Patent Publication Number: US-6700036-B2

Title: Acquisition distribution layer having void volumes for an absorbent article

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. Ser. No. 09/668,649 filed on Sep. 22, 2000. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to absorbent articles such as diapers, incontinent articles, sanitary napkins, and the like. More particularly, this invention relates to absorbent articles having a topsheet and a film acquisition distribution layer (ADL) having a void volume space. 
     BACKGROUND OF THE INVENTION 
     A variety of absorbent articles that are adapted to absorb body fluids are well known. Examples of absorbent articles include diapers, incontinent articles, and sanitary napkins. 
     One problem associated with known absorbent articles is waste product leakage, which may contaminate clothing articles, such as pants, shirts, and bedding. The amount of leakage experienced by a wearer can be reduced by increasing the rate that liquid enters the absorbent core. Therefore, an absorbent article wherein liquid rapidly penetrates the topsheet and is contained in the absorbent core will experience less leakage than an absorbent article wherein liquid is able to run across the topsheet before penetrating into the absorbent core. Consequently, run-off reduction reduces the amount of leakage associated with an absorbent article. 
     Another problem associated with absorbent articles is dryness of the skin contacting surface of the article. Generally, the drier the skin contacting surface, the more comfortable the absorbent article. Attempts have been made to reduce surface wetness in disposable diaper structures. For example, U.S. Pat. No. 3,945,386 issued to Anczurowski on Mar.23, 1976 and U.S. Pat. Nos. 3,965,906 and 3,994,299 issued to Karami on Jun. 29, 1976 and Nov. 30, 1976, respectively, teach diaper structures having a perforated thermoplastic film interposed between the topsheet and the absorbent core. U.S. Pat. No. 4,324,247 issued to Aziz on Apr. 13, 1982 describes an effort directed to both reducing run-off and reducing the surface wetness of absorbent articles. 
     In addition to the dryness of the skin contacting surface, the feel of the skin contacting surface is also an important consideration. One problem is that some consumers do not like the plastic feel associated with formed films. A number of efforts have been directed at improving the feel of the surface of absorbent articles. One example is described in U.S. Pat. No. 3,967,623 issued to Butterworth, et al. The Butterworth patent teaches an absorbent pad having a facing sheet made of a perforated thermoplastic web that has an integral fibrous or sueded outer surface. 
     An additional problem with typical absorbent articles, in particular adult incontinence diapers. As a wearer urinates a second time or more, a sensation of wetness is felt as unabsorbed fluid flows laterally through the topsheet from an area of saturated core material to an area of unsaturated core material for absorption. This sensation is highly uncomfortable and undesirable. 
     The products described in most of the above references, however, are less than ideal in achieving a good combination of all three desired properties of reduced surface run-off, improved ability to prevent a feeling of wetness of the topsheet, and improved feel. 
     SUMMARY OF THE INVENTION 
     The invention relates to an absorbent article having a topsheet and an absorbent core material. An acquisition distribution layer is located between the topsheet and the absorbent core material. The acquisition distribution layer is made of a three dimensional formed film with apertures, wherein the acquisition distribution layer has a body facing side, i.e. a female side, and a garment facing side, i.e. a male side. In accordance with the invention, the acquisition distribution layer defines a high void volume space. The large under-side void volume space provides space for unabsorbed fluid to flow over the top plane of saturated core regions and flow to new, unsaturated regions of the core material without contacting the topsheet, thereby avoiding a feeling of wetness for the user. Unabsorbed fluid results from repeated insults to a saturated zone of an absorbent core. In another embodiment, the acquisition distribution layer has at least one raised ridge extending upwards to a higher plane on the female side. The raised ridge runs in the machine direction for directing unabsorbed fluid to flow primarily in the machine direction of the absorptive device to help prevent side leakage. The “machine direction” is a term of art that indicates the general direction of movement of materials during processing. Typically, if no separate tentering step is performed on the material, polymer strands within the material orient themselves generally in the machine direction of the film. In another embodiment a first and a second three dimensional apertured film forms an acquisition distribution layer having a further enlarged void volume space for flow of unabsorbed fluid and that provides a greater spacial separation between areas of containment of wetness and the topsheet. In still another embodiment, the acquisition distribution layer has a high loft, which forms relatively deep cells or buckets. When repeated insults are delivered to a saturated core region, a bucket or buckets in the insult region is filled. Subsequent insults result in fluid spilling over to adjacent buckets. The spill over action disperses the liquid volume of the insults over a larger area of the core material so that the fluid may be absorbed by unsaturated core material. 
     Further embodiments provide channels that are cut below a surface plane formed by the female or garment facing side of either the acquisition distribution layer having a large under-side void volume space, i.e., “spill under embodiment” or acquisition distribution layer having a high loft that forms buckets, i.e., “spill over embodiment”. The channels may also be used with other embodiments. The channels provide void space for fluid flow and directs the fluid flow in desired directions. The channels provide a new spill over passage that provides a spill over volume not previously possible with a “spill under” embodiment described above. Additionally, the channels improve the volume of the spill over in the “spill over” embodiment discussed above by providing a preferred directional pathway for spilling into the next “bucket” as well as by providing more volumetric pathways to spill and redistribute the fluid. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is perspective view of an absorbent article of the invention that utilizes an acquisition distribution layer. 
     FIG. 2 is a cross sectional schematic view of the absorbent article of FIG. 1 taken along line  2 — 2  wherein the acquisition distribution layer is of a prior art type. 
     FIG. 3 is an enlarged cross sectional view of the prior art acquisition distribution layer of FIG.  2 . 
     FIG. 4 is a plan view of a three dimensional apertured film of a first embodiment of the invention for use as an acquisition distribution layer in the absorbent article of FIG.  1 . 
     FIG. 5 is a cross sectional view of the absorbent article of FIG. 1 taken along line  2 — 2  of FIG. 1 wherein the acquisition distribution layer shown is a cross sectional view of the three dimensional apertured film of FIG. 4 taken along line  5 — 5  of FIG.  4 . 
     FIG. 6 is a plan view of a three dimensional apertured film of a second embodiment of the invention for use as an acquisition distribution layer in the absorbent article of FIG.  1 . 
     FIG. 7 is a cross sectional view of the absorbent article of FIG. 1 taken along line  2 — 2  of FIG. 1 wherein the acquisition distribution layer shown is a cross sectional view of the three dimensional layer apertured film of FIG. 6 taken along line  7 — 7  of FIG.  6 . 
     FIG. 8 is a plan view of a three dimensional apertured film of a third embodiment of the invention for use as an acquisition distribution layer in the absorbent article of FIG.  1 . 
     FIG. 9 is a cross sectional view of the absorbent article of FIG. 1 taken along line  2 — 2  of FIG. 1 wherein the acquisition distribution layer shown is a cross sectional view of the three dimensional layer apertured film of FIG. 8 taken along line  9 — 9  of FIG.  1 . 
     FIG. 10 is a plan view of a disposable diaper utilizing the three dimensional apertured film of FIGS. 8 and 9. 
     FIG. 11 is a cross sectional view of the absorbent article of FIG. 1 wherein the acquisition distribution layer is a multi-layer apertured film of a fourth embodiment of the invention. 
     FIG. 12 is a cross sectional view of the absorbent article of FIG. 1 wherein the acquisition distribution layer is a multi-layer apertured film of a fifth embodiment of the invention. 
     FIG. 13 is a plan view of a three dimensional apertured film of an additional embodiment of the invention having channels formed therein, wherein the three dimensional apertured film is for use as an acquisition distribution layer in the absorbent article of FIG.  1 . 
     FIG. 14 is a cross-sectional view of the absorbent article of FIG. 1 taken along line  2 — 2  of FIG. 1 when the acquisition distribution layer shown is a cross-sectional view of the channeled three dimensional apertured film of FIG. 13 taken along line  14 — 14  of FIG.  13 . 
     FIG. 15 is a plan view of a three dimensional apertured film of an additional embodiment of the invention having channels formed therein, wherein the three dimensional apertured film is for use as an acquisition distribution layer in the absorbent article of FIG.  1 . 
     FIG. 16 is a cross-sectional view of the absorbent article of FIG. 1 taken along line  2 — 2  of FIG. 1 wherein the acquisition distribution layer shown is a cross-sectional view of the channeled three dimensional layer apertured film of FIG. 15 taken along line  16 — 16  of FIG.  15 . 
     FIG. 17 is a schematic drawing an Liquid Acquisition Apparatus that is used to test the various embodiments of the absorbent articles of FIGS. 1-12. 
     FIG. 18 is a graphical representation of data from Table 1 that shows Total Fluid Overflow and Inverse Loft for various samples of absorbent articles shown in FIGS. 1-12. 
     FIG. 19 is a plan view at 50X magnification of Sample 2 and Sample 4 for purposes of comparing the void volume space of the samples. 
     FIG. 20 is a cross-sectional view at 50X magnification of Sample 2 and Sample 4 for purposes of comparing the void volume space of the samples. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention relates to absorbent articles having a three dimensional apertured film acquisition distribution layer. Examples of absorbent articles include diapers, incontinent articles, sanitary napkins, and similar articles. 
     For purposes of this application, the term “absorbent article” will refer to articles that absorb and contain body exudates. More specifically, the term refers to articles which are placed against or in proximity to the body of a wearer for absorbing and containing various exudates discharged from the body. The term “absorbent article”, as used herein, is intended to include diapers, incontinent articles, sanitary napkins, pantiliners, and other articles used to absorb body exudates. 
     The term “diaper” refers to a garment typically worn by infants and incontinent persons that is drawn up between the legs and fastened about the waist of the wearer. Examples of diapers from the prior art include diapers described in U.S. Pat. Re. No. 26,152, issued to Duncan, et al. on Jan. 31, 1967; U.S. Pat. No. 3,860,003 issued to Buell on Jan. 14, 1975; U.S. Pat. No. 4,610,678 issued to Weisman, et al. on Sep. 9, 1986; U.S. Pat. No. 4,673,402 issued to Weisman, et al. on Jun. 16, 1987; U.S. Pat. No. 4,695,278 issued to Lawson on Sep. 22, 1987; U.S. Pat. No.4,704,115 issued to Buell on Nov. 3, 1987; U.S. Pat. No. 4,834,735 issued to Alemany, et al. on May 30, 1989; U.S. Pat. No. 4,888,231 issued to Angstadt on Dec. 19, 1989; and U.S. Pat. No. 4,909,803 issued to Aziz, et al. on Mar. 20, 1990. 
     The term “incontinent article” refers to pads, undergarments, e.g., pads held in place by a suspension system, such as a belt, or other device, inserts for absorbent articles, capacity boosters for absorbent articles, briefs, bed pads, and similar devices, whether worn by adults or other incontinent persons. Examples of incontinent articles include those disclosed in U.S. Pat. No. 4,253,461 issued to Strickland, et al. on Mar. 3, 1981; U.S. Pat. Nos. 4,597,760 and 4,597,761 issued to Buell; the above-mentioned U.S. Pat. Nos. 4,704,115; 4,909,802 issued to Ahr, et al.; U.S. Pat. No. 4,964,860 issued to Gipson, et al. on Oct. 23, 1990; and in U.S. patent application Ser. Nos. 07/637,090 and 07/637,571 filed respectively by Noel, et al. and Feist, et al. on Jan. 3, 1991. 
     The term “sanitary napkin” refers to an article that is worn by a female adjacent to the pudendal region that is intended to absorb and contain various exudates which are discharged from the body, e.g., blood, menses, and urine. Examples of sanitary napkins are disclosed in U.S. Pat. No. 4,285,343, issued to McNair on Aug. 25, 1981; U.S. Pat. Nos. 4,589,876 and 4,687,478, issued to Van Tilburg on May 20, 1986 and Aug. 18, 1987 respectively; U.S. Pat. Nos. 4,917,697 and 5,007,906 issued to Osborn, et al. on Apr. 17, 1990 and Apr. 16, 1991, respectively; and U.S. Pat. Nos. 4,950,264, and 5,009,653 issued to Osborn on Aug. 21, 1990 and Apr. 23, 1991, respectively; and in U.S. patent application Ser. No. 07/605,583 filed Oct. 29, 1990 in the name of Visscher, et al. 
     The term “pantiliner” refers to absorbent articles that are less bulky than sanitary napkins that are generally worn by women between their menstrual periods. Examples of pantiliners are disclosed in U.S. Pat. No. 4,738,676 entitled “Pantiliner” issued to Osborn on Apr. 19, 1988. 
     The disclosures of all patents, patent applications and any patents which issue therefrom, as well as any corresponding published foreign patent applications, and publications mentioned throughout this patent application are hereby incorporated by reference herein. It is expressly not admitted, however, that any of the documents incorporated by reference herein teach or disclose the present invention. It is also expressly not admitted that any of the commercially available materials or products described herein teach or disclose the present invention. 
     Referring now to FIG. 1, a simplified representation of a typical absorbent article  10  is shown. It should be understood, however, that FIG. 1 is shown for purposes of example only, and should not be construed to limit the particular type or configuration of absorbent article. As shown in FIG. 2, absorbent article  10  basically comprises topsheet  12 , backsheet  14 , an acquisition distribution layer  15 , and an absorbent core  16 . Absorbent core  16  has a top or body facing side  17 . 
     The absorbent article  10  has two surfaces, a body-contacting surface or body surface  18  and a garment-contacting surface or garment surface  20 . The body surface  18  is intended to be worn adjacent to the body of the wearer. The garment surface  20  (FIG. 2) of the absorbent article  10  is on the opposite side and is intended to be placed adjacent to the wearer&#39;s undergarments or clothing when the absorbent article  10  is worn. 
     The absorbent article  10  has two centerlines, a longitudinal centerline  22  (FIG. 1) and a transverse centerline  24  (FIG.  1 ). Absorbent article  10  has two spaced apart longitudinal edges  26  and two spaced apart transverse or end edges, i.e., ends  28 , which together form the periphery  30  of the absorbent article  10 . 
     The individual components of the absorbent article  10  will now be looked at in greater detail. Topsheet  12  is compliant, soft-feeling and non-irritating to the wearer&#39;s skin. Further, topsheet  12  is liquid permeable, permitting liquids to readily penetrate through its thickness. The topsheet  12  has a body-facing side  33  (FIG. 2) and a garment-facing side  34  (FIG.  2 ), two longitudinal or side edges  36  and two end edges  38  (FIG.  1 ). Absorbent core  16  has a top or body facing side  17 . Throughout the remainder of this application, similar components will share the same numbers for all embodiments of the invention, e.g., “topsheet” will be designated by the numeral  12  in each embodiment. 
     Topsheet  12  is preferably made of a nonwoven material or of a vacuum formed film layer. Topsheet  12  may be bonded to acquisition distribution layer  15  (FIG.  2 ), although in the preferred embodiment, topsheet  12  is not bonded to but instead lays in contact with acquisition distribution layer  15 . The absorbent article of FIG. 3 utilizes a three dimensional apertured plastic film  44  as an anti-rewet (or anti-wicking) layer. Three dimensional apertured plastic film  44  has a body facing side or female side  46  and a garment facing side or male side  48 . The garment-facing side  34  of the topsheet  12  is preferably maintained in close contact with the female side  46  of the apertured plastic film  44 . The topsheet  12  and acquisition distribution layer  15  are examined in greater detail below. 
     The topsheet  12  may be any nonwoven fabric that is permeable to liquids. A suitable nonwoven fabric may be manufactured from a various materials including natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester, polypropylene) or a combination thereof. The topsheet  12  is preferably made from fibers selected from a group consisting of polypropylene, polyester, polyethylene, polyvinylalcohol, starch base resins, polyurethanes, cellulose and cellulose esters. 
     Various manufacturing techniques may be used to manufacture nonwoven fabric for use in topsheet  12 . For example, the nonwoven fabric may be resin-bonded, needle punched, spunbonded, or carded. Carded nonwoven fabrics may be thermally bonded, air-thru bonded, and spunlaced fabrics. A preferred nonwoven fabric is a thermally bonded polypropylene fabric. 
     A typical topsheet  12  is a non-woven fabric having a pattern of thermal bond sites. One example of a nonwoven fabric has a carded thermally dot bonded polypropylene web. The thermal bonds of such a fabric are typically rectangularly-shaped in plan view. The bonds are typically arranged in staggered rows. Another typical nonwoven is a spunbonded polypropylene web with similarly arranged thermal bonds. Still another typical nonwoven fabric is a carded polypropylene web that is embossed in accordance with the method taught in U.S. Pat. No. 4,781,710 issued to Megison, et al. This nonwoven fabric has embossed and thermal bonded areas that are diamond-shaped in plan view. The diamond-shaped bonds are spaced apart and arranged in a diamond-shaped grid such as is shown in FIGS. 1 and 2 of the Megison, et al. patent. Typically, the embossing does not extend to the underlying core, however. 
     Preferably, acquisition distribution layer  15  is a perforated thermoplastic film with tapered capillaries which has a run off percent of less than about 10 percent and which has an increased liquid flow rate through the tapered capillaries. The method of making such a film includes a two-fold surface treatment, which is taught by U.S. Pat. Nos. 4,535,020 and 4,456,570 to Thomas et al. entitled, “Perforated Film” and “Treatment of Perforated Film”, respectively. U.S. Pat. Nos. 4,535,020 and 4,456,570 are incorporated herein by reference. The method teaches that one surface treatment is provided by adding an internal chemical additive, namely a surfactant, to a film forming polyolefin resin. The additive is compounded or otherwise mixed or blended with the resin prior to the film being formed from the resin. After the film is formed the other surface treatment is accomplished by treating the film with a corona discharge treatment which acts on the chemical additive to provide the perforated film with a zero or near zero percent run off. 
     The surfactant provides a film surface which has greater polarizability than the polyolefin film would have without the surfactant being added. Higher surface polarity yields higher wettability. Although the chemically treated film is more polar than untreated film, corona discharge treatment of the film itself provides the desired maximum wettability. Any surfactant which achieves this polarity and which migrates to the surface of the film may be used in this invention. 
     Referring now to FIG. 3, the apertured plastic film  44  is typically located between the topsheet  12  and the absorbent core  16 . As shown in FIG. 3, the apertured plastic film  44  is a three-dimensional structure having a plurality of tapered capillaries  50 , each of which has abase opening  52 , and an apex opening  54 . The apex of the openings  54  are in intimate contact with the absorbent core  16 . Additionally, most of the surface area of male side  48  of film  44  is in contact with core  16 . 
     The apertured plastic film  44  is typically manufactured from a liquid impervious, thermoplastic material. One suitable material is a low density polyethylene film having a thickness of from 0.001 to 0.002 inches (0.0025 to 0.0051 cm.). The thermoplastic material for use in the manufacture of a typical apertured plastic film  44  is selected from a group consisting generally of polyethylene, polypropylene, polyvinyl chloride, starch base resins, polyvinylalcohol, polyurethanes, polycaprolactone and cellulose esters, or combinations thereof. 
     In one typical embodiment, the thermoplastic material is provided with a multiplicity of tapered capillaries  50  in a manner, size, configuration, and orientation set forth in U.S. Pat. No. 3,939,135 issued to Thompson on Dec. 30, 1975. Other typical apertured plastic films are disclosed in U.S. Pat. No. 4,324,246, issued to Mullane, et al. on Apr. 13, 1982, U.S. Pat. No. 4,342,314, issued to Radel, et al. on Aug. 3, 1982, and U.S. Pat. No.4,463,045, issued to Ahr, et al. on Jul. 31, 1984. The apertured plastic film  44  can also consist of other types of apertured plastic films that are not thermoplastic. The type of film used depends on the type of processing that the film and nonwoven components are subjected to during the manufacture of the topsheet  12 . Thermoplastic films are typically used when the topsheet  12  and the acquisition distribution layer  15  or film  44  are integrally formed into a composite structure by melting. Other types of apertured films include, but are not limited to hydro-formed films. Hydro-formed films are described in at least some of the following U.S. Pat. Nos.: 4,609,518, 4,629,643, 4,695,422, 4,772,444, 4,778,644, and 4,839,216 issued to Curro, et al., and U.S. Pat. No. 4,637,819 issued to Ouellette, et al. 
     Typically, the nonwoven fabric of topsheet  12  and the apertured plastic film  44  are placed into a face-to-face relationship. The two components may be secured or unsecured. The two components, if secured, may be secured to each other by various methods. Typical methods for securing the nonwoven fabric and the apertured film  44  include, but are not limited to adhesives, fusion including heat bonding and/or pressure bonding, ultrasonics, and dynamic mechanical bonding. 
     The adhesives can be applied in a uniform continuous layer, a patterned layer, or an array of separate lines, spirals, beads, or spots of adhesive. The adhesive attachment typically comprises an open pattern network of filaments of adhesive such as is disclosed in U.S. Pat. No. 4,573,986 issued to Minetola, et al. on Mar. 4, 1986, or an open pattern network of filaments having several lines of adhesive filaments swirled into a spiral pattern as illustrated by the apparatus and method shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Zieker, et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. Another method of heat/pressure bonding that could be used is described in U.S. Pat. No. 4,854,984 issued to Ball, et al. on Aug. 8, 1989. 
     The nonwoven, fabric of topsheet  12  and the apertured plastic film  44  may alternatively be indirectly secured. For example, the nonwoven fabric and the apertured film  44  could be secured to or through a thin layer of airfelt, or a layer-of-hydrophobic material positioned between the nonwoven fabric and the apertured plastic film  44 . Typically, such additional layer or layers are treated with a surfactant as described in greater detail below. 
     The nonwoven fabric of topsheet  12  and the apertured plastic film  44  can alternatively be integrally formed into a composite structure, as taught by Merz et al. in U.S. Pat. No. 4,995,930. The terms “composite”, “composite structure” or “combination”, as used herein, refer to relationships in which portions of the nonwoven fabric extend into the film  44 , and vice versa so that they are integrally attached. 
     Referring now to FIGS. 4 and 5, a first embodiment of an improved absorbent article of the applicant&#39;s invention utilizes an acquisition distribution layer  42  made of a three dimensional apertured film  56  imparted with a hexagonal pattern. Although a hexagonal pattern is used for purposes of illustration, it should be understood that other patterns may also be used for any of the films described herein. Examples of other patterns include circular, oval, elliptical, polygonal, or other suitable patterns or combinations of patterns. The hexagonal pattern forms a plurality of adjacent hexagons or cells  58 . In the preferred embodiment, the hexagonal pattern is based on a 8.75 mesh wherein “mesh” is the number of cells  58  aligned in a one-inch length. Although a mesh count of 8.75 is preferred, a mesh count of from 2 to 25 or more preferably from 4 to 15 may be used. Preferably, each cell  58  is provided with an aperture  60  that has a large hole diameter, e.g., 59 mils, which are large enough to allow insult fluids to be acquired through the three dimensional apertured film  56  as rapidly as the fluids are delivered. 
     Referring in particular to FIG. 5, which shows an enlarged cross sectional view of film  56  taken along line  5 — 5  of FIG. 4, three dimensional apertured film  56  has a body facing side or female side  62  and a garment facing side or male side  64 . The garment-facing side  34  of the topsheet  12  is preferably maintained in close contact with the female side  62  of the apertured plastic film  56 . Preferably topsheet  12  maintains in contact with film  56  but is unbonded to film  56 . 
     As can be seen in FIG. 5, the film  56  is located between a topsheet  12  and an absorbent core  16 . The apertured plastic film  56  is a three-dimensional structure having a plurality of capillaries  66 , each of which has a base opening  68  and an apex opening  70 . The apex openings  70  of the capillaries  66  are in intimate contact with the absorbent core  16 , and preferably apex openings  70  are affixed to core  16  to insure this intimate contact. It should also be noted that essentially only the apex openings  70  of the capillaries  66  are in intimate contact with the core  16 , thereby assuring that the void spaces  74  providing for lateral spillage remain substantially unencumbered. A land area  72  is formed between adjacent apertures  60  on the female side  62  of the apertured plastic film  56 . A void volume space  74  (FIG. 5) is formed on the male side  64  of the apertured plastic film  56  that provides a fluid passageway between each of the cells  58 . Preferably, the ratio of void volume space  74  versus apex opening space  70  is 2:1. The three dimensional apertured film  56  has a loft  75 , i.e. the distance between the surface on the female side  62  and the planar surface on the male side  64 , of from 0.031″ to 0.125″, more preferably 0.045″ to 0.100″, and most preferably of 0.050″. The thermoplastic material used in the film  56  preferably has a density in the range of from about 0.919 g/cc to 0.960 g/cc, with the more preferred range of densities being from about 0.930 g/cc to 0.950 g/cc. The general melt indices range for a typical material is preferably from about 0.10 to about 8.50, with the more preferred range typically being from about 1.5 to about 4.5. 
     Referring now to FIGS. 6 and 7, a second embodiment of an improved absorbent article of the applicant&#39;s invention utilizes an acquisition distribution layer  15  made of a three dimensional apertured film  76  imparted with a hexagonal pattern. Although a hexagonal pattern is discussed herein, it should be understood that other patterns may also be used. Examples of other patterns include circular, oval, elliptical, polygonal, or other suitable patterns or combinations of patterns. The hexagonal pattern forms a plurality of adjacent hexagons or cells  78 . In the preferred embodiment, each cell  78  is {fraction (1/32)}″ to ½″ as measured from the flat to flat portion of the hexagon making up each cell  78  of the hexagonal pattern. More preferably, cells  78  of {fraction (1/16)}″ to ⅕″ are used. Still more preferably, cells  78  measuring ⅛″ across are used. 
     Referring more particularly to FIG. 7, which shows an enlarged cross sectional view of film  76  taken along line  7 — 7  of FIG. 6, three dimensional apertured film  76  has a body facing side or female side  82  and a garment facing side or male side  84 . The garment-facing side  34  of the top layer  12  is preferably maintained in close contact with the female side  82  of the apertured plastic film  76 . Preferably, top layer  12  maintains contact with but is unbonded to film  76 . 
     As can be seen in FIG. 7, the film  76  is located between a top layer  12  and an absorbent core  16 . The apertured plastic film  76  is a three-dimensional structure having a plurality of large openings or buckets  86 , each of which has a base opening  88  and an apex opening  90 . The apex openings  90  of buckets  86  are in intimate contact with the absorbent core  16 , and preferably apex opening  90  is affixed to core  16  to insure this intimate contact. A land area  92  is formed between adjacent apertures  80  on the female side  82  of the apertured plastic film  76 . In the honeycomb embodiment, land area  92  is preferably relatively narrow. The three dimensional apertured film  76  has a loft  94  (FIG.  7 ), i.e. the distance between the surface on the female side  82  and the planar surface on the male side  84 , of greater than 30 mils. In the preferred embodiment, the loft  94  is 50 mils. 
     Referring now to FIGS. 8 and 9, a third embodiment of an improved absorbent article of the applicant&#39;s invention utilizes an acquisition distribution layer  15  made of a three dimensional apertured film  96  imparted with a hexagonal pattern. Although a hexagonal pattern is discussed for purposes of illustration, it should be understood that other patterns may also be used for any of the films discussed herein. Examples of other patterns include circular, oval, elliptical, polygonal, or other suitable patterns. The hexagonal pattern forms a plurality of adjacent hexagons or cells  98 . In the preferred embodiment, the hexagonal pattern is based on a 8.75 mesh wherein “mesh” is the number of cells  98  aligned in a one-inch length. Although a mesh count of 8.75 is preferred, a mesh count of from 2 to 25 or more preferably from 4 to 15 may be used. Preferably, each cell  98  is provided with apertures  100  that have large hole diameters, e.g., 59 mils. A plurality of raised ridges  101  are formed on the three dimensional apertured film  96 . The raised ridges  101  preferably run longitudinally or parallel to longitudinal centerline  22  (FIG. 1) of the absorbent article  10 . 
     Referring in particular to FIG. 9, which shows an enlarged cross sectional view of film  96  taken along line  9 — 9  of FIG. 8, three dimensional apertured film  96  has a body facing side or female side  102  and a garment facing side or male side  104 . The garment-facing side  34  of the topsheet  12  is preferably maintained in close contact with the female side  102  of the apertured plastic film  96 . Preferably, top layer  12  maintains contact with but is unbonded to film  96 . The thermoplastic material used in the film  76  preferably has a density in the range of from about 0.919 g/cc to 0.960 g/cc, with the more preferred range of densities being from about 0.930 g/cc to 0.950 g/cc. The general melt indices range for a typical material is preferably from about 0.10 to about 8.50, with the more preferred range typically being from about 1.5 to about 4.5. 
     As can be seen in FIG. 9, the film  96  is located between topsheet  12  and an absorbent core  16 . The apertured plastic film  96  is a three-dimensional structure having a plurality of capillaries  106 , each of which has a base opening  108  and an apex opening  110 . The apex openings  110  of capillaries  106  are in intimate contact with the absorbent core  16 , and preferably apex openings  110  are affixed to core  16  to insure this intimate contact. It should also be noted that essentially only the apex openings  110  of capillaries  106  are in intimate contact with the core  16 , thereby assuring that the void spaces  114 - 116  providing for lateral spillage remain substantially unencumbered. A land area  112  is formed between adjacent apertures  100  on the female side  102  of the apertured plastic film  96 . A void volume space  114  is formed on the male side  104  of the apertured plastic film  96  that provides a fluid passageway between each of the cells  98 . A channel  115  (FIG. 9) is formed on the male side  104  of each raised ridge  101 . An enlarged void volume space  116  is formed when the channel  115  communicates with the void volume space  114  of the apertured plastic film  96 . The three dimensional apertured film  96  has a loft  118  (FIG.  9 ), i.e. the distance between the surface on the raised ridges  101  on female side  102  and the planar surface of the male side  104 , in the range of 0.065, i.e., the raised ridge  101  preferably adds 0.015″ to the preferred loft of 0.050″ for film  96 . Although 0.050″ is the most preferred loft, a loft of from 0.031″ to 0.125″ and more preferably 0.045″ to 0.100″ may be used. Raised ridges  101  may be formed by affixing a wire around the circumference of a vacuum forming screen or by forming an elongated protrusion upon a vacuum formed screen and passing a film over the screen in a manner known in the art. The thermoplastic material used in the film  96  preferably has a density in the range of from about 0.919 g/cc to 0.960 g/cc, with the more preferred range of densities being from about 0.930 g/cc to 0.950 g/cc. The general melt indices range for a typical material is preferably from about 0.10 to about 8.50, with the more preferred range typically being from about 1.5 to about 4.5. 
     A disposable diaper  120  utilizing a section of three dimensional apertured film  96  having raised ridges  101  is shown in FIG.  10 . Disposable diaper  120  has a longitudinal centerline  122  and a transverse centerline  124 . It should be understood that disposable diaper  120  is shown here as an example only, and the invention described herein should not be construed to be limited to disposable diapers but may also include incontinent articles, sanitary napkins, pantiliners or other absorbent articles. 
     Referring now to FIG. 11, a fourth embodiment of an improved absorbent article of the applicant&#39;s invention utilizes an acquisition distribution layer  15  made of three dimensional apertured film  56  (FIGS. 4 and 5) and three dimensional apertured film  96  (FIGS.  8  and  9 ), which shall be referred to as multi-layer apertured film  126 . Three dimensional apertured film  56  forms the body facing sublayer  128  of multi-layer apertured film  126 . Three dimensional apertured film  96  forms the garment facing sublayer  130  of multi-layer apertured film  126 . The garment-facing side  34  of the topsheet  12  is preferably maintained in close contact with the female side  62  of the apertured plastic film  56  that forms the body facing sublayer  128 . Preferably, top layer  12  maintains contact with but is unbonded to sublayer  128 . 
     As can be seen in FIG. 11, the multi-layer apertured film  126  is located between a topsheet  12  and an absorbent core  16 . The multi-layer apertured film  126  is a three-dimensional structure that allows fluids to pass therethrough. The three dimensional apertured film  56  that forms the body facing sublayer  128  is in contact with raised ridges  101  that are formed on the sublayer  130 . The apex openings  110  of the three dimensional apertured film  96  that forms the garment facing sublayer  130  are preferably in intimate contact with the absorbent core  16 . The void volume space  114  and channel  115 , which form the enlarged void volume space  116 , of the apertured plastic film  96  that forms the garment facing sublayer  130  is complimented by the additional void volume space  74  of three dimensional apertured film  56  that forms the body facing sublayer  128 . A further enlarged void volume space  136  is formed by the space between the sublayers  128  and  130  as a result of the height of channels  101 . The multi-layer apertured film  126  has a loft  138 , i.e. the distance between the female side  62  of the three dimensional apertured film  56  that forms the body facing sublayer  128  and the planar surface of the male side  104 , of three dimensional apertured film  96 . The preferred loft  138  for the multi-layer apertured film  126  is 0.90″, which is the sum of a preferred loft of 50 mils for film  96 , 15 mils for raised ridges  101  and 25 mils for top layer  12 . Sublayers  128  and  130  of multi-layer film  126  are preferably bonded together in a manner taught by U.S. Pat. No. 5,635,275 to Biagioli, et al., entitled, “Lamination of non-apertured three-dimensional films to apertured three-dimensional films and articles produced therefrom”. U.S. Pat. No. 5,635,275 is hereby incorporated by reference. However, the multi-layer film  126  is preferably unbonded to topsheet  12 . 
     Referring now to FIG. 12, a fifth embodiment of an improved absorbent article of the applicant&#39;s invention utilizes an acquisition distribution layer  15  made of three dimensional apertured film  56  (FIGS. 4 and 5) and three dimensional apertured film  76  (FIGS.  6  and  7 ), which shall be referred to as multi-layer apertured film  146 . Three dimensional apertured film  56  forms the body facing sublayer  148  of multi-layer apertured film  146 . Three dimensional apertured film  76  forms the garment facing sublayer  150  of multi-layer apertured film  146 . The garment-facing side  34  of the topsheet  12  is preferably maintained in close contact with the female side  62  of the apertured plastic film  56  that forms the body facing sublayer  148 . Preferably, top layer  12  maintains contact with but is unbonded to sublayer  148 . 
     As can be seen in FIG. 12, the multi-layer apertured film  146  is located between a topsheet  12  and an absorbent core  16 . However, it is contemplated that multi-layer apertured film  146  could also function without topsheet  12 . The multi-layer apertured film  146  is a three-dimensional structure that allows fluids to pass therethrough. The three dimensional apertured film  56  that forms the body facing sublayer  148  is in contact with land area  92  of three dimensional apertured film  76  that forms the sublayer  150 . The body facing sublayer  148  separates the topsheet  12  from unabsorbed fluids that spill over from bucket  86  to an adjacent bucket  86 . The void volume space  74  of body facing sublayer  148  and the buckets  86  of garment facing sublayer  150  form a further enlarged void volume space  156 . The multi-layer apertured film  146  has a loft  158 , i.e. the distance between the female side  62  of the three dimensional apertured film  56  that forms the body facing sublayer  148  and the planar surface of the male side  84 , of three dimensional apertured film  76 . The preferred loft  158  for the multi-layer apertured film  146  is 70 mils, i.e., 50 mils for the garment facing sublayer  150  and 20 mils for the body facing sublayer  148 . Sublayers  148  and  150  of multi-layer film  146  are preferably bonded together in a manner taught by U.S. Pat. No. 5,635,275 to Biagioli, et al., which is hereby incorporated by reference. However, the multi-layer film  146  is preferably unbonded to topsheet  12 . The composite multi-layer apertured films  126  and  146  may be constructed in accordance with the teachings of U.S. Pat. No. 5,635,275 to Biagioli, et al., which is hereby incorporated by reference. 
     Referring now to FIG. 13, a sixth embodiment of an improved absorbent article of the applicants&#39; invention utilizes an acquisition distribution layer  242  made of a three dimensional apertured film  256  imparted with a hexagonal pattern. Although a hexagonal pattern is used for purposes of illustration, it should be understood that other patterns may also be used for any of the films described herein. Examples of other patterns include circular, oval, elliptical, polygonal or other suitable patterns or combinations of patterns. The hexagonal pattern forms a plurality of adjacent hexagons or cells  258 . In the preferred embodiment, the hexagonal pattern is based on a 8.75 mesh wherein “mesh” is the number of cells  258  aligned in a one inch length. Although a mesh count of 8.75 is preferred, a mesh count from 2 to 25 and more preferably from 4 to 15 may be used. Preferably, each cell  258  is provided with an aperture  260  that has a large hole diameter, e.g., 59 mils, which is large enough to allow insult fluids to be acquired through the three dimensional apertured film  256  as rapidly as the fluids are delivered. This embodiment provides channels  278 . Channels  278  provide a path way for fluid flow and direct fluid flow in preferred directions. 
     Referring now particularly to FIG. 14, which shows an enlarged cross sectional view of film  256  taken along line  14 — 14  of FIG. 13, a three dimensional apertured film  256  has a body facing (female) side  262  and a garment facing (male) side  264 . The garment facing side  234  of the top sheet  12  is preferably maintained in close contact with the female side  262  of the apertured plastic film  256 . Preferably top sheet  12  maintains contact with film  256 , but is unbonded to film  256 . 
     As can be seen in FIG. 14, the film  256  is located between a top sheet  12  and an absorbent core  16 . The apertured plastic film  256  is a three dimensional structure having a plurality of capillaries  266 , each of which has a base opening  268  and an apex opening  270 . The apex openings  270  of the capillaries  266  are in intimate contact with the absorbent core  16  and preferably apex openings  270  are affixed to core  16  to ensure this intimate contact. It should also be noted that essentially only the apex opening  270  of the capillaries  266  are in intimate contact with the core  16 , thereby assuring that the void space  274 , which provides for lateral spillage, remains substantially unencumbered. A land area  272  is formed between adjacent apertures  260  on the female side  262  of the apertured plastic film  256 . A void volume space  274  (FIG. 14) is formed on the male side  264  of the apertured plastic film  256  that provides a fluid passageway between each of the cells  258 . Preferably, the ratio of void volume space  274  versus apex opening space  270  is 2:1. The three dimensional apertured film  256  has a loft  275 , i.e., the distance between the surface on the female side  262  and the planar surface on the male side  264 , from 0.031″ to 0.125″, more preferably 0.045″ to 0.100″, and most preferably of 0.050″. The channels  278  are preferably about ⅓ of the total loft  275  of the acquisition distribution layer (ADL). Channel depths of ⅛ of the total loft  275  will show some effect, as well. In a preferred embodiment, a 50 mil ADL loft, 8.75 hex material has a nominal channel depth of 15 mils. The channels  278  are preferably spaced about ¼ inch apart on centers and are approximately {fraction (1/16)} inches wide. Spacing as tight as ⅛ inch apart can be utilized, and channel widths from {fraction (1/32)} inch to ¼ inch can be applied. 
     The thermoplastic material used in the film  256  preferably has a density in the range from 0.919 g/cc to 0.960 g/cc, with a more preferred range of densities being from about 0.930 g/cc to 0.950 g/cc. The general melt indices range for a typical material is preferably from about 0.10 to about 8.50, with the more preferred range typically being from about 1.5 to about 4.5. 
     The preferred method of preparing channeled films is to position a forming cylinder on a lathe. The cylinder is then rotated and channels are ground into the screen&#39;s outer diameter to desired depths. It is also preferred, but not essential, to provide the cylinder with an internal mandrel for maintaining True Indicated Runout (TIR). This will minimize the difficulty of grinding the channels to a consistent depth around the circumference of the cylinder. The practical depth limit of a channel is ½ the loft. This limitation is realized because of the forming screen&#39;s limitation of being machined in order to provide the forming pattern for channels. If you cut more than half the depth of the forming cylinder, you will weaken it beyond its economical use potential. 
     Referring now to FIGS. 15 and 16, a seventh embodiment of an improved absorbent article of the Applicants&#39; invention utilizes an acquisition distribution layer  315  made of a three dimensional apertured film  376  imparted with a hexagonal pattern. Although a hexagonal pattern is discussed herein, it should be understood that other patterns may be used. Examples of other patterns include circular, oval, elliptical, polygonal, or other suitable patterns or combinations of patterns. The hexagonal pattern forms a plurality of adjacent hexagons with cells  378 . In a preferred embodiment, each cell  378  is {fraction (1/32)} inch to ½ inch as measured from the flat to flat portion of the hexagon making of each cell  378  of the hexagonal pattern. More preferably, cells  378  of {fraction (1/16)} inch to ⅕ inch are used. Still more preferably cells  378  measuring ⅛ inch across are used. 
     Referring more particularly to FIG. 16, which shows an enlarged cross sectional view of the film  376  taken along line  16 — 16  of FIG. 15, three dimensional apertured film  376  has a body facing (female) side  382  and garment facing (male) side  384 . The garment side  34  of the top layer  12  is preferably maintained in close contact with the female side  382  of the apertured plastic film  376 . Preferably, top layer  12  maintains contact with, but is unbonded, to film  376 . 
     As can be seen in FIG. 16, the film  376  is located between a top layer  12  and an absorbent core  16 . The apertured plastic film  376  is a three dimensional structure having a plurality of large openings or buckets  386 , each of which has a base opening  388  and an apex opening  390 . The apex opening  390  of a bucket  386  is in intimate contact with the absorbent core  16 , and preferably apex opening  390  is affixed to core  16  to ensure this intimate contact. A land area  392  is formed between adjacent apertures  380  on the female side  382  of the apertured plastic film  376 . In the honeycomb embodiment, land area  392  is preferably relatively narrow. The three dimensional apertured film  376  has a loft  394  (FIG.  16 ), i.e., the distance between the surface on the female side  382  and the planer surface on the male side  384 , of greater than 30 mil). In the preferred embodiment, the loft  394  is 50 mils. Channels  396  are cut below the plane of the female side  382 . Channels  396  provide a spill over space for fluid flow and directs the fluid in preferred directions. The preferred depth of channels  396  is ⅓ the total loft of the ADL. Channel depths of ⅛ of the total loft  394  will show some effect, as well. 
     In practice, the three dimensional apertured films  56 ,  76 ,  96  and multi-layer apertured films  126  and  146  may be used as an acquisition distribution layer  15  in an absorbent article  10 . Absorbent article  10  is used for applications where fluid absorption is desirable. In use, body exudates, such as an urine insults from male or female babies or adults, are deposited on the absorbent article  10 . The urine insults are typically delivered in a generally singular point of fluid flow. Upon repeated insults, an undesirable leakage or undesirable feeling of wetness by the user may occur due to the core material  16  becoming saturated in the repeat insult region. In other words, the absorbent core  16  may experience an inability to absorb repeated insults in a particular region. As a result, additional fluid insults that are delivered to the absorbent article  10  may be unabsorbed by the core  16  and remain on the top or body facing side  17  of the core layer  16 . Applicant&#39;s invention provides a method for the unabsorbed fluid from the core layer  16  to be directed to unsaturated zones of the core layer  16 . Narrow land areas  92  on the female side  82  of film  76  preferably have a small enough surface area such that fluid contained thereon is insufficient in amount to provide a wetness sensation to the user when portions of the topsheet  12  are momentarily wetted by the spill over of unabsorbed fluid from one bucket  86  to an adjacent bucket  86 . When unabsorbed fluid contacts topsheet  12  an unpleasant feeling of wetness of topsheet  12  occurs. A wet topsheet  12  results in uncomfortable fluid contact with the skin of a wearer. 
     For example, when three dimensional apertured film  56  (FIGS. 4 and 5) is used in absorbent article  10  (FIG.  1 ), fluid that is not absorbed or that spills-over from core layer  16  is able to flow within void volume space  74  to an unsaturated area of core  16 . The void volume space  74  on the male side  64  (FIG. 5) of adjacent cells  58  (FIG. 4) are interconnected to allow a high volume of fluid to pass to unsaturated regions of core  16 . The plurality of adjacent hexagons form a large under-side void volume space that provides space for fluid that spills over the top plane or body facing side  17  of saturated core regions  16  and find new, unsaturated regions. The unabsorbed fluid that results from repeated insults may then flow from a saturated zone of absorbent core material  16  and be redirected through the under-side void volume space  74  to an unsaturated zone of the absorbent core material  16 . Without the void volume space  74  of the three dimensional apertured film  56 , the topsheet  12 , which is contact with the skin, will become wet as the insult fluid seeks new regions to be absorbed. The male side void volume area  74  is a much greater total void volume area than previously known anti-rewet or anti-wicking layers. 
     As another example, when three dimensional apertured film  76  (FIGS. 6 and 7) is used in absorbent article  10  (FIG.  1 ), insult fluid that is delivered to an area after core material  16  in the area has been saturated pools within buckets  86 . When a bucket  86  at the insult point becomes full, buckets  86  adjacent to the insult point are filled as the fluid within full bucket  86  spills over. This process is repeated as spill-over occurs between adjacent buckets  86  to accommodate the full insult fluid volume. Eventually, the spill-over from buckets  86  flows into a bucket  86  that is located proximate an area of unsaturated core material  16  and the fluid is absorbed. Since the spill over of unabsorbed fluid from a bucket  86  to adjacent buckets  86  disperses the unabsorbed liquid over a larger area of core material  16  where the fluid may be absorbed, an undesirable wetness of the topsheet  12  may be avoided. The open-cell void volume areas  86 , is much more total void volume area than previously known film anti-rewet or anti-wicking layers. The preferred percentages range of land areas  92  for three dimensional apertured film  76  is 5 to 20% of the total surface area. The large patterned acquisition distribution layer material or three dimensional apertured film  76  also provides a greater measure of loft, e.g. greater than 30 mils and more preferably, 50 mils in the ⅛″ honeycomb embodiment. The greater loft  94  or thickness between the upper-most plane and lower-most plane of the of the three dimensional apertured film  64  provides a ‘wick-proof’ barrier or layer between the wetted core  16  and the skin contact area of a user. A greater loft  94  results in an improved feeling of dryness. Since the material in the topsheet  12  is only a small percent of the total occupied volume, the greater the volume, the more “air cushion” that is provided next to the skin contact region. 
     As a still further example, when three dimensional apertured film  96  (FIGS. 8 and 9) is used in absorbent article  10  (FIG.  1 ), insult fluid that is not absorbed in core layer  16  is able to flow within void volume space  114 . The void volume space  114  on the male side  104  (FIG. 9) of adjacent cells  98  (FIG. 9) are interconnected to allow a high volume of fluid to pass to unsaturated regions of core  16 . Additionally, raised ridges  101  form channels  115  to further accommodate unabsorbed fluids via enlarged void volume space  116 . A further advantage of the channels  115  is that the channels  115  direct unabsorbed fluids in a desired direction, such as in the longitudinal direction, i.e., parallel to longitudinal centerline  122  of disposable diaper  120  (FIG.  10 ). By directing the unabsorbed fluid in the longitudinal direction, the fluid may be directed to locations with greater amounts of unsaturated core material  16  as opposed to directing the fluid towards undesirable locations such as a perimeter of the diaper. The channels  115  direct fluid away from a direction that is parallel to the transverse centerline of disposable diaper  120 . The raised ridges are, therefore, effective at eliminating side leakage from disposable diaper  20 . 
     Additionally, various embodiments of acquisition distribution layer  42  may be combined into a multi-layer apertured film, such as film  126  (FIG. 11) or film  146  (FIG.  12 ). Multi-layer apertured film  126  provides a further enlarged void volume space  136  to accommodate unabsorbed fluids. The further enlarged void volume space  136  allows unabsorbed fluids to flow to regions where core material  16  is unsaturated without allowing the unabsorbed fluids to come into contact with the topsheet  12 , thereby avoiding an unpleasant feeling of wetness for the user. 
     Multi-layer apertured film  146  (FIG. 12) provides a further enlarged void volume space  156  to accommodate unabsorbed fluids. The further enlarged void volume space  156  allows unabsorbed fluids to spill over lands  92  from buckets  86  to adjacent buckets  86  where core material  16  is unsaturated. Body facing sublayer  148 , i.e. film  56 , substantially prevents unabsorbed fluids from contacting the topsheet  12  when unabsorbed fluids spill over land  92  from a bucket  86  of garment facing sublayer  150 , i.e. film  76 , to adjacent buckets, thereby further reducing the unpleasant feeling of wetness for the user. 
     As a further example, when three dimensional channeled apertured film  256  (FIGS. 13 and 14) is used in absorbent article  10  (FIG.  1 ), insult fluid that is not absorbed when it spills over from core layer  16  is able to flow within void volume space  274  to an unsaturated area of core  16 . The void volume space  274  on the male side  264  (FIG. 14) of adjacent cells  158  (FIG. 13) are interconnected to allow a high volume of fluid to pass to unsaturated regions of core  16 . The plurality of adjacent hexagons form a large under side void volume space that provides space for fluid that spills over the top plane or body facing side  17  of saturated core region  16  to find new unsaturated regions. Additionally, the channels  278 , which are cut below the top plane of the apertured film  256  provide a void space for facilitating increased fluid flow and to direct the fluid in preferred directions. The unabsorbed fluid that results from repeated insults may then flow from a saturated zone of absorbent core material  16  and be redirected through the under side void volume space  274  to an unsaturated zone of the absorbent core material  16 . Additionally, without the void volume space  274  of the three dimensional apertured film  256 , the top sheet  12  which is in contact with the skin, will become wet as the insult fluid seeks new regions to be absorbed. The male side void volume area  274  has a much greater total void volume area than previously known in anti-rewet or anti-wicking layers. Further, the addition of channels  278  add a significant spill over value. In the preferred embodiment, a 50 mil ADL loft, 8.75 hex material has a nominal channel depth of 15 mils. Channels are spaced about ¼ inch apart on the centers and are approximately {fraction (1/16)} inch wide. Spacing as tight as ⅛ inch apart can be utilized, and channel widths from {fraction (1/32)} inch to ¼ inch can be applied. 
     As a still further example, when three dimensional apertured film  176  (FIGS. 15 and 16) is used in absorbent article  10  (FIG.  1 ), insult fluid that is delivered to an area after core material  16  in the area has been saturated pools within buckets  386 . When a bucket  386  at the insult point becomes full, buckets  386  adjacent to the insult point are filled as the fluid within full buckets  386  spills over. This process is repeated as spill over occurs between adjacent buckets  386  to accommodate the full insult fluid volume. Eventually the spill over from adjacent buckets  386  flows into a bucket  386  that is located approximate an area of unsaturated core material  16  and the fluid is absorbed. Since the spill over of unabsorbed fluid from a bucket  386  to adjacent buckets  386  disperses the unabsorbed liquid over a larger area of core material  16  where the fluid may be absorbed, an undesirable wetness of the top sheet  12  maybe avoided. The open cell void volume areas  386  is much more total void volume area than previously known film anti-rewet or anti-wicking layers. Further, the addition of channels  396  provides a preferred directional pathway for spill over into the next bucket  386 , as well as an increased volumetric pathways to spill and redistribute the fluid. Preferably, channels  396  are spaced ¼ inch apart on centers and are approximately {fraction (1/16)} inch wide. Spacing as tight as ⅛ inch apart can be utilized and channel widths from {fraction (1/32)} inch to ¼ inch can be applied. The preferred percentages range for land areas  382  for three dimensional apertured film  376  is 5 to 20% of the total surface area. The large patterned acquisition distribution layer material of three dimensional apertured film  376  also provides a greater measure of loft, e.g., greater than 30 mils and more preferably, 50 mils in the ⅛ inch honeycomb embodiment. The greater loft  394  or thickness between the uppermost plane and lowermost plane of the three dimensional apertured film  364  provides a “wick proof” barrier or layer between the wetting core  16  and the skin contact area of a user. A greater loft  394  results in an improved feeling of dryness. Since the material on the top sheet  12  is only a small percentage of the total occupied volume, the greater the volume, the more “air cushion” that is provided next to the skin contact region. 
     The use of three dimensional apertured films  56 ,  76 ,  96 , and multi-layer apertured films  126  and  146  increase the loft of the acquisition distribution layer  15  of the absorbent article  10 . The greater loft  75 ,  94 ,  118 ,  138  and  158  or thickness between the upper-most plane and lower-most plane of the of the three dimensional apertured films  56 ,  76 ,  96 , and multi-layer apertured films  126  and  146  provides a ‘wick-proof’ barrier or layer between the wetted core  16  and the skin contact area of a user. A greater loft  75 ,  94 ,  118 ,  138  and  158  results in an improved feeling of dryness. Since the material in the topsheet  12  is only a small percent of the total occupied volume, the greater the volume, the more “air cushion” that is provided next to the skin contact region. 
     The large female side void volume of the “spill-over” embodiments facilitates dispersion of unabsorbed fluids. Preferably, for a square meter of film, the female side void volume is greater than 500 cm 3 , more preferably greater than 750 cm 3 , and most preferably greater than 1000 cm 3 . Additionally, the large male side void volume of the “spill-under” embodiments also facilitates dispersion of unabsorbed fluids. Preferably, for a square meter of film, the male side void volume is preferably greater than 500 cm 3 , more preferably greater than 600 cm 3 , and most preferably greater than 750 cm 3 . 
     Test Data 
     Testing was performed using the Multiple Insult Acquisition method. Several methods are described in detail in an article by James P. Hanson in an article appearing in Nonwovens World, Fall 1997, page 57-63, entitled, “The Test Mess Part III—Credible Testing for Liquid Acquisition”, which is incorporated herein by reference. 
     More specifically, the applicant&#39;s test was conducted as follows. Referring now to FIG. 17, die cut samples  160  are cut from absorbent article  10  in an area where acquisition distribution layer  15  is present. The topsheet  12  and acquisition distribution layer  15  are removed from the absorbent article  10 , paying particular attention not to change the orientation of the materials. The topsheet  12  and acquisition distribution layer  15  of the core cuts or die samples  160  are then randomly weighed and the average weight and standard deviation for the weight are randomly recorded. Each die cut sample  160  is then reconstructed by adding the absorbent core  16 . 
     To perform the Acquisition Rate Performance on all three layers, a Liquid Acquisition Apparatus  162  is used. Apparatus  162  is made up of a plate  164  having an opening  166  in the center of the plate  164  for placement on top of sample  160 . A controlled volume chamber  168  extends upwardly from the plate  164  for receiving a desired fluid flow rate and dosage from a fluid supply  170 . An overflow pipe  172  extends outwardly from the controlled volume chamber  168  at a location slightly above the plate  164 . 
     Six samples were tested by the above described method wherein the fluid supply  170  pumped fluid into the controlled volume chamber  168  at a rate of 7 ml/sec. Samples 1-3 are samples having an acquisition distribution layer similar to that shown in FIG. 3 wherein the samples have varying amounts of loft or thickness as is indicated in Table 1, below. In particular, Sample 1 is a prior art film in accordance with the teachings of United States Invention Registration no. H1670, to Aziz et al. having 20 mils of loft, a pattern of round or hex cells and a 22 mesh count. Sample 2 is a prior art film in accordance with the teachings of United States Invention Registration no. H1670, to Aziz et al. having 23 mils of loft, a pattern of hex cells and a 25 mesh count. Samples 4 and 5 are examples of films embodying the invention of the application wherein Sample 3 has an acquisition distribution layer  15  with male side void volume flow area similar to that shown in FIGS. 4 and 5. Sample 4 is the embodiment of the invention shown in FIGS. 6 and 7, i.e., the “bucket” embodiment, having a ⅛″ honeycomb pattern on the acquisition distribution layer. Sample 3 has slightly lower loft (it is 49 mils vs. 51 mils) but a greater male side void volume than Sample 4. In particular, Sample 3 has a hex pattern with 50 mils loft on a 8.75 mesh count. Sample 4 has a ⅛″ honeycomb pattern with 50 mils of loft on an 8 mesh count. The results are shown in Table 1, below. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                   
                 Total Fluid 
                 Inverse 
                   
                   
               
               
                   
                 Overflow 
                 Expanded Loft 
               
               
                 Sample No. 
                 (ml) 
                 (1/mm) 
                 Loft (mm) 
                 Mesh 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 Sample 1 
                 62.71 
                 0.787402 
                 20 
                 22 
               
               
                 Sample 2 
                 59.09 
                 0.905512 
                 23 
                 25 
               
               
                 Sample 3 
                 54.15 
                 1.929134 
                 49 
                 8.75 
               
               
                 Sample 4 
                 52.65 
                 2.007874 
                 51 
                 8 
               
               
                   
               
            
           
         
       
     
     The results of the test is shown graphically in FIG.  18 . FIG. 18 is comprised of a bar graph that shows fluid overflow (ml) for each sample 1-4. Additionally, FIG. 18 is comprised of a line graph that shows the inverse of the expanded thickness or loft of each sample. Overflow is defined as fluid that flows out of overflow pipe  172  of the Liquid Acquisition Apparatus  162  when 15 mL amount of fluid is delivered at 7 ml/sec into controlled volume chamber  168 . The fluid that does not flow through overflow pipe 172 is absorbed by the sample  160 . 
     It can be seen from FIG. 18, that the greater the loft for a particular sample, the less fluid overflow that is observed for a particular sample. The films of applicant&#39;s invention, i.e. Samples 3 and 4 have a markedly greater loft than the films having the prior art design, i.e. Samples 1 and 2. Samples 3 and 4 show a markedly lower amount of fluid overflow. It should be noted that the total void volume for Samples 1 and 2 is less than 550 cc/m 2  of sample material while the total void volume for Samples 3 and 4, which illustrate embodiments of applicant&#39;s invention, is more than 1000 cc/m 2 . The preferred total void volume for applicant&#39;s invention is greater than 750 cc/m 2 , more preferably greater than 875 cc/m 2 , and most preferably greater than 1000 cc/m 2 . 
     To further illustrate the substantial increase in void volume space of the films of the invention over existing films, microphotographs of Sample 2 and Sample 4 are set forth in FIGS. 19 and 20. FIGS. 15 and 16 show Samples 2 and 4 at 50X magnification. FIG. 19 shows a plan view of samples 2 and 4. FIG. 20 shows a side cross-sectional view of samples 2 and 4. The substantial increase in void volume space is apparent from each of FIGS. 19 and 20. 
     Finally, microphotographs of known magnification and scale of dimensions were taken of each of Samples 1-4 to enable empirical calculations of void volume spaces. While the cells of the embodiments described herein are best approximated as a geometric frustum, as taught in Thompson U.S. Pat. No. 4,939,135, it is within the scope of the invention to include other cell shapes such as substantially straight walled cells, as taught in Radel U.S. Pat. No. 4,342,314, and cells which converge to a narrow point and then diverge again toward the apertured end, as taught by Rose U.S. Pat. No. 4,895,749. The resulting geometric calculation for void volume space data for Female Side void volume, Male Side void volume, and the Total Void Volumes are shown below in Table 3. 
     
       
         
           
               
               
               
               
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                   
                   
                   
                   
                 Female 
                 Male 
                 Total 
               
               
                   
                   
                   
                   
                 side 
                 side 
                 Void 
               
               
                 Sample 
                 Loft 
                   
                 Cells/m 2   
                 volume 
                 volume 
                 Volume 
               
               
                 No. 
                 (mils) 
                 Mesh 
                 of film 
                 (cc/m 2 ) 
                 (cc/m 2 ) 
                 (cc/m 2 ) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 1 
                 20 
                 22 
                 872,170 
                 189 
                 339 
                 528 
               
               
                 2 
                 23 
                 25 
                 1,090,755 
                 247 
                 236 
                 483 
               
               
                 3 
                 49 
                 8.75 
                 131,771 
                 294 
                 752 
                 1046 
               
               
                 4 
                 51 
                 8 
                 105,649 
                 1357 
                 475 
                 1832 
               
               
                   
               
            
           
         
       
     
     It can be seen from table 3 that the “spill-under” embodiment of applicant&#39;s invention, demonstrated by Sample 3 has a substantially greater male side void volume, i.e., 752 cm 3 , than do any of the other samples. The “spill-over” embodiment of applicant&#39;s invention, demonstrated by Sample 4 has a substantially greater female side volume, i.e. 1357 cm 3 , than do any of the other samples. 
     In the embodiments shown in FIGS. 13-16, which involve the utilization of channels  278 ,  396  that are cut below the original plane of the surface of the 8.75 hex (spill under) or honeycomb (spill over) patterns or other patterns not discussed above. The channels  278 , 396  provide void space or a passageway for fluid flow and direct the fluid flow in preferred directions. 
     The 8.75 hex spill under pattern, when provided with channels  278 ,  396 , provide an additional spill over volume within the channels  278 ,  396 . The combination of spill-under and channel facilitated spill-over is highly effective, as shown in Table 4 below. Note that the three dimensional apertured film taught by U.S. Pat. No. 4,324,247 to Aziz lacks void volume for facilitating a good distribution of fluid. The film  278  and  396  of this application exhibits improvement of three dimensional apertured film  56  more than a factor of 2 as compared to the high void volume of the 8.75 hex, which provides high void volume for spill-under distribution. 
     When the same pattern was given channels  278 ,  396 , the film improved by more than double again. Data for Table 4, below, was derived by introducing 5 mL per insult into a weighted chamber 1 inch in diameter by ¾ inch deep. The weight applies ½ pound per square inch pressure over 4″ by 4″ sample area of three types. The chamber has electrodes that sense the presence of liquid and then absence of liquid. When the electrodes sense the presence and absence of liquid, a timer is stopped and started. ADL material is assembled on top of three layers of absorbent paper in the same 4″ by 4″ area. The ADL preferably should avoid compression and provide void volume. The Aziz type samples have a 22 mil loft. The standard ADL is of the type described in Table 3, Sample 3. The negative channel ADL type is the standard ADL described above with the addition of channels approximately 15 mil deep, approximately ½″ wide and spaced ¼″ on centers. 
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 Repeated Insult ADL Data 
               
            
           
           
               
               
               
               
            
               
                   
                 Sample 
                 Insult # 
                 Seconds 
               
               
                   
                   
               
               
                   
                 Aziz ‘247 Type at 
                 1 
                 2.36 
               
               
                   
                 22 mil loft 
                 2 
                 3.86 
               
               
                   
                   
                 3 
                 4.26 
               
               
                   
                 Std. ADL 
                 1 
                 1.45 
               
               
                   
                 (described in Table 
                 2 
                 1.75 
               
               
                   
                 3, Sample 3) 
                 3 
                 1.80 
               
               
                   
                 Neg. Chnl. ADL 
                 1 
                 0.67 
               
               
                   
                 (standard ADL 
                 2 
                 0.80 
               
               
                   
                 described above 
                 3 
                 0.80 
               
               
                   
                 with channels 
               
               
                   
                 added) 
               
               
                   
                   
               
            
           
         
       
     
     From the above, it will be appreciated that applicant&#39;s invention will reduce or eliminate the wetness sensation felt by the user during and after repeated insults as unabsorbed fluid flows from an area of saturated core material to an area of unsaturated core material for absorption. Applicant&#39;s invention redirects unabsorbed fluids to non-saturated areas of a core material  16  while preventing substantial contact of the unabsorbed fluids with the topsheet  12 . The invention of the applicant prevents an unpleasant feeling of wetness of the topsheet  12  while providing the ability to receive multiple insults at a singular point. 
     The present invention is illustrated herein by example, and various modifications may be made by a person of ordinary skill in the art. For example, various geometries, materials and multiple-layer film combinations fall within the scope of the invention. As another example, although the present invention has been described in connection with diapers, incontinent articles, sanitary napkins, and related products, the absorbent articles of the present invention are fully applicable to other, similar products, including, without limitation, other body coverings where absorbent materials may be desired. Such body coverings may include medical drapes, medical gowns, medical smocks, ostomy appliances, feminine hygiene products, body transfer sheets, fluid collection pouches, industrial clean room garments and other products. 
     It is therefore believed that the present invention will be apparent from the foregoing description. While the methods and articles shown or described have been characterized as being preferred it should be obvious that various changes and modifications may be made therefrom without departing from the spirit and scope of the invention as defined in the following claims.