used to practice the present invention. After reading the whole of the following description, one of ordinary skill of the art will be able to select appropriate apparatus to perform the steps indicated above. A preferred embodiment of an apparatus which can be used in the practice of this invention to construct a forming structure in the form of an endless belt is shown in schematic outline in  FIG. 23 . For convenience, the invention will be described in terms of that apparatus. 
     The first step of the process is applying a backing film to the working surface of a forming unit. In  FIG. 23 , forming unit  613  has working surface  612  and is indicated as being a circular element; it is preferably a rotatable drum. The diameter of the forming unit  613  and its length are selected for convenience. Its diameter should be great enough so that the backing film and the foraminous element are not unduly curved during the process. It must also be large enough in diameter that there is sufficient distance of travel about its surface so that the necessary steps can be accomplished as the forming unit  613  is rotating. The length of the forming unit  613  is selected according to the width of the forming structure  350  being constructed. Forming unit  613  is rotated by a drive means not illustrated. Optionally, and preferably, working surface  612  absorbs light of the activating wavelength. Preferably, forming unit  613  is provided with means for insuring that backing film  653  is maintained in close contact with working surface  612 . Backing film  653  can be, for example, adhesively secured to working surface  612  or forming unit  613  can be provided with means for securing backing film  653  to working surface  612  through the influence of a vacuum applied through a plurality of closely spaced, small orifices across working surface  612  of forming unit  613 . Preferably, backing film  653  is held against working surface  612  by tensioning means not shown in  FIG. 23 . 
     Backing film  653  can be introduced into the system from backing film supply roll  631  by unwinding it therefrom and causing it to travel in the direction indicated by directional arrow D 3 . Backing film  653  contacts working surface  612  of forming unit  613 , is temporarily constrained against working surface  612  by the means discussed hereinbefore, travels with forming unit  613  as the latter rotates, is eventually separated from working surface  612 , and travels to backing film take-up roll  632  where it is rewound. 
     In the embodiment illustrated in  FIG. 23 , backing film  653  is designed for a single use after which it is discarded. In an alternate arrangement, backing film  653  can take the form of an endless belt traveling about a series of return rolls where it is cleaned as appropriate and reused. Necessary drive means, guide rolls, and the like are not illustrated in  FIG. 23 . The function of the backing film  653  is to protect the working surface  612  of the forming unit  613  and to facilitate removal of the partially cured forming structure  350  from the forming unit. The film can be any flexible, smooth, planar material such as polyethylene or polyester sheeting. Preferably, the backing film  653  is made from polypropylene and is from about 0.01 to about 0.1 millimeter (mm) thick. 
     The second step of the process is the juxtaposing of a foraminous element  601  to the backing film in such a way that the backing film is interposed between the foraminous element  601  and the forming unit  613 . The foraminous element  601  is the material about which the curable resin is constructed. One suitable foraminous element is a metal wire screen  430  as illustrated in  FIGS. 21 and 22 . Screens having polyester filaments are suitable. Screens having mesh sizes from of about 6 to about 30 filaments per centimeter are suitable. Square weave screens are suitable as are screens of other, more complex weaves. Filaments having either round or oval cross sections are preferred. Although advantageous, it is not necessary that the filaments be transparent to light of the activating wave-length. In addition to screens, foraminous elements can be provided by woven and nonwoven fabrics, papermaking fabrics, thermoplastic netting, and the like. The precise nature of the foraminous element selected and its dimensions will be dictated by the use in which the forming structure  350  will be placed after it is constructed. Since the forming structure  350  constructed by the apparatus illustrated in  FIG. 23  is in the form of an endless belt, foraminous element  601  is also an endless belt, formed, for example, by seaming together the ends of a length of screening. 
     As illustrated in  FIG. 23 , foraminous element  601  travels in the direction indicated by directional arrow D 1  about return roll  611  up, over, and about forming unit  613  and about return rolls  614  and  615 . Other guide rolls, return rolls, drive means, support rolls and the like can be utilized as necessary, and some are shown in  FIG. 23 . Foraminous element  601  is juxtaposed backing film  653  so that backing film  653  is interposed between foraminous element  601  and forming unit  613 . The specific design desired for the forming structure  350  will dictate the exact method of juxtaposition. In the preferred embodiment, foraminous element  601  is placed in direct contacting relation with backing film  653 . 
     When the liquid photosensitive resin  652  is applied to foraminous element  601  from source  620 , the resin  652  will be disposed principally to one side of foraminous element  601  and foraminous element  601  will, in effect, be located at one surface of the forming structure  350 . Foraminous element  601  can be spaced some finite distance from backing film  653  by any convenient means, but such arrangement is not usually preferred. Resin source  620  can be a nozzle, or any of known means for depositing liquid photosensitive resin, including extrusion, slot coating, and the like. 
     The third step in the process of this invention is the application of a first layer of coating of liquid photosensitive resin  652  to the foraminous element  601 . The first layer of coating is the layer that will ultimately comprise the portion of forming structure  350  between the planes of the first and second surfaces,  1020  and  1060 , respectively (shown as hf 1  in  FIG. 22 ). Any technique by which the liquid material can be applied to the foraminous element  601  is suitable. For example, nozzle  620  can be used to supply viscous liquid resin. It is necessary that liquid photosensitive resin  652  be evenly applied across the width of foraminous element  601  prior to curing and that the requisite quantity of material be applied so as to enter the openings of the foraminous member  601  as the design of the forming structure  350  requires. For woven foraminous elements the knuckles, i.e., the raised cross-over points of a woven screen structure, are preferably in contact with the backing film, so that it will likely not be possible to completely encase the whole of each filament with photosensitive resin; but as much of each filament as possible should be encased. 
     Suitable photosensitive resins can be readily selected from the many available commercially. They are materials, usually polymers, which cure or cross-link under the influence of radiation, usually ultraviolet (UV) light. References containing more information about liquid photo-sensitive resins include Green et al, “Photocross-linkable Resin Systems”, J. Macro-Sci. Revs. Macro Chem., C21 (2), 187-273 (1981-82); Bayer, “A Review of Ultraviolet Curing Technology”, Tappi Paper Synthetics Conf. Proc., Sep. 25-27, 1978, pp. 167-172; and Schmidle, “Ultraviolet Curable Flexible Coatings”, J. of Coated Fabrics, 8, 10-20 (July, 1978). All the preceding three references are incorporated herein by reference. Especially preferred liquid photosensitive resins are included in the Merigraph L-055 series of resins made by MacDermid Imaging Technology Inc., Wilmingtion, Del., USA USA. 
     The next step in the process of this invention is controlling the thickness of the coating to a preselected value. The preselected value corresponds to the thickness desired for the forming structure  350  between first and second surfaces  1020  and  1060 , respectively. That is, the thickness hf 1  as shown in  FIG. 22 . When the forming structure  350  is to be used to make the web  80  suitable for use as a topsheet in a disposable absorbent article, it is preferred that hf 1  be from about 1 mm to about 2 mm thick. Other applications, of course, can require thicker forming structures  350  which can be 3 mm thick or thicker. 
     Any suitable means for controlling the thickness can be used. Illustrated in  FIG. 23  is the use of nip roll  641 . The clearance between nip roll  641  and forming unit  613  can be controlled mechanically by means not shown. The nip, in conjunction with mask  654  and mask guide roll  641 , tends to smooth the surface of liquid photosensitive resin  652  and to control its thickness. 
     The fifth step in the process of the invention comprises juxtaposing a first mask  654  in contacting relation with the liquid photosensitive resin  652 . The purpose of the mask is to shield certain areas of the liquid photosensitive resin from exposure to light. First mask  654  is transparent to activating wavelengths of light, e.g., UV light, except for a pattern of opaque regions corresponding to the pattern of apertures  71  desired in the forming structure  350 . A portion of a suitable first mask  654  showing one pattern of opaque, i.e., shaded, portions  657  and light-transparent portions  658  is shown in  FIG. 27 . Note that  FIG. 27  shows a measuring scale superimposed thereunder. The smallest increment of the scale shown is 0.1 mm. 
     The light-transparent portions  658  of first mask  654 , i.e., the areas that are not shielded from the activating light source correspond to those areas of liquid photosensitive resin that will be cured to form the connecting members  910  of forming structure  350 . Likewise, the opaque portions  657  of first mask  654  correspond to pattern of the depressions  710  of forming structure  350 . First mask  654 , can, therefore, have opaque portions  657  corresponding to the pattern of hexagon-shaped depressions of forming structure  350  shown in  FIG. 21 , or the pentagonal-shaped depressions  710  shown in  FIG. 13 , or the teardrop-shaped depressions  710  shown in  FIG. 15 . In general, for a forming structure  350  used to form a web  80  for use as a topsheet in a disposable absorbent article, the opaque portions  657  of first mask  654  should be of a suitable size, shape, and spacing to provide the necessary structure of apertures  71  for web  80  such that it exhibits desirable fluid flow properties. 
     First mask  654  can be any suitable material which can be provided with opaque and transparent regions. A material in the nature of a flexible film is suitable. The flexible film can be polyester, polyethylene, or cellulosic or any other suitable material. The opaque regions can be formed by any convenient means such as photographic or gravure processes, flexographic processes, and inkjet or rotary screen printing processes. First mask  654  can be an endless loop or belt (the details of which are not shown) or it can be supplied from one supply roll and transverse the system to a takeup roll, neither of which is shown in the illustration. First mask  654  travels in the direction indicated by directional arrow D 4 , turns under nip roll  641  where it is brought into contact with the surface of liquid photosensitive resin  652 , travels to mask guide roll  642  in the vicinity of which it is removed from contact with the resin. In this particular embodiment, the control of the thickness of the resin and the juxtaposition of the mask occur simultaneously. 
     The sixth step of the process of this invention comprises exposing the liquid photosensitive resin  652  to light of an activating wavelength through the first mask  654  thereby inducing at least partial curing of the resin in those regions which are in register with the transparent regions  658  of first mask  654 . The resin need not be fully cured in this step, but at least partial curing is achieved when exposed resin retains its desired shape during post-light-exposure steps, such as washing away non-cured resin, as described below. In the embodiment illustrated in  FIG. 23 , backing film  653 , foraminous element  601 , liquid photosensitive resin  652 , and mask  654  all form a unit traveling together from nip roll  641  to the vicinity of mask guide roll  642 . Intermediate nip roll  641  and mask guide roll  642  and positioned at a location where backing film  653  and foraminous element  601  are still juxtaposed forming unit  613 , liquid photosensitive resin  652  is exposed to light of an activating wavelength as supplied by exposure lamp  655 . Exposure lamp  655  is selected to provide illumination primarily within the wavelength which causes curing of the liquid photosensitive resin. That wavelength is a characteristic of the liquid photosensitive resin. In a preferred embodiment the resin is UV-light curable and exposure lamp  655  is a UV light source. Any suitable source of illumination, such as mercury arc, pulsed xenon, electrodeless, and fluorescent lamps, can be used. 
     As described above, when the liquid photosensitive resin is exposed to light of the appropriate wavelength, curing is induced in the exposed portions of the resin. Curing is generally manifested by a solidification of the resin in the exposed areas. Conversely, the unexposed regions remain fluid. The intensity of the illumination and its duration depend upon the degree of curing required in the exposed areas. The absolute values of the exposure intensity and time depend upon the chemical nature of the resin, its photo characteristics, the thickness of the resin coating, and the pattern selected. Further, the intensity of the exposure and the angle of incidence of the light can have an important effect on the presence or absence of taper in the walls of connecting members  910  through the thickness hf 1  of forming structure  350 . Accordingly, the light can be collimated to achieve the desired degree of taper. 
     The seventh step in the process is removing from the cured or partially-cured composite of foraminous element/partly cured resin  621  substantially all of the uncured liquid photosensitive resin. That is to say, the resin which has been shielded from exposure to light is removed from the system. In the embodiment shown in  FIG. 23 , at a point in the vicinity of mask guide roll  642 , first mask  654  and backing film  653  are physically separated from the composite comprising foraminous element  601  and the now partly cured resin  621 . The composite of foraminous element  601  and partly cured resin  621  travels to the vicinity of first resin removal shoe  623 . A vacuum is applied to one surface of the composite at first resin removal shoe  623  so that a substantial quantity of the liquid (uncured) photosensitive resin is removed from the composite. As the composite travels farther, it is brought into the vicinity of resin wash shower  624  and resin wash station drain  625  at which point the composite is thoroughly washed with water or other suitable liquid to remove more of the remaining liquid (uncured) photosensitive resin, which is discharged from the system through resin wash station drain  625 . The wash shower is preferably primarily water or an aqueous solution at a temperature above about 115 degrees F. 
     A second resin removal shoe  626  (or a third, etc., as necessary) can be used for further removal of residual un-cured resin at this stage of the process. (A second curing station in the form of a second light source  660  and an air-displacing medium, such as water bath  630 , is shown in  FIG. 23  but is not used in the first stage of the process.) At this stage of the process for making forming structure  350 , which is the end of the first stage, the composite now comprises essentially foraminous element  601  and the partially-cured resin  621  that represents the portion of forming structure  350  comprising connecting elements  910 , first surface  900  and second surface  850  and depressions  710 . 
     The next step is to form protrusions  2250  on the partially-formed forming structure  350 . To form protrusions  2250 , the process is essentially repeated in a second stage, and with a second mask  656  replacing first mask  654 . 
     Therefore, step eight starts with partially formed forming structure, denoted as  603  in  FIG. 23  advancing in the direction indicated by directional arrow D 1  about return roll  611  up, over, and about forming unit  613  and about return rolls  614  and  615 . As before, other guide rolls, return rolls, drive means, support rolls and the like can be utilized as necessary, and some are shown in  FIG. 23 . Partially formed forming structure  603  is juxtaposed backing film  653  so that backing film  653  is interposed between partially formed forming structure  603  and forming unit  613 . The specific design desired for the forming structure  350  will dictate the exact method of juxtaposition. In the preferred embodiment, partially formed forming structure  603  is placed in direct contacting relation with backing film  653 . Backing film  653  can be the same backing film referred to previously for the first stage of the process. 
     In the ninth step of the process a second coating of liquid photosensitive resin  652  is again applied as discussed above to partially formed forming structure  603  from source  620 , the resin  652  being applied to fill the depressions, i.e., depressions  710 , of partially formed forming structure  603  and, in addition, apply a coating above the level of partially cured resin of partially formed forming structure  603 . As before, partially formed forming structure  603  can be spaced some finite distance from backing film  653  by any convenient means, but such arrangement is not usually preferred. 
     The second layer of coating is the layer will ultimately be cured to form the protrusions  2250  of forming structure  350 . If uniform heights of protrusions  2250  are desired, it is necessary that the second layer of liquid photosensitive resin  652  be evenly applied across the width of partially formed forming structure  603 . A requisite quantity of photosensitive resin to form protrusions  2250  is enough so as to fill the openings of the partially formed forming structure  603  and to over fill to a preselected thickness corresponding to the desired protrusion height, such as a thickness corresponding to distance hf 2  of  FIG. 22 . When the forming structure  350  is to be used to make the web  80  suitable for use as a topsheet in a disposable absorbent article, it is preferred that hf 2  be from about 1.1 mm to about 2.1 mm thick. As before, any suitable means for controlling the thickness can be used, including the use of nip roll  641 . 
     The tenth step in the process illustrated in  FIG. 23  comprises juxtaposing a second mask  656  in contacting relation with the second layer of liquid photosensitive resin  652 . As before, the purpose of the mask is to shield certain areas of the liquid photosensitive resin from exposure to light. A portion of a suitable first mask  654  showing one pattern of opaque, i.e., shaded, portions  657  and light-transparent portions  658  is shown in  FIG. 28 . Note that, although difficult to see,  FIG. 28  shows a measuring scale superimposed thereunder. The smallest increment of the scale shown is 0.1 mm. 
     As shown in  FIG. 28 , second mask  656  is opaque to activating wavelengths of light, e.g., UV light, except for a pattern of transparent regions  658  corresponding to the pattern of protrusions  2250  desired in the forming structure  350 . The light-transparent portions of second mask  656 , i.e., the areas that are not shielded from the activating light source correspond to those areas of liquid photosensitive resin that will be cured. Therefore, the transparent regions of second mask  656  correspond to the preselected pattern of the protrusions  2250  of forming structure  350 . Second mask  656 , can, therefore, have a pattern of transparent regions being closely-spaced spots or dots, which spots or dots have a one-to-one correspondence to the closely-spaced, round (in cross-section) protrusions, such as those shown in  FIGS. 24 and 25 . The pattern of transparent regions of mask  656  can, of course, be other shapes and patterns, depending on the particular end use of forming structure  350 . In general, for a forming structure  350  used to form a web  80  for use as a topsheet in a disposable absorbent article, the transparent regions  658  of second mask  656  should be of a suitable size, shape, and spacing to provide the necessary structure of protrusions  2250  for web  80  such that it exhibits desirable tactile properties, such as perceived softness. In one embodiment, transparent regions  658  of second mask  656  are each circular with a diameter of about 65 microns, spaced apart on a center-to-center distance of about 188 microns, in a uniform spacing of about 3875 transparent regions  658  per square centimeter (about 25,000 per square inch). 
     Second mask  656  can be the same material as first mask  654  such as a flexible film in which the opaque regions can be applied by any convenient means such as photographic or gravure processes, flexographic processes, and inkjet or rotary screen printing processes. Second mask  656  can be an endless loop (the details of which are not shown) or it can be supplied from one supply roll and transverse the system to a takeup roll, neither of which is shown in the illustration. Second mask  656  travels in the direction indicated by directional arrow D 4 , turns under nip roll  641  where it is brought into contact with the surface of liquid photosensitive resin  652 , travels to mask guide roll  642  in the vicinity of which it is removed from contact with the resin. In this particular embodiment, the control of the thickness of the resin and the juxtaposition of the mask occur simultaneously. 
     The eleventh step of the process comprises again exposing the liquid photosensitive resin  652  to light of an activating wavelength through the second mask  656  thereby inducing curing of the resin in those regions which are in register with the transparent regions of second mask  656 , that is, protrusions  2250 . In the embodiment illustrated in  FIG. 23 , backing film  653 , partially formed forming structure  603 , liquid photosensitive resin  652 , and second mask  656  all form a unit traveling together from nip roll  641  to the vicinity of mask guide roll  642 . Intermediate nip roll  641  and mask guide roll  642  and positioned at a location where backing film  653  and partially formed forming structure  603  are still juxtaposed forming unit  613 , liquid photosensitive resin  652  is exposed to light of an activating wavelength as supplied by exposure lamp  655 . As before, exposure lamp  655 , in general, is selected to provide illumination primarily within the wavelength which causes curing of the liquid photosensitive resin. That wavelength is a characteristic of the liquid photosensitive resin. As before, n a preferred embodiment the resin is UV-light curable and exposure lamp  655  is a UV light source (in fact, is the same light source used in the first stage of the process, described above). 
     As described above, when the liquid photosensitive resin is exposed to light of the appropriate wavelength, curing is induced in the exposed portions of the resin. Curing is manifested by a solidification of the resin in the exposed areas. Conversely, the unexposed regions remain fluid (or partially-cured in the case of the previously-cured portions of partially formed forming structure  603 ). The intensity of the illumination and its duration depend upon the degree of curing required in the exposed areas. The absolute values of the exposure intensity and time depend upon the chemical nature of the resin, its photo characteristics, the thickness of the resin coating, and the pattern selected. Further, the intensity of the exposure and the angle of incidence of the light can have an important effect on the presence or absence of taper in the walls of the protrusions  2250 . As mentioned before, a light collimator can be utilized to reduce tapering of the walls. 
     The twelfth step in the process is again removing from the partially-cured forming structure  350  substantially all of the uncured liquid photosensitive resin. That is to say, the resin which has been shielded from exposure to light in the second curing step is removed from the system. In the embodiment shown in  FIG. 23 , at a point in the vicinity of mask guide roll  642 , second mask  656  and backing film  653  are physically separated from the now partly cured resin  621  which now includes partially- or substantially fully-cured resin of the completed forming structure  350 , i.e., having both depressions  710  and protrusions  2250 . The partly cured resin  621  travels to the vicinity of first resin removal shoe  623 . A vacuum is applied to one surface of the composite at first resin removal shoe  623  so that a substantial quantity of the liquid (uncured) photosensitive resin, as well as cured “protrusions” adjacent depressions  710 , is removed from the composite. Note that in the second curing step, second mask  656  does not limit curing of resin only on portions corresponding to first surface  900  of forming structure  350 . The second curing step actually cures “protrusions” uniformly across the entire area of partially cured composite  603 . However, only portions of cured resin over connecting members  910  join to connecting members  910  at first surface  900  and become essentially integral with the previously-cured resin portions. Thus, in the vacuum and water washing steps, the portions of cured resin corresponding to “protrusions” that are in the adjacent depressions  710  are simply removed to prior to a final light-exposure for final curing, as described more fully below. 
     As the composite travels farther, it is brought into the vicinity of resin wash shower  624  and resin wash station drain  625  at which point the composite is thoroughly washed with water or other suitable liquid to remove substantially all of the remaining liquid (uncured) photosensitive resin, as well as any cured resin not forming part of the finished forming structure  350 , all of which is discharged from the system through resin wash station drain  625  for recycling or disposal. For example, cured resin formed in the second stage light activation in the regions of the depressions are washed away. Such cured resin is preferably non-adhered to the underlying foraminous member, and, if adhered, the level of adhesion is preferably insufficient to prevent the unwanted cured material to wash away. 
     After substantially all of the uncured resin is removed and the remaining resin is in the final form for forming structure  350 , the remaining resin is fully cured by a second light source  660 , preferably in an oxygen free medium, such as water bath  630 . The oxygen free medium ensures that oxygen does not interfere with the final UV-light curing of the remaining uncured resin. Oxygen can slow down or stop chain growth in free radical polymerization. 
     As shown in  FIG. 23  a series of guide roll  616  can be used as required to guide the partially-formed forming structure  350  into a water bath  630 . However, in practice, any process configuration can be used, including simply letting the partially-formed forming structure  350  be immersed in shallow, e.g., 25.4 mm deep, water tray by its own weight. The final exposure of the resin to activating light  660  ensures complete curing of the resin to its fully hardened and durable condition. 
     The above-described twelve-step, two-stage process continues until such time as the entire length of foraminous element  601  has been treated and converted into the forming structure  350 . The finished forming structure, denoted as belted forming structure  351 , can then be used in a web forming process, such as the process described with reference to  FIG. 29 , for example. 
     Therefore, in general, curing can be done in stages, so that first a negative mask having UV blocking portions corresponding to forming structure apertures  710  (having UV blocking portions in a pattern of teardrops, for example), can be used to first partially cure the polymer by directing a UV light source orthogonal to the mask for a sufficient amount of time. Once the polymer is partially cured in the unmasked areas, a second mask comprising a plurality of closely spaced UV-transparent spots or dots can be placed between the light source and the partially cured polymer. The polymer is again cured by UV-light to fully cure the portions of the polymer that will be the protrusions  2250 . Once the protrusions are fully cured, the remaining uncured polymer (and partially cured polymer) can be removed to leave a forming structure having similar characteristics as those shown in  FIGS. 22-26 . The procedure described can be used for prototyping hand sheets of material, for example. 
     Example of Formation of Belted Forming Structure: 
     The forming structure  350  shown in  FIGS. 24-26  was made according to the process described above with respect to  FIG. 23 . In particular, foraminous element  601  was an 18×16 mesh bright aluminum screening available from Hanover Wire Cloth Star Brand Screening, Hanover, Pa. The screening was approximately 0.5 mm (0.021 inches) thick, 61 cm (24 inches) wide and comprised a woven mesh of filaments, each filament having filament diameter of about 0.24 mm. The screening was about 15 meters (50 feet) long and was formed into an endless belt by a sewn seam. 
     The backing film was a 0.1 mm (0.004 inch) thick biaxially clear polyester film, available as Item No. R04DC30600 from Graphix, 19499 Miles Road, Cleveland, Ohio, USA. The photosensitive resin was XPG2003-1 purchased from MacDermid Imaging Technology Inc., Wilmingtion, Del., USA USA which was used at room temperature as received from the manufacturer. 
     The first mask was a 0.1 mm (0.004 inch) Color Clear Film, 787N, available from Azon of Chicago Ill., USA and was printed with teardrop pattern as shown in  FIG. 27 . The first mask was created by inkjet printing the pattern directly onto the Azon Color Clear Film. 
     The forming unit comprised a drum about 108 cm (42.5 inches) in diameter and about 71 cm (28 inches) wide. It rotated with a surface velocity of about 41 cm (16 inches) per minute. 
     For the first cast, the photosensitive resin was applied through a nozzle to a controlled overall thickness of about 1.7 mm (0.067 inches), with the thickness being controlled by the spacing of the forming unit and nip roll as described above. 
     The exposure lamp, i.e., lamp  655  discussed above, was a UV light system VPS/1600 system, Model No. VPS-6, purchased from Fusion UV Systems, 910 Clopper Road, Gaithersburg, Md., USA. The exposure lamp was placed about 35 cm (14 inches) from the first mask and the exposure was controlled by a quartz aperture (optional, a quartz aperture helps create a uniform light density across the exposed area of the mask) which was positioned about 6.4 mm (2.5 inches) from the surface of the mask, and which extended the width of the forming unit and about 10 cm (4 inches) in the direction of travel (i.e., about the periphery of forming drum  613 ). The light was collimated (collimator is optional but helps collimate the light for better curing resolution) through a 12.5 mm (0.5 inch) hexagonal honeycomb collimator that was 38 mm (1.5 inches) tall (i.e., 38 mm long tubes having a honeycomb structure). 
     After the first resin layer was exposed to UV light, the first mask was separated from the composite of partially-cured resin and the uncured resin was washed from the composite by an aqueous solution of water (100 gallons/per minute), Mr. Clean® (0.065 gallons/minute) and Merigraph System W6200 defoamer (0.089 gallons/minute) at a temperature of about 115 degrees F. through 4 sets of showers, each comprising a 28 inch wide manifold of 17 nozzles. Three showers sprayed from the top of the composite and one from the bottom. 
     After the first stage the composite was partially cured, which means that the first cast of resin was not fully cured by second UV source, e.g., lamp  660  described above. The partially cured composite comprising the first cast of resin now comprised the teardrop shaped depressions  710  of forming structure  350 . The first cast of resin exhibited a thickness above the foraminous element of about 1.3 mm (0.050 inch). The partially cured composite was run back over the forming unit a second time in the second stage of the process. The same photosensitive resin was applied to an overall thickness of about 2 mm (0.077 inches), which was about 0.24 mm (0.010 inches) thicker than the first application of resin. A second mask was used, the second mask having a pattern of small transparent circles 0.08 mm (0.003 inches) in diameter and spaced 0.18 mm (0.007 inches) center-to-center in an equilateral triangle array as illustrated in  FIG. 28 . 
     The composite was cured again by light source  655  as described above and subjected to the showers  624 , as described above. After the showers removed substantially all of the uncured resin, the composite was post cured by directing a post-cure UV light at the composite, e.g., from source  660 , while the composite was submerged in 2.5 cm (1 inch) of water containing 36 grams of sodium sulfite/gallon of water. The sodium sulfite is optional, but is a good oxygen scavenger. The post-cure UV light source was placed about 20 cm (8 inches) from the composite. 
     The resulting belted forming structure  351  exhibited columnar-shaped pillars (i.e., protrusions  2250 ) having a substantially uniform circular cross-section extending from the first surface. The protrusions each had a height about 105 microns, a diameter of about 66 microns, and a center-to-center spacing of about 188 microns. The belted forming structure  351  additionally exhibited uniform teardrop-shaped depressions  710 . Photomicrographs of representative portions of the belted forming structure made by the process described above are shown in  FIGS. 24-26 . Note that protrusions are seamless, integral extensions of the first surface of the forming structure. This is believed to be due to the polymer being only partially cured in the first stage of the process, and finally cured after formation of the protrusions. 
     Variations on the method of forming a forming structure of the present invention utilizing the photosensitive resin-curing process described above can be made without departing from the scope of the present invention. For example, in one embodiment, the above described twelve-step process can be modified by eliminating the first mask  654 , or by simply having mask  654  being completely transparent. In this embodiment, all the resin deposited in first layer, or coating,  652  of UV-curable resin is partially cured to form a monolithic “slab” of partially cured resin. The remaining steps of the process are carried out as described above, including the formation of protrusions  2250  by use of second mask  656 . In this manner, a forming structure is formed having protrusions  2250  but having no depressions  710 . Depressions  710  can thereafter be formed by a separate process, such as by laser etching. 
     Other methods of making forming structures are contemplated. For example, resins, such as thermally-cured (e.g., vulcanizable resins) or UV-curable resins can be partially cured (i.e., partially polymerized) into “slabs” of material, the partial curing being sufficient to handle the slabs in a process of wrapping the slabs onto cylindrical sleeves. Once wrapped, either by spiral wrapping, or by piecing discrete slabs into a complete cylindrical form, the partially-cured resin can be fully cured, thereby forming a unitary, fully cured, cylindrical sleeve of polymerized material that can thereafter by laser etched, for example, to form depressions  710  and/or protrusions  2250 . The benefit of such a process is that the cylindrical form of the forming structure can be achieved without the need to make a seam. Thus, unlike a typical belt-making process that involves a seaming step, a forming structure so made is inherently seamless. Additionally, individual layers of curable resin can be laid up in a predetermined manner such that layers having differing material properties can be arranged to form a forming structure having varying material properties throughout its thickness, for example. As an additional processing step, it may be beneficial to apply layers of uncured curable resin between layers of partially-cured resin in the layering process described above. 
     Further, as another optional variation on the method of making a forming structure by use of partially-cured “slabs” of material on a cylindrical form, the partially-cured slabs can be layered, with the outer-most layer being a layer having formed thereon protrusions  2250 . Thus, upon fully curing, the fully cured resin need only have depressions  710  formed, e.g., via laser etching, to produce the final cylindrical forming structure. 
     One advantage of making a forming structure by use of partially-cured “slabs” of material placed on a cylindrical form is that the cylindrical form utilized can be part of an overall support structure for the forming structure. For example, the partially-cured slabs can be layered over a foraminous member, such as a metal or polymer screen member. Once fully cured, the partially-cured slabs can become adhered to the foraminous member, which is then a unitary part of the forming structure and can provide for strength and durability for the forming structure. Further, the partially-cured slabs can be laid up onto a relatively rigid but air-permeable membrane, such as a honeycomb membrane that can provide support and rigidity to the forming structure. Metal honeycomb structures, for example, can be provided in tubular forms, such that upon fully curing the partially-cured slabs of material, the final structure is a relatively rigid, cylindrical, air-permeable forming structure. 
     Other methods of making forming structures are contemplated, including creation via a molding technique, in which the forming structure  350  is cast in a negative impression mold, cured, and removed. In one embodiment, a substrate, such as a polymeric substrate can be laser machined to form the negative of forming structure  350 , i.e., a mold having the internal shape of forming structure  350 . Once laser machined, a polymer could be directly cast into the mold (with appropriately-applied release agents, and the like, as is known in the art). The resulting forming structure  350  would have the positive shape of the mold. Alternatively, the laser-machined mold could have built up therein by electroplating, for example, a metallic forming structure  350 . Also, forming structures could be formed by way of electroplating techniques, in which successive layers of material are built up into a suitable form. 
     One of the advantages to making forming structure  350  from a flexible polymeric material, such as the material described with respect to FIGS.  15  and  24 - 26  is that the forming structure is flexible enough to be utilized as a continuous belt, much like a papermaking belt is used in the above-mentioned Trokhan &#39;289 patent. Such a continuous belt is referred to herein as a flexible “belted” forming structure  351 . By “belted” is meant that the forming structure is in the form of a continuous, flexible band of material, much like a conveyor belt or papermaking belt, as opposed to a relatively rigid tubular drum-shaped structure. In fact, the forming structure of the present invention can be utilized as a papermaking belt in papermaking processes for making textured paper, such as tissue paper. 
       FIG. 29  shows in simplified schematic representation one embodiment of a process for making a polymeric web  80  of the invention using a flexible belted forming structure  351 . As shown, belted forming structure  351  can be a continuous belted member guided and held tensioned by various rollers, e.g., rollers  610 . Belted forming structure  351  is guided over forming drum  518 . While on forming drum  518  belted forming structure is supported by forming drum  518  and precursor film  120  is supported on forming structure  351 . The formation of web  80  on forming structure  351  proceeds the same way as described above with respect to  FIG. 9  and forming drum  350 . Therefore, precursor web  120  can be subjected to liquid jet  540 , (or jets) as well as drying means  590  (or drying/annealing means). However, in the process described schematically in  FIG. 29 , drying means  590  on forming drum  518  is optional, because drying (and/or annealing) is provided for elsewhere in the process, as described more fully below. Therefore, in the embodiment described with respect to  FIG. 29 , drying means  590  can be replaced by re-heat means to further form precursor web  120 . 
     In one embodiment, liquid jets  540  are not used, and the process is essentially a liquid-free process. In such a process liquid jets  540  and or drying means  590  are replaced by re-heat means as described above. Precursor film  120  is heated by reheat means that, together with vacuum if necessary, conform precursor web  120  to forming structure  351 . Because no liquid is used in this process, no drying is necessary, and the drying steps disclosed herein can be eliminated. 
     As can be seen in  FIG. 29 , belted forming structure  351  does not simply rotate on forming drum  518  but is guided onto and off of forming drum  518 . As belted forming structure  351  is guided onto forming drum  518  it is preferably dry. After belted forming structure  351  is supported by forming drum  518 , or concurrently therewith, precursor web  120  is guided over belted forming structure  351  and hydroformed as described above. After passing drying means  590  the belted forming structure  351  and a three-dimensional, apertured, formed film web  80  of the present invention are guided off of forming drum  518  together. That is, polymer web  80  is intimately in contact with and supported by belted forming structure  351 . This permits further processing, such as drying or annealing, if necessary, to take place while the polymer web  80  is still supported by the belted forming structure  351 . In this manner, polymer web  80  can endure much greater work without collapsing, tearing, or otherwise deforming in a negative manner. 
     Belted forming structure  351  and polymer web  80  are guided in the direction indicated in  FIG. 29 , i.e., the machine direction, to a through-air drying means  800 . Through air drying means can be in the form of a rotating drum as shown in  FIG. 29 , but can be in any of other known configurations. Drying means  800  preferably utilizes air which is forced through polymer web  80  and belted forming structure  351  to effect drying of the web. However, other drying means are contemplated, such as the use of capillary drying or limited orifice drying techniques common in the papermaking industry for drying paper webs. 
     Drying means shown in  FIG. 29  comprises rotating porous drying drum  802 . As belted forming structure  351  and polymeric web  80  are supported by drying drum  802  a drying fluid, such as air, is forced through belted forming structure  351  and polymeric web  80 . Fluid, such as air, can be forced from the outside to the inside of drying drum  802 , as shown in  FIG. 29 , or it can be forced from the inside to the outside. In either configuration, the point is that the fluid effects drying of polymeric web  80  while web  80  remains fully supported on belted forming structure  351 . Drying drum dimensions, fluid flow rates, fluid moisture content, drying drum rotation velocity can all be adjusted as necessary to ensure adequate drying of polymeric web  80  prior to being guided off of drying drum  802 . 
     Drying drum  802  can have a vacuum chamber  808  to aid in fluid flow through polymeric web  80  and belted forming structure  351 . Additionally, fluid removal means can be utilized to remove liquid removed from polymeric web  80 . Fluid removal means can include a simple drain in forming drum  802 , but can also include active removal via pumps as is known in the art to recycle water back to the hydroforming apparatus. Drying drum  802  can have a positive pressure chamber  810  which aids in removing excess moisture from the surface of forming drum  802  prior to repeating the process of supporting belted forming structure  351 . Liquid removed can be simply captured in container  804  and removed appropriately, such as by draining into a water recycle system. 
     Once polymeric web  80  and belted forming structure  351  are guided off of drying drum  802 , polymeric web  80  is separated from belted forming structure  351  at separation point  830 . From this point polymeric web  80  may be, if necessary, subjected to additional drying, such as by radiant heat drying means  840 , and likewise, belted forming structure may be subjected to additional drying means, such as forced air drying means  850 . In all cases, other drying means as suitable under the processing conditions can be utilized as necessary to ensure that polymeric web  80  is sufficiently dry prior to final processing into roll stock and belted forming structure  351  is sufficiently dry to avoid introducing moisture into the interior of hair like fibrils  225  of polymeric web  80 . Sufficiently dry means dry enough such that post-manufacture moisture related problems such as mold or mildew in the polymeric web are minimized or eliminated.