Patent Description:
Nonwoven materials are commonly used in absorptive devices, such as diapers and feminine napkins. Nonwoven materials are often used as topsheet components of such absorptive devices where it is desirable to achieve softness due to the contact of the topsheet with the skin of the wearer of the absorptive device. A ratio of high loft to total thickness of the nonwoven material often indicates softness, because the nonwoven material is compressible, which in turn renders a softness sensation to the wearer of the absorptive device that includes the nonwoven material. While relatively high loft nonwovens are perceived to be soft and cool when used against the skin, special processing is typically needed to achieve such characteristics, which may increase the cost of the product.

Fiber entanglement by injecting and withdrawing barbed needles is one known method for creating relatively high loft nonwoven materials, but the process is relatively slow and costly. A faster production method for generating high loft nonwoven materials is a spunlacing process for hydro-entanglement of loose fibers. The spunlacing process may create relatively high lofted soft nonwoven materials that are soft and cool to the touch by using high pressure water jets that are essentially in the shape and diameter of needles to hydro-entangle the fibers.

Spunlacing is a process of entangling a web of loose fibers on a porous belt or a moving perforated or patterned screen to form a sheet structure by subjecting the fibers to multiple rows of fine high-pressure jets of water. The spunlacing process uses an array of very fine high velocity water jets, essentially the diameters of needles, instead of barbed needles, to entangle the fibers in order gain web integrity while yielding a relatively high loft nonwoven material. The needle-like water jets are applied by a high pressure header, and the pressure may range from <NUM> MPa (<NUM> psi) to over <NUM> MPa (<NUM> psi). The water needle jet holes are typically about <NUM> (<NUM> inch) in diameter and a single header may include between <NUM> and <NUM> holes per inch in a row. Three to eight headers may be placed in a row that is aligned in the machine direction, and the web of untangled fibers may move in the machine direction on a perforated belt or screen-like material. A vacuum zone exists underneath the belt to extract the water. After the fibers are hydro-entangled into a web, the web may be dried and wound into a roll that can then be unwound when converted and used as a layer in an absorptive device. The spunlacing process generally does not lend itself to produce laminates with a film layer while the lofting is occurring because the high pressure and needle-like shape of the water jets may damage the film layer, and may possibly remove most or all of the film from the nonwoven layer.

Spun bonded nonwovens are less costly than spunlace nonwovens, but typically have much less loft and are often not as soft as other nonwoven materials. The spun bonded process for making a nonwoven web is known. In a so-called Reicofil system, polymer pellets are fed into an extruder that extrudes continuous fibers through a die with a plurality of small openings. The fibers are thinned or stretched and cooled as the polymer exits the die. The fibers are then spun to random positions by air currents provided by manifolds or other devices. After the fibers are spun, the fibers are randomly positioned on a moving belt made of open screen material to create a matt of spun fibers. Suction may be applied to ensure the entangled fibers lay flat in a substantially horizontal orientation and are essentially pinned on the moving screen.

The matt of entangled fibers may then be fed into a calendar roll nip, with one roll having a smooth surface and one roll having raised points in a pattern. Both rolls may be heated to a point above the melting point of the polymer in the fibers. The matt is compressed as the raised points compress the matt against the smooth roll. The heat and pressure applied to the matt creates bonded points that hold the fibers in place to create a spun bonded nonwoven web.

Nonwoven materials, whether created by spun bonded, air laid, carded, spun laced, hydro-entangled, or other processes, have a basis weight that defines the mass of the fibers contained therein (typically measured in grams) within a square area (typically measured in a square meter) so that the basis weight is measured in grams per square meter ("gsm"). In addition, all fibers have a thickness or diameter that is referred to as denier. A nonwoven material having fibers with a heavier denier and fewer fibers can have the same basis weight as a nonwoven material having fibers with a lighter, or thinner denier and many more fibers. Features such as loft (thickness), which is a distance measured from the top of the nonwoven web to the bottom of the nonwoven web, for a given mass of fibers may be manipulated by choosing a fiber denier and process technique for creating loft, while entangling or bonding the fiber web so the web will have tensile strength and web integrity. Unfortunately, the spun bonded process does not lend itself to producing higher lofted nonwovens due its tendency to have horizontal fibers.

The properties of spun bonded nonwovens may be manipulated by changing the denier and basis weight of the fibers, as well as changing the polymer(s) used to create the fibers. Some polymers are stiffer, such as polyesters, and some polymers are more flexible, such as polypropylene and polyethylene. Only recently have polyethylene polymers been created with enough draw down to be made into a fiber. Polypropylene is a common polymer used in spun bonded nonwovens and a spun bonded polypropylene nonwoven web is typically referred to as "SBPP".

It is also desirable for the fibers in the nonwovens to be used in topsheets for absorptive devices be hydrophilic. Natural cellulose fibers are hydrophilic and have historically been used in topsheets. For example, <CIT> to Mizutani, et al. teaches that relatively short hydrophilic fibers may be interspersed with longer hydrophobic fibers to form a topsheet material, and that hydrophobic synthetic fibers may be used if coated with a surfactant to make them hydrophilic. However, the surfactant will generally wash away when subjected to a large amount of liquid, thereby making the synthetic fibers hydrophobic again.

Although synthetic hydrophilic fibers such as rayon, viscose, acetate and spun nylon exist, these polymer types are generally relatively rigid and stiff, and many are difficult to extrude into thin fibers. Therefore, if such materials are used in fibers for a topsheet, the resulting topsheet would tend to be harsh and uncomfortable to the wearer of the absorptive device.

It is desirable to use less costly spun bonded nonwoven materials in absorptive devices and still deliver the softness of a typical spunlace nonwoven material.

The present invention provides a method as defined in claim <NUM>. Each of the extended cells are contemplated to include continuous sidewalls extending away from the nonwoven layer. At least one of the fibers extends into one or more of the extended cells.

In one embodiment, at least one of the extended cells includes an aperture at a distal end thereof.

In another embodiment, a portion of the at least one of the fibers extends through the aperture.

Still further, it is contemplated that the extended cells may have a mesh count of between <NUM> cells per linear <NUM> (inch) and <NUM> cells per linear <NUM> (inch).

In another embodiment, the extended cells may be micro-cells having a mesh count of between <NUM> cells per linear <NUM> (inch) and <NUM> cells per linear <NUM> (inch).

The composite material of the present invention also may include a plurality of apertures having a mesh count of less than <NUM> cells per linear <NUM> (inch).

If included, the apertures may have a mesh count of between <NUM> cells per linear <NUM> (inch) and <NUM> cells per linear <NUM> (inch).

The composite material may include a plurality of apertures extending through the composite material.

The composite material may have an embossed three-dimensional pattern.

The nonwoven layer may include a surfactant.

Alternatively, the fibers may include the surfactant.

The present invention encompasses a method for manufacturing a composite material. The method includes forming a composite precursor material with a nonwoven layer having a plurality of fibers and a polymer film layer. The method includes forming a plurality of extended cells in the polymer film layer, each of the extended cells having a continuous sidewall extending away from the nonwoven layer. The method also includes pushing at least one of the fibers into at least one of the extended cells, while forming the extended cells, with a fluid.

In accordance with the invention, when forming the composite precursor material, a nonwoven web is passed through low pressure nip rolls while a molten polymer film is simultaneously extruded into the nip to form the polymer film layer on the nonwoven web.

In another contemplated embodiment, when forming the extended cells in the polymer film layer and pushing the at least one of the fibers into the at least one of the extended cells, the polymer film layer may be contacted with a forming structure having a pattern of apertures as a plurality of pressurized liquid jets are applied onto the nonwoven layer while the composite precursor material passes over the forming structure and a vacuum slot area located beneath the forming structure.

The method also may include forming a plurality of apertures in a pattern having a mesh count of less than <NUM> cells per linear <NUM> (inch), after pushing the at least one of the fibers into the at least one of the extended cells.

It is also contemplated that the method may include aperturing the composite material.

Apertures may be formed by passing the composite material through a nip between a pin roll having a pattern of pins protruding from a surface thereof and a counter roll having a matching pattern of cavities recessed in a surface thereof while the pin roll and the counter roll rotate in opposite directions.

Still further, the method may include passing the composite material through a nip between an embossing roll having a three-dimensional pattern on an outer surface thereof and a counter roll while the embossing roll and the counter roll rotate in opposite directions to form the three-dimensional pattern in the composite material.

It is contemplated that the method also may include aperturing the composite material by contacting the composite material with a forming structure having a pattern of apertures as a plurality of pressurized liquid jets are applied onto the composite material while the composite precursor material passes over the forming structure and a vacuum slot area located beneath the forming structure.

These and other aspects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification.

As used in the specification and in the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

The components of the following figures are illustrated to emphasize the general principles of the present disclosure and are not necessarily drawn to scale. Reference characters designating corresponding components are repeated as necessary throughout the figures for the sake of consistency and clarity.

Various embodiments of the present invention will now be highlighted. The discussion of any one embodiment is not intended to limit the scope of the present invention. To the contrary, aspects of the embodiments are intended to emphasize the breadth of the invention, whether encompassed by the claims or not.

Throughout this description, the term "web" refers to a material capable of being wound into a roll. Webs can be film webs, nonwoven webs, laminate webs, apertured laminate webs, etc. The face of a web refers to one of its two dimensional surfaces, as opposed to its edge. The term "composite web" or "composite material" refers to a web that comprises two or more separate webs that are attached to each other in a face to face relationship. The attachment can be through the edges of the component webs, although the component webs lie in a face to face relationship with each other, or the attachment can be at particular spot locations across the component webs.

The term "film" in this description refers to a web made by extruding a molten sheet of thermoplastic polymeric material by a cast or blown extrusion process and then cooling said sheet to form a solid polymeric web. Films can be monolayer films, coextruded films, coated films, and composite films. Coated films are films comprising a monolayer or coextruded film that are subsequently coated (for example, extrusion coated, impression coated, printed, or the like) with a thin layer of the same or different material to which it is bonded. Composite films are films comprising more than one film where the at least two films are combined in a bonding process. Bonding processes may incorporate adhesive layers between the film layers.

Throughout this description, the expression "apertured films" denotes films in which there exist a plurality of holes that extend from one surface to a second surface. A two dimensional apertured film is a film in which no three-dimensional structure exists in the holes, which then connect the second surface of a flat film to the first surface of the film. A "formed film" is a three-dimensional film is a film with protuberances or extended cells, and a three dimensional apertured film is a film in which a three dimensional structure exists in the apertures (e.g., the apertures have a depth that is thicker than the thickness of the film) or the extended cells have apertures therethrough.

The term "nonwoven web" means a web comprising a plurality of fibers. The fibers may be bonded to each other or may be unbonded. The fibers may be staple fibers or continuous fibers. The fibers may comprise a single material or may comprise a multitude of materials, either as a combination of different fibers or as a combination of similar fibers each comprised of different materials. As used herein, "nonwoven web" is used in its generic sense to define a generally planar structure that is relatively flat, flexible and porous, and includes staple fibers or continuous filaments. The nonwoven web may be the product of any process for forming the same, such as nonwoven spunbond and melt blown nonwoven webs. The nonwoven web may include a composite or combination of webs. In an embodiment, the nonwoven web is a spunbond material, made of polypropylene fiber. The nonwoven web may, however, comprise any polymeric material from which a fiber can be produced. For example, the nonwoven web may comprise fibers of polyethylene, polypropylene, elastomers, polyesters, rayon, cellulose, nylon, and blends of such polymers fibers. Fibers that comprise different polymers may also be blended.

The term "screen" as used herein refers to a three-dimensional molding apparatus comprising indentations used to form extended cells, protuberances or apertures in films, or protuberances in nonwoven webs. In an embodiment, screens comprise tubular members, having a width and a diameter. In alternative embodiments screens comprise belts having a width and a length. The transverse direction is the direction parallel to the width of the screen. The machine direction is the direction parallel to the direction of rotation of the screen, and is perpendicular to the transverse direction.

The term "extended cell" as used herein refers to a three-dimensional member or protuberance comprising an apertured base portion located in the plane of the first surface of the web and a sidewall portion extending generally in the direction of the second surface of the web. Each base portion has a sidewall portion. Sidewall portions terminate in "ends" or "apexes" located in the plane of the second surface of the web. The ends of the extended cells may be apertured or unapertured. "Apertured extended cell" as used herein refers to an extended cell that has an aperture at its distal end in the plane of the second surface. The apertures in the base portions of the extended cells, also called "primary apertures," may be in the shape of polygons, for example squares, hexagons, pentagons, ellipses, circles, ovals, or slots, in a regulated or random pattern. In an embodiment, the apertures may be in the shape of a boat, as described in, for example, <CIT>. The protubered ends, if apertured, are called "secondary apertures," and may be in the shape of polygons, e.g., squares, hexagons, pentagons, ellipses, circles, ovals, slots, or boats.

As used herein, the expression "absorbent articles" and "absorptive devices" denote articles that absorb and contain body fluids and other body exudates. More specifically, an absorbent article/absorptive device includes garments that are placed against or in proximity to the body of a wearer to absorb and contain the various exudates discharged from a body.

As used herein the term "elastic" is used to describe a material which upon application of a tensile force is extensible to a stretched length preferably at least 2x its initial, unstretched length, and that will retract to at most <NUM>. 75x of its initial, unstretched length upon release of the elongating force.

<FIG> is a top view of a portion of a spun bonded nonwoven web <NUM> having a basis weight of <NUM> gsm. The nonwoven web <NUM> includes a plurality of fibers <NUM>, and a plurality of compressed bond sites <NUM> that were created by a spun bonding process, as described above.

<FIG> illustrates a cross-section of the nonwoven web <NUM> of <FIG>. As illustrated, the plurality of fibers <NUM> are generally oriented horizontally when the nonwoven web <NUM> is placed on a generally horizontal surface, i.e. each fiber lies in a plane that is generally horizontal and the fibers <NUM> are generally parallel to each other. The compressed bond sites <NUM> are also visible in <FIG>. The fibers <NUM> are closely packed and therefore generally lack vertical spacing therebetween. The illustrated nonwoven web <NUM> has an average loft or thickness <NUM> of <NUM> (<NUM> inch). Although a nominal <NUM> gsm spun bonded nonwoven web <NUM> is illustrated, embodiments of the invention are not so limited. The term "nominal" as used herein refers to an approximate value. For example, a nominal <NUM> gsm spun bonded nonwoven web may actually have an average basis weight of up to <NUM> gsm. Spun bonded nonwoven webs having basis weights as low as nominal <NUM> gsm may be used in accordance with embodiments of the invention.

Although there may be no upper limit to the basis weight that may be used in embodiments of the invention, spun bonded nonwoven webs having a relatively high basis weight (and higher cost) may also have a higher loft and therefore may not be as desirable to use in embodiments of the invention. The illustrated embodiment is not intended to be limiting in any way. It is an aspect of embodiments of the invention to start with a light, inexpensive spun bonded nonwoven web and expand the web to simulate and function like a higher cost, lofty nonwoven web made with other processes, such as the spunlacing process described above.

The fibers <NUM> are made from polymer, which may be a polyolefin, such as polypropylene. In an embodiment, the nonwoven web <NUM> may be an SBPP, as described above. In an embodiment, the nonwoven web <NUM> may be coated with a surfactant so that the fibers <NUM> are hydrophilic on outer surfaces thereof. In an embodiment, a surfactant may be incorporated into the polymer of the fibers <NUM> in the form of a semi-viscous fluid that is located inside the polymer's amorphous regions so that the fibers <NUM> are hydrophilic and remain hydrophilic, even after the fibers <NUM> are subjected to liquids, as discussed in further detail below.

<FIG> illustrates a cross-section of a portion of a hydroformed expanded spun bonded nonwoven web <NUM> that was hydroformed and expanded from the nonwoven web <NUM> illustrated in <FIG> and <FIG> according to embodiments of the invention, described below. As illustrated, many of the fibers <NUM> of the original spun bonded nonwoven web <NUM> have been expanded to a greater vertical spacing therebetween, as indicated by arrows <NUM>. During expansion of the nonwoven web <NUM>, some of the fibers <NUM> may curve upward from their original generally horizontal orientations to become curved fibers <NUM>. In addition, some of the fibers <NUM>, which were previously continuous along the length of the nonwoven web <NUM>, may break into shortened fibrils <NUM> during the expansion process, and at least some of the shortened fibrils <NUM> may be reoriented to a more vertical alignment and become substantially vertical fibrils <NUM>, as illustrated.

The hydroformed expanded spun bonded nonwoven web <NUM> has an average expanded loft or thickness <NUM> of <NUM> (<NUM> inch), which is <NUM> times greater than the original loft <NUM> of the original spun bonded nonwoven web <NUM>. Embodiments of the invention provide an expanded spun bonded nonwoven web with a loft expanded to at least about <NUM> times the original spun bonded nonwoven web loft, which is sufficient for enhancing softness, for enhancing surface dryness, and for enhancing coolness as perceived by the wearer of an absorptive device that includes the hydroformed expanded spun bonded nonwoven web <NUM>. In addition, the air permeability of the hydroformed expanded spun bonded nonwoven web <NUM> may be increased by at least <NUM> times, as compared to the air permeability of the original spun bonded nonwoven web <NUM>, as described in further detail below.

<FIG> is a schematic side view of an embodiment of a hydroforming apparatus <NUM> for manufacturing a hydroformed expanded spun bonded nonwoven web, such as the hydroformed expanded spun bonded nonwoven web <NUM> described above and/or a hydroformed composite material described below, in accordance with embodiments of the invention. Specifically, the apparatus <NUM> of <FIG> provides a process of hydroforming a spun bonded nonwoven web, such as the spun bonded nonwoven web <NUM> illustrated in <FIG> and <FIG> to expand its loft and produce a hydroforming expanded spun bonded nonwoven, such as the hydroformed expanded spun bonded nonwoven web <NUM> illustrated in <FIG>.

As illustrated in <FIG>, a roll <NUM> of an original unexpanded spun bonded nonwoven web <NUM> having an original loft as a result of the spun bonding process described above may be loaded on a spindle <NUM> of the apparatus <NUM> in an orientation and position that allows the nonwoven web <NUM> to be unwound from the roll <NUM> and further processed. The apparatus <NUM> includes a forming structure <NUM>, which may be in the form of a rotatable forming screen, and the nonwoven web <NUM> may be advanced in a continuous motion over the forming structure <NUM>. In embodiments in which the forming structure <NUM> is a rotatable forming screen, the nonwoven web <NUM> may be moved and the screen may be rotated at a synchronized speed across a long and narrow-width vacuum slot area <NUM> that extends into the paper containing the Figure. The forming structure <NUM> may have a plurality of apertures 44a having a mesh count of between about <NUM> apertures per linear <NUM> (inch;i.e. "<NUM> mesh") and about <NUM> apertures per linear <NUM> (inch ;i.e. "<NUM> mesh"). In an embodiment, the mesh count may be about <NUM> apertures per linear <NUM> (inch;i.e. "<NUM> mesh").

A plurality of pressurized liquid jets <NUM> is arranged in a long and narrow-width zone that extends into the paper containing <FIG>, and is generally aligned with the long and narrow-width vacuum slot area <NUM> under the forming structure <NUM>. The liquid jets <NUM> are configured to provide overlapping streams of a liquid <NUM>, such as water, at a pressure of from <NUM> MPa (<NUM> psi) to <NUM> MPa (<NUM> psi) onto an outer surface of the nonwoven web <NUM> while the web <NUM> is passing over the vacuum slot area <NUM>. In an embodiment, the liquid in the liquid jets <NUM> may have a pressure of from <NUM> MPa (<NUM> psi) to <NUM> MPa (<NUM> psi). The streams of liquid <NUM> have sufficient pressure to push and reorient a majority of the spun bonded fibers <NUM> from a close packed horizontal orientation (illustrated in <FIG>) to a greater vertical spacing (illustrated in <FIG>).

Many of the fibers of the spun bonded nonwoven <NUM> may be pushed to curve upward and at least some of the formerly continuous fibers may be broken into shortened fibrils, as illustrated in <FIG>. Such disruption of the original spun bonded nonwoven web <NUM> results in the expanded spun bonded nonwoven web <NUM> having an expanded loft of at least <NUM> times greater than the loft of the original spun bonded nonwoven web <NUM>, and an increased air permeability of at least <NUM> times greater than the air permeability of the original spun bonded web. In addition, the liquid jets <NUM> have sufficient pressure to push portions of the nonwoven web <NUM> into the plurality of apertures 44a in the forming structure <NUM> and form a plurality of protuberances that extend from one surface of the expanded nonwoven web, as described in further detail below.

<FIG> illustrates an individual liquid jet <NUM> in accordance with embodiments of the invention that may be used in the apparatus <NUM> of <FIG>. As illustrated, the liquid jet <NUM> includes a nozzle <NUM> that is configured to project the stream of liquid <NUM> (such as water) that has a cross section in the shape of a fan. The stream of liquid <NUM> is generally shaped as an elongated ellipse having a width 'w' and a length 'l'. The stream of liquid <NUM> exiting an individual nozzle <NUM> may have an elongated ellipse shape having a length to width ratio (l/w) of between <NUM>:<NUM> and <NUM>:<NUM>. In an embodiment, the stream of liquid <NUM> may have an elongated ellipse shape having a length to width ratio of :<NUM>, with a length measuring <NUM> (<NUM> inches) and a width measuring about <NUM> (<NUM> inch) at the location that impacts the nonwoven web <NUM>.

The plurality of liquid jets <NUM> is illustrated in further detail in in <FIG>. As illustrated, the individual nozzles <NUM> are aligned and affixed to a manifold <NUM> that is supplied with a pressurized liquid at an inlet <NUM>. In an embodiment, the individual nozzles are spaced apart along the manifold <NUM> every <NUM>-<NUM> (<NUM> - <NUM> inches). In an embodiment, the individual nozzles are spaced apart along the manifold every <NUM> (<NUM> inches). The streams of liquid <NUM> each slightly overlap an adjacent stream at their respective edges <NUM>. Together, the plurality of streams of liquid <NUM> produce a long and narrow-width zone of pressurized liquid <NUM> that is formed by the individual spray nozzles <NUM> that each shape the liquid into a respective elongated ellipse illustrated in <FIG>. Edges <NUM> of the streams of liquid <NUM> overlap such that the pressurized liquid may be provided to the spun bonded nonwoven web <NUM> across the full width of the spun bonded nonwoven web <NUM>, while maintaining a narrow width ('w' in <FIG>), even as a collective.

Returning to <FIG>, the vacuum slot area <NUM> may have sufficient suction to remove any residual liquid from the surface of the spun bonded nonwoven web that may reduce the force of the streams of liquid <NUM> striking the spun bonded nonwoven web <NUM>. The expanded spun bonded nonwoven web <NUM> may then be subsequently dried in one or more dryers <NUM> and slit to preferred widths with at least one slitting blade <NUM>. The expanded spun bonded nonwoven web <NUM> may be wound by a winder <NUM> into at least one roll <NUM>. In an embodiment, the expanded spun bonded nonwoven web <NUM> may also be coated with a surfactant or otherwise treated to further enhance the properties of the expanded spun bonded nonwoven web <NUM>.

As discussed above, in an embodiment, the fibers <NUM> may include a surfactant that may migrate to the outer surfaces of the fibers over time. Not to be bound by theory, the pressure differential between the pressure applied to surfactant fluid within the internal structure of the polymer of the fibers and the ambient atmosphere on the outside of the fibers will cause the surfactant to migrate toward the outside surfaces of the fibers until an equilibrium is achieved. It is suspected that only a small amount of the surfactant, which is incorporated in the polymer, migrates to the surface when achieving an equilibrium condition. If the surfactant is washed off of the surface of the fibers, either by the initial hydroforming process described above or by a liquid insult while being worn be a user, the equilibrium with be lost, and more surfactant will migrate towards the outer surfaces of the fibers to achieve a new equilibrium. The amount of surfactant to incorporate into the fibers may be determined in view of the amount expected to be lost during the hydroforming process, as well as during use of the absorptive device into which the fibers will be incorporated. If the hydroformed expanded nonwoven web <NUM> has a surfactant incorporated into the fibers thereof is used as, for example, a topsheet or an acquisition distribution layer ("ADL") in an absorptive device, the functional fluid acquisition rate value of the topsheet may continue to perform even after the absorptive device exceeds its fluid containment capacity.

<FIG> are side views of a portion of a hydroformed expanded spun bonded nonwoven web <NUM> produced on a hydroforming apparatus, such as the apparatus <NUM> of <FIG>. The hydroformed expanded spun bonded nonwoven web <NUM> was produced from an original spun bonded nonwoven web having a nominal basis weight of <NUM> gsm and an average loft or thickness of <NUM> microns (<NUM> inches), as measured with an Ames <NUM> thickness gauge using a <NUM> gram (<NUM> ounce) weight. <FIG> illustrates a first surface <NUM> of a first side of the hydroformed expanded spun bonded nonwoven web <NUM> that was subjected to the liquid jets <NUM> of the hydroforming apparatus <NUM>, and <FIG> illustrates a second surface <NUM> of a second side of the hydroformed expanded spun bonded nonwoven web <NUM> that is opposite the first surface <NUM> and was in contact with the forming structure <NUM> of the hydroforming apparatus <NUM>. As illustrated, the first surface <NUM> is substantially planar, while the second surface <NUM> has a pattern of protuberances <NUM> extending therefrom. The protuberances <NUM> are in substantially the same pattern as the pattern of apertures 44a in the forming structure <NUM>, which has a mesh count of about <NUM> cells per linear <NUM> (inch;i.e. <NUM> mesh). The hydroformed expanded spun bonded nonwoven web <NUM> has an average loft or thickness of <NUM> microns (<NUM> inches), as measured with an Ames <NUM> thickness gauge using a <NUM> gram (<NUM> ounce) weight, or <NUM> times (<NUM>%) greater than the loft of the original unexpanded spun bond nonwoven web.

<FIG> illustrates a cross-section of a portion of a hydroformed composite material <NUM> that includes an expanded spun bonded nonwoven layer <NUM> and a polymer film layer <NUM>. The film layer <NUM> includes a plurality of extended cells <NUM> that extend away from the expanded spun bonded nonwoven layer <NUM>. In the illustrated embodiment, the extended cells <NUM> of the film layer <NUM> are each apertured at their respective apex <NUM>, and the extended cells <NUM> are macro extended cells having a mesh count of <NUM> cells per linear <NUM> (inch;i.e. "<NUM> mesh"), which is substantially the same as the mesh count of the apertures 44a of the forming structure <NUM>. The macro extended cells have sidewalls comprising a continually thinning portion of the polymer film layer of the hydroformed composite material extending away from what was an original plane of a composite precursor material (described below), and each of the plurality of extended cells is spaced apart from an adjacent extended cell by a land <NUM> having a width comprised of an undisturbed substantially planar surface of the hydroformed composite material. At least one of the extended cells of the polymer film layer may have an aperture at a distal end thereof. In the hydroformed composite material <NUM>, portions of fibers and fibrils from the expanded spun bonded nonwoven layer <NUM> have been pushed into the extended cells <NUM> of the film layer <NUM>, and some of the fibrils <NUM> extend through the apertures and beyond a plane that contains the apexes <NUM> of the extended cells <NUM> of the film layer <NUM>.

A composite precursor material that is subjected to the hydroforming process may be created by different methods, as illustrated in <FIG>, for example. In an apparatus <NUM> illustrated in <FIG>, the roll <NUM> of the original unexpanded nonwoven web <NUM> may be placed on a spindle <NUM>, and a roll <NUM> of a polymer film <NUM> may be placed on a separate spindle <NUM>. The polymer of the polymer film <NUM> may include one or more polyolefins, including but not limited to polyethylene, ultra-low density polyethylene, polypropylene, ethylene-vinyl acetates, metallocene, linear low density and linear medium density polyethylene, as well as other polymers, including but not limited to elastomeric polymers, including but not limited to polypropylene based elastomers, ethylene based elastomers, copolyester based elastomers, olefin block copolymers, styrenic block copolymers and the like, or combinations thereof. The polymer film <NUM> may be a solid polymer film or may be apertured. In an embodiment, the polymer film <NUM> may have a pattern of micro-cells or micro-apertures that were created using a vacuum forming, hydroforming, mechanical aperturing and/or embossing process.

Each of the original unexpanded nonwoven web <NUM> and the polymer film <NUM> may be fed into a nip <NUM> between two calendar rolls <NUM>, <NUM>, at least one of which may be heated to a temperature that allows the nonwoven web <NUM> and/or the polymer film <NUM> to soften. In an embodiment, at least one of the calendar rolls <NUM>, <NUM> may have a three-dimensional pattern on its surface so that the polymer <NUM> film and the nonwoven web <NUM> are subjected to a point bonding process, as is known in the art. The pressure applied to the nonwoven web <NUM> and the polymer film <NUM> in the nip <NUM> allow the nonwoven web <NUM> and the polymer film <NUM> to adhere to each other to create a composite precursor material <NUM> prior to being subjected to the liquid jets <NUM> as the composite precursor material <NUM> comprising the nonwoven web <NUM> and the polymer film <NUM> passes over the forming structure <NUM>. The combination of the liquid jets <NUM>, the forming structure <NUM>, and the vacuum slot <NUM> create a hydroformed composite material <NUM> that includes an expanded spun bonded nonwoven layer and a polymer film layer having extended cells in a pattern corresponding the pattern of apertures 44a in the forming structure, as described above with respect to the embodiment illustrated in <FIG>. For example, if the forming structure <NUM> has a mesh count from about <NUM> apertures per linear <NUM> (inch;i.e. "<NUM> mesh") to about <NUM> apertures per linear <NUM> (inch; i.e. "<NUM> mesh"), then the hydroformed film cells will be extended micro-cells having a mesh count from <NUM> mesh to <NUM> mesh. If the forming structure has a mesh count of less than <NUM> mesh, then the hydroformed film cells will be extended macro extended cells having a mesh count of less than <NUM> mesh.

After passing through the dryer(s) <NUM>, the hydroformed composite material <NUM> may be slit and rolled into a roll 99a with the winder <NUM>. In an embodiment, at least the expanded spun bonded nonwoven layer of the hydroformed composite material <NUM> may also be coated with a surfactant or otherwise treated to further enhance the properties of the hydroformed composite material <NUM>. In an embodiment, the fibers of the hydroformed composite material <NUM> may already contain a surfactant, as described above.

In an embodiment, the parts of the apparatus <NUM> located upstream of the liquid jets <NUM> and the forming structure <NUM> may be located off-line to form the composite precursor material <NUM>, and a roll of the composite precursor material may be placed on the spindle <NUM> of the apparatus <NUM> of <FIG> and processed as described above.

<FIG> illustrates an embodiment of an apparatus <NUM> that is configured to create a laminated composite precursor material <NUM> by extruding a layer of molten polymer <NUM> from a film extrusion die <NUM> directly onto the original unexpanded spun bonded nonwoven web <NUM> at a nip <NUM> created by a metal roll <NUM> and a rubber roll <NUM> as the original unexpanded spun bonded nonwoven web <NUM> passes through the nip <NUM>. The layer of molten polymer <NUM> may include one or more polyolefins, including but not limited to polyethylene, ultra-low density polyethylene, polypropylene, ethylene-vinyl acetates, metallocene, linear low density and linear medium density polyethylene, as well as other polymers, including but not limited to elastomeric polymers, including but not limited to polypropylene based elastomers, ethylene based elastomers, copolyester based elastomers, olefin block copolymers, styrenic block copolymers and the like, or combinations thereof.

A conveying roll <NUM> may be used to reorient the laminated composite precursor material <NUM> so that the polymer film layer of the laminated composite precursor material <NUM> contacts the forming structure <NUM> and the liquid jets <NUM> provide streams of liquid <NUM> directly onto the original spun bonded nonwoven web <NUM>. It should be understood that additional rolls may be used in the apparatus <NUM> and the illustrated embodiment is not intended to be limiting in any way. The combination of the liquid jets <NUM>, the forming structure <NUM>, and the vacuum slot <NUM> create a hydroformed composite material <NUM> that includes an expanded spun bonded nonwoven layer and a polymer film layer having extended cells in a pattern corresponding the pattern of apertures 44a in the forming structure <NUM>, as described above.

In the embodiment illustrated in <FIG>, a conveying roll <NUM> is used to align the hydroformed composite material <NUM> with the dryer(s) <NUM>, and after passing through the dryer(s) <NUM>, the hydroformed composite material <NUM> may be slit and rolled into a roll 108a with the winder <NUM>. In an embodiment, at least the expanded spun bonded nonwoven layer of the hydroformed composite material <NUM> may also be coated with a surfactant or otherwise treated to further enhance the properties of the hydroformed composite material <NUM>. In an embodiment, the fibers of the hydroformed composite material <NUM> may already contain a surfactant, as described above.

It should be understood that additional rolls may be used to convey the hydroformed composite material <NUM> and the illustrated embodiment is not intended to be limiting in any way. In an embodiment, the parts of the apparatus <NUM> located upstream of the liquid jets <NUM> and the forming structure <NUM> may be located off-line to form the laminated composite precursor material <NUM>, and a roll of the laminated composite precursor material may be placed on the spindle <NUM> of the apparatus <NUM> of <FIG> and hydroformed as described above.

<FIG> illustrates an embodiment of an apparatus <NUM> that is configured to create a laminated composite precursor material <NUM> by extruding the layer of molten polymer <NUM> from the film extrusion die <NUM> directly onto the original unexpanded spun bonded nonwoven web <NUM> as the original unexpanded spun bonded nonwoven web <NUM> moves over a second forming structure <NUM> at a synchronized speed so that the spun bonded nonwoven web <NUM> passes over a second vacuum slot area <NUM> as the molten polymer <NUM> contacts the nonwoven web <NUM>. The second forming structure <NUM> has a pattern of apertures that are configured to allow the vacuum created in the second vacuum slot area <NUM> to pull the spun bonded nonwoven web <NUM> against the forming structure <NUM>, and due to the permeability of the spun bonded nonwoven web <NUM>, the polymer film layer will conform to the nonwoven web <NUM> as the polymer cools. Conveying rolls <NUM>, <NUM> may be used to provide further cooling to the polymer layer and/or reorient the laminated composite precursor material <NUM> so that the polymer film layer of the laminated composite precursor material <NUM> contacts the forming structure <NUM> and the liquid jets <NUM> provide streams of liquid <NUM> directly onto the original spun bonded nonwoven web <NUM>. It should be understood that additional rolls may be used to convey the composite precursor material <NUM> and the illustrated embodiment is not intended to be limiting in any way. The combination of the liquid jets <NUM>, the forming structure <NUM>, and the vacuum slot <NUM> create a hydroformed composite material <NUM> that includes an expanded spun bonded nonwoven layer and a polymer film layer having extended cells in a pattern corresponding the pattern of apertures 44a in the forming structure, as described above.

In the embodiment illustrated in <FIG>, an additional conveying roll <NUM> is used to align the hydroformed composite material <NUM> with the dryer(s) <NUM>, and after passing through the dryer(s) <NUM>, the hydroformed composite material <NUM> may be slit and rolled into a roll 118a with the winder <NUM>. In an embodiment, at least the expanded spun bonded nonwoven layer of the hydroformed composite material <NUM> may also be coated with a surfactant or otherwise treated to further enhance the properties of the hydroformed composite material <NUM>. In an embodiment, the fibers of the hydroformed composite material <NUM> may already contain a surfactant, as described above.

It should be understood that additional rolls may be used to convey the hydroformed composite material <NUM> and the illustrated embodiment is not intended to be limiting in any way. In an embodiment, the parts of the apparatus <NUM> located upstream of the liquid jets <NUM> and the forming structure <NUM> may be located off-line to form the laminated composite precursor material <NUM>, and a roll of the laminated composite precursor material <NUM> may be placed on the spindle <NUM> of the apparatus <NUM> of <FIG> and hydroformed as described above.

Other conventional processes may be used to create the composite precursor material and the processes described herein should not be considered to be limiting in any way. For example, in an embodiment, an adhesive material may be used to bond the polymer film and the original unexpanded spun bonded nonwoven web together. In an embodiment, an ultrasonic bonding device may be used to create bonds between the polymer film and the original unexpanded spun bonded nonwoven web.

A potential advantage of creating a laminated composite precursor material using a thermo-bonding process that includes extruding a layer of molten polymer directly onto the spun bonded nonwoven web, as described above with respect to <FIG> and <FIG>, is that the resulting polymer film layer may be thinner than processes that use an already-formed polymer film. For example, direct extrusion methods may allow for a very thin polymer film having a nominal basis weight of <NUM>-<NUM> gsm.

The hydroformed expanded spun bonded nonwoven material having protuberances or the hydroformed composite material having extended cells (with or without apertures) may then be run a second time through the hydroforming process using the hydroforming apparatus <NUM> of <FIG> that includes a different forming structure <NUM> having a different mesh count of less than <NUM> apertures per linear <NUM> (inch) so that a pattern of macro protuberances or extended cells (with or without apertures) may be produced. The macro extended cells may have sidewalls that include a continually thinning portion of the hydroformed composite material extending away from an original plane of the hydroformed composite material. In an embodiment, the hydroforming apparatus <NUM> of <FIG> may be used to create a more three-dimensional surface by embossing the hydroformed composite material and not creating apertures.

In an embodiment, a pattern of macro extended cells may be formed in the hydroformed expanded spun bonded nonwoven material or the hydroformed composite material already having protuberances or micro extended cells, respectively, via a method of mechanically perforating the material by passing the material through an apparatus configured to form large-scale apertures, such as an apparatus <NUM> illustrated <FIG>. As illustrated, the apparatus <NUM> includes a pin roll <NUM> having a pattern of pins <NUM> and a counter roll <NUM> having a matching pattern of cavities <NUM> configured to receive the pins <NUM>. The pin roll <NUM> and the counter roll <NUM> may be rotated in opposite directions to form a nip <NUM> through which a hydroformed composite material <NUM> may be fed. The pins <NUM> protrude from the surface of pin roll <NUM> and the cavities <NUM> are recessed into the surface of the counter roll <NUM>. The pin roll <NUM> and the counter roll <NUM> may be aligned so that the pins <NUM> mate with the cavities <NUM> such that when the rolls <NUM>, <NUM> are rotating, the pins <NUM> are inserted into the cavities <NUM> at the nip <NUM> and the hydroformed composite material <NUM> between the rolls <NUM>, <NUM> is perforated by the pins <NUM>, thereby forming a pattern of macro extended cells with apertures.

The resulting material includes micro extended cells (or protuberances) and macro extended cells with apertures and may be wound into a roll <NUM> for later conversion into a topsheet or other layer, such as an ADL, in an absorptive device. The macro extended cells may have a mesh count of less than about <NUM> cells per linear <NUM> (inch; i.e. "<NUM> mesh"). The macro extended cells may extend away from the original plane of the hydroformed composite material, be spaced apart by lands that each has a width and comprised of a plane of the hydroformed composite material having micro extended cells. Such a mechanical perforation method is described in further detail in co-assigned <CIT>.

In an embodiment, a pattern of macro protuberances or macro extended cells may be formed in the hydroformed expanded nonwoven web and/or the hydroformed composite material using an apparatus <NUM> illustrated in <FIG>. As illustrated, the pin roll <NUM> and the counter roll <NUM> of the apparatus <NUM> of <FIG> are replaced by matching embossing rolls <NUM>, <NUM> so that a three-dimensional surface (without apertures) may be created on the hydroformed expanded spun bonded nonwoven material or the hydroformed composite material, represented by <NUM> in <FIG>. After the material <NUM> passes between the embossing rolls <NUM>, <NUM>, the material may be rolled into a roll <NUM> for further processing.

<FIG> provides a graphical, cross-sectional view of a portion of the hydroformed composite material illustrated, for example, in <FIG>. This graphical illustration is provided to clarify the various structures that are combined to form the invention.

<FIG> illustrates the expanded spun bonded nonwoven layer <NUM> and the polymer film layer <NUM> that, together, form the composite material <NUM>. The film layer <NUM> includes a plurality of extended cells <NUM> that extend away from the expanded spun bonded nonwoven layer <NUM>. One of the extended cells <NUM> is shown in <FIG>.

As should be apparent, <FIG> also illustrates the protuberances <NUM> that are formed in register with the extended cells <NUM>. As discussed above, the protuberances <NUM> and the extended cells <NUM> are contemplated to be formed via a hydroforming process. However, as also made apparent from the foregoing, processes other than hydroforming may be employed without departing from the scope of the invention.

The extended cell <NUM> is contemplated to be representative of all of the extended cells <NUM> included in the composite material <NUM>, except that not all of the extended cells <NUM> are contemplated to include fibers and/or fibrils <NUM>. Specifically, it is contemplated that one or more of the extended cells <NUM> may exclude fibers or fibrils <NUM>. The absence of fibers or fibrils <NUM> from one or more extended cells <NUM> is contemplated to fall within the scope of the invention.

To assist with the discussion that follows, the first surface 84a and the second surface 84b of the film layer <NUM> are designated.

In the illustrated embodiment, the extended cell <NUM> extends away from the nonwoven layer <NUM> in the direction of the second surface 84b. The extended cell <NUM> is designated by the dotted line circle in the illustration.

The extended cell <NUM> encompasses at least the portion of the film layer <NUM> that forms the sidewalls <NUM>. As illustrated, the extended cell <NUM> defines a three-dimensional aperture AP that extends from the portion of the film layer <NUM> at the lands <NUM> to the apex <NUM>. As discussed above, the sidewalls <NUM> of the extended cell <NUM> are contemplated to thin from the portion of the film layer <NUM> adjacent to the lands <NUM> to the apex <NUM>. As also noted, some of the fibers and/or fibrils <NUM> extend into the aperture AP, through the plane defined by the lands <NUM>, and even beyond a plane that contains the apex <NUM> of the extended cell <NUM> of the film layer <NUM>. In other words, as made apparent from the discussion of the invention, the fibers or fibrils <NUM> extend into one or more of the extended cells <NUM> such that the fibers <NUM> are out of plane with the nonwoven web <NUM>. As such, the fibers and fibrils <NUM> form what are defined herein as the protuberances <NUM>.

The aperture AP defined by the extended cell <NUM> is illustrated as a "cone" or "volcano" extending away from the lands <NUM> of the film layer <NUM> in the direction of the second surface 84b. Thus, the aperture AP defines a first aperture AP1 (a proximal aperture) consistent with the plane of the lands <NUM> and a second aperture AP2 (a distal aperture) that is defined by the apex <NUM>. Without limiting the present invention, the aperture AP may have any shape, as required or as desired. For example, the aperture AP may have the conical shape depicted, where the sidewalls <NUM> are disposed such that the first aperture AP1 defines an area greater than the area of the second aperture AP2. Still further, the aperture AP may have a cylindrical shape. If so, the sidewalls <NUM> are contemplated to be substantially perpendicular to a plane defined by the lands <NUM>. Here the areas of the first aperture AP1 and the second aperture AP2 are contemplated to be equal or substantially equal. In yet another embodiment, the aperture AP may have a flared cross-section or funnel shape, where the sidewalls <NUM> extend outwardly such that the first aperture AP1 defines an are smaller than the area of the second aperture AP2.

Claim 1:
A method for manufacturing a composite material, the method comprising:
forming a composite precursor material comprising a nonwoven layer comprising a plurality of fibers, and a polymer film layer;
forming a plurality of extended cells in the polymer film layer, each of the extended cells having a continuous sidewall extending away from the nonwoven layer; pushing at least one of the fibers into at least one of the extended cells, while forming the extended cells, with a fluid, and wherein the composite precursor is formed by passing a nonwoven web through low pressure nip rolls while a molten polymer film is simultaneously extruded into the nip to form the polymer film layer on the nonwoven web.