Patent Description:
A variety of well-known absorbent articles are configured to absorb body fluids. Examples of such absorbent articles include, but are not limited to, feminine hygiene products, such as sanitary napkins or pads, baby diapers, adult incontinence products, and bandages. A typical absorbent article is generally constructed with a fluid permeable user-facing topsheet, which may be an apertured polymer film or a nonwoven web or a film/nonwoven laminate, an absorbent core, and a fluid impermeable garment or outwardly-facing backsheet, which may be a solid polymer film, for example.

In general, topsheets that are made from polymer films have better performance characteristics when used in the end-product as compared to topsheets that are made from nonwoven materials. However, a topsheet made from a polymer film may have a visual appearance that is higher in gloss and therefore may be more "plastic-looking" than a non-woven topsheet, and a polymer film topsheet may feel more "sticky" or "tacky" and less soft to the wearer than a nonwoven topsheet. <CIT> discloses an activated composite web which includes a nonwoven layer, and a formed film layer attached to the nonwoven layer. The formed film layer includes a plurality of first aperured protuberances having a mesh count of at least <NUM>, and a plurality of second apertured protuberances. Each of the second apertured protuberances has a cross-section area larger than each of first apertured protuberances. A plurality of first lanes are aligned in a first direction and have a first width extending in a second direction substantially perpendicular to the first direction. The first apertured protuberances are located in the first lanes. A plurality of second lanes are aligned in the first direction and have a second width, less than the first width, extending in the second direction. The first and second lanes alternate with each other in the second direction, and the second apertured protuberances are located in the second lanes. <CIT> describes a hydro-formed film which includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about <NUM> to <NUM> apertures per linear <NUM>. The hydro-formed film has a Compression Sensor Point count of at least ABOUT <NUM>. Us <NUM>,<NUM>,<NUM> B2 discloses a method of thermo-mechanically forming macrotextures in a microtextured film wherein a heat shield is utilized to thermally insulate the microtexture during the forming process. In <CIT>, an absorbent nonwoven fabric is described having a first major surface and a second major surface, whereby an apertured film is secured to the first major surface of the nonwoven fabric.

It is desirable to create a topsheet that delivers extraordinary softness to the user, assures performance at least comparable to traditional films.

According to an aspect of the invention, there is provided a film for use in an absorbent article. The film has a first side and a second side opposite the first side, and a plurality of apertured protuberances arranged in a pattern having <NUM> to <NUM> protuberances per linear <NUM> (inch) in at least one direction. Each of the protuberances includes a continuous sidewall extending from the first side. The second side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. The film has a melt index of at least about <NUM>/<NUM> minutes, and an air permeability of at least about <NUM> meter<NUM>/meter<NUM>/minute.

In an embodiment, the film has a basis weight between about <NUM> gsm and about <NUM> gsm.

According to an aspect of the invention, there is provided a laminate for use in an absorbent article. The laminate includes a film layer having a first side and a second side opposite the first side. The film layer includes a plurality of apertured protuberances arranged in a pattern having <NUM> to <NUM> protuberances per linear <NUM> (inch) in at least one direction. Each of the protuberances includes a continuous sidewall extending from the first side. The second side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. The film layer has a melt index of at least about <NUM>/<NUM> minutes and an air permeability of at least about <NUM> meter<NUM>/meter<NUM>/minute. The laminate includes a nonwoven layer laminated to the second side of the film layer. The nonwoven layer includes a plurality of fibers attached to the formed film at the land areas of the film layer.

In an embodiment, the nonwoven layer has a basis weight of between about <NUM> gsm and about <NUM> gsm.

In an embodiment, the nonwoven layer includes a spunbond nonwoven.

In an embodiment, the nonwoven layer includes a carded nonwoven.

In an embodiment, the nonwoven layer comprises a spunlace nonwoven.

In an embodiment, the film layer has a basis weight of between about <NUM> gsm and about <NUM> gsm.

In an embodiment, the laminate includes a plurality of apertures extending through the film layer and the nonwoven layer. The plurality of apertures has a pattern with a mesh count between about <NUM> and about <NUM> apertures per linear <NUM> (inch) in at least one direction.

In an embodiment, the laminate has an embossed pattern.

In an embodiment, the embossed pattern includes a plurality of narrow ridges. In an embodiment, the plurality of narrow ridges includes narrow, wavy ridges.

According to an aspect of the invention, there is provided a laminate for use in an absorbent article. The laminate includes a first film layer having a first side and a second side opposite the first side. The first film layer includes a first plurality of apertured protuberances arranged in a pattern having <NUM> to <NUM> protuberances per linear <NUM> (inch) in at least one direction. Each of the first plurality of apertured protuberances includes a continuous sidewall extending from the first side. The second side has a first plurality of apertures aligned with the first plurality of apertured protuberances and first land areas in between each of the first plurality of apertures. The first film layer has a melt index of at least about <NUM>/<NUM> and an air permeability of at least about <NUM><NUM>/m<NUM>/min. The laminate also includes a second film layer having a first side and a second side opposite the first side. The second film layer includes a second plurality of apertured protuberances arranged in a pattern having <NUM> to <NUM> protuberances per linear <NUM> (inch) in at least one direction. Each of the second plurality of apertured protuberances includes a continuous sidewall extending from the first side. The second side has a second plurality of apertures aligned with the second plurality of apertured protuberances and second land areas in between each of the second plurality of apertures. The second side of the first film layer is attached to the second side of the second film layer.

In an embodiment, the first film layer has a basis weight of between about <NUM> gsm and about <NUM> gsm.

In an embodiment, the second film layer has a basis weight of between about <NUM> gsm and about <NUM> gsm.

According to an aspect of the invention, there is a provided a method for making a material for an absorbent article. The method includes vacuum forming a plurality of apertured protuberances into a polymer web to create a first film using a forming structure comprising a pattern of <NUM> to <NUM> apertures per linear <NUM> (inch) in at least one direction. The first film has a melt index of at least about <NUM>/<NUM> minutes and an air porosity of at least about <NUM> meter<NUM>/meter<NUM>/minute.

In an embodiment, the method includes laminating a nonwoven to the first film to form a film/nonwoven laminate.

In an embodiment, the method includes aperturing the film/nonwoven laminate to create a plurality of apertures having a mesh count between about <NUM> to about <NUM> apertures per linear <NUM> (inch) in at least one direction.

In an embodiment, the method includes embossing the film/nonwoven laminate to create an embossed pattern in the film/nonwoven laminate.

In an embodiment, the embossed patterned includes a plurality of narrow ridges. In an embodiment, the plurality of narrow ridges includes narrow, wavy ridges.

In an embodiment, the method includes laminating a second film to the first film to form a film/film laminate.

In an embodiment, the second film includes a plurality of apertures arranged in a pattern of <NUM> to <NUM> apertures per linear <NUM> (inch) in at least one direction.

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.

As used herein, the expression "absorbent articles" 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. Non-limiting examples of absorbent articles include, but are not limited to feminine hygiene products, baby diapers, adult incontinence products, and bandages.

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 one of its edges.

The term "laminate web" or "laminate" refers to a web that comprises two or more separate webs that are attached to each other in a face to face relationship. The two or more separate webs may include one or more film webs and/or nonwoven webs. The attachment may be at particular spot locations across the component webs, or the attachment may be continuous across the component webs.

The term "film" or "polymer film" in this description refers to a web made by extruding a molten curtain or sheet of thermoplastic polymeric material by a cast or blown extrusion process and then cooling the sheet to form a solid polymeric web. Films can be monolayer films, coextruded films, coated films, and/or composite films.

Throughout this description, the expression "apertured films" and "apertured laminates" denote films and laminates that have a plurality of apertures that extend from a first surface of the film or laminate to a second, opposing surface of the film or laminate.

A "two-dimensional apertured film" is a film in which no three-dimensional structure exists in the apertures, which then connect the second surface of a flat film to the first surface of the film.

A "formed film" or a "three-dimensional film" is a film with protuberances, protrusions, or extended cells extending from at least one side thereof, and an "apertured formed film" or 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 protuberances or protrusions or extended cells have apertures therethrough.

The term "protuberance" as used herein refers to a three-dimensional member comprising an apertured base portion located in the plane of the first surface of the film and a sidewall portion extending generally in the direction of the second surface of the film. Each base portion has an associated sidewall portion. Sidewall portions terminate in "distal ends" located in the plane of the second surface of the film. The distal ends of the protuberances may be apertured or unapertured.

"Apertured protuberance" as used herein refers to a protuberance that has an aperture at its base portion or proximal end in the plane of the first surface, as well as its distal or protubered end. The apertures in the base portions of the protuberances, 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>, which is incorporated herein by reference.

The apertured distal or protubered ends are called "secondary apertures," and may be in the shape of polygons, e.g., squares, hexagons, pentagons, ellipses, circles, ovals, slots, or boats. The sidewall portion of the apertured protuberance extends from the primary aperture to the secondary aperture.

The term "nonwoven" 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 or filaments. 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 with 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 fibers or 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. The nonwoven web may comprise any polymeric material from which a fiber can be produced and/or may comprise cotton or other natural fibers. In an embodiment, the nonwoven web may be a spunbond material, made of polypropylene fiber. Fibers that comprise different polymers may also be blended. In an embodiment, the fibers may be so-called bi-component ("bi-co") fibers that comprise a core of one material and a sheath of another material.

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

The term "air permeability" as used herein is a measure of air flow through a material using a Textest FX3300 Air Permeability Tester in accordance with ASTM D737. The units are reported in cubic meters per square meter per minute (m<NUM>/m<NUM>/min).

The term "melt index" as used herein is a measure of material flow when the material is heated to <NUM> and subjected to a <NUM> mass in accordance with ASTM D1238. The units are grams per <NUM> minutes (g/<NUM>).

Various embodiments of the present invention will now be described. 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. Furthermore, any and all variations of the embodiments, now known or developed in the future, also are intended to fall within the scope of the invention.

<FIG> schematically illustrates an absorbent article <NUM> in accordance with embodiments of the invention. As illustrated, the absorbent article <NUM> includes a topsheet <NUM>, a backsheet <NUM>, and an absorbent core <NUM> positioned in between the topesheet <NUM> and the backsheet <NUM>. The absorbent article <NUM> may also include a fluid distribution material <NUM> positioned in between the topsheet <NUM> and the absorbent core <NUM>.

The topsheet <NUM>, which may be in the form of a two-dimensional or three-dimensional apertured film, a nonwoven web, or a laminate of an apertured film and a nonwoven web, is permeable to fluids and is configured to face the user wearing the absorbent article <NUM> and contact the user's skin. The topsheet <NUM> receives insults of fluid from the user, and the fluid passes through the topsheet <NUM> to the fluid distribution material <NUM>. The fluid distribution material <NUM>, if used, is also permeable and is configured to receive the fluid from the topsheet <NUM> and distribute the fluid to the absorbent core <NUM>. The absorbent core <NUM>, which includes absorbent materials, receives the fluid from the fluid distribution material <NUM> and stores the fluid until the absorbent article <NUM> is discarded. The backsheet <NUM>, which is impermeable to liquid and may be in the form of a polymer film or laminate of a polymer film and nonwoven web, prevents liquid and other body exudates from leaking out of the bottom side of the absorbent core <NUM>. The backsheet <NUM> may be breathable so that air, but not liquid, may pass through.

<FIG> is a microphotograph of a portion of a film <NUM> according to an embodiment of the invention, which may be used as the topsheet material <NUM> of <FIG>, and <FIG> schematically illustrates a cross-section of the topsheet material <NUM> taken along lines 2B-2B of <FIG>. As illustrated, the film <NUM> a first side <NUM> and a second side <NUM> that is opposite the first side <NUM>. The film <NUM> includes a plurality of apertured protuberances <NUM>. Each of the apertured protuberances <NUM> includes a continuous sidewall <NUM> extending from the first side <NUM> of the film <NUM> to a distal end <NUM> that includes a secondary aperture <NUM>, as illustrated. The first side <NUM> of the film <NUM> also includes land areas <NUM> in between the apertured protuberances <NUM>.

The second side <NUM> of the film <NUM> has a plurality of primary apertures <NUM> aligned with the plurality of protuberances <NUM>. As such, the primary apertures <NUM> in the second side <NUM> of the film <NUM> are also considered to be proximal apertures <NUM> of the apertured protuberances <NUM>, while the secondary apertures <NUM> at the distal ends <NUM> of the apertured protuberances <NUM> may also be considered to be distal apertures <NUM> of the apertured protuberances <NUM>. The second side <NUM> of the film <NUM> also includes land areas <NUM> in between the proximal apertures <NUM>.

In an embodiment, the apertured protuberances <NUM> may be arranged in a pattern having about <NUM> to about <NUM> protuberances per linear inch or "mesh," i.e., about <NUM> mesh to about <NUM> mesh in at least one direction. The pattern may be a hexagonal pattern, a square pattern, a staggered pattern, or any other type of pattern or design. In an embodiment, the proximal apertures <NUM> may be hexagonal in shape and have approximately the same size.

The polymer of the film <NUM> may include one or more polyolefins, including but not limited to polyethylene, ultra-low density polyethylene, low density polyethylene, linear low density polyethylene, linear medium density polyethylene, high density polyethylene, polypropylene, ethylene-vinyl acetates, metallocene, as well as other polymers, such as bio-based polymers that are produced from plants, including but not limited to sugarcane, or polylactic acid ("PLA"). Other polymers also include, but are 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. Additives, such as surfactants, fillers, colorants, opacifying agents and/or other additives known in the art may also be used in the film <NUM>.

In an embodiment, the film <NUM> may have a basis weight of between about <NUM> grams per square meter ("gsm") and about <NUM> gsm. In an embodiment, the film <NUM> may have a basis weight of between about <NUM> gsm and about <NUM> gsm.

<FIG> schematically illustrates an apparatus <NUM> that may be used to manufacture the film <NUM> of embodiments of the invention described herein. As illustrated, an extrusion die <NUM> extrudes polymer melt curtain <NUM> onto a forming structure <NUM> that rotates about a cylinder <NUM> that has a vacuum slot <NUM> through which a vacuum is pulled. The polymer melt curtain <NUM> may include, for example, one or more polyolefin materials and a surfactant, as well as one or more additives, such as a colorant.

As the polymer web (which solidifies to form, for example, the film <NUM> of <FIG> and <FIG>) is apertured, air flow is initiated through the apertured protuberances (e.g., <NUM>) which cools and solidifies the apertured protuberances (e.g., <NUM>). The polymer web is also cooled by the forming structure <NUM>. The resulting vacuum formed film <NUM> is pulled off of forming structure <NUM> by a peel roller <NUM> and travels to one or more subsequent rollers <NUM> until it may be wound by a winder <NUM> into a roll <NUM>. Additional rollers and/or other pieces of equipment may be used in the apparatus <NUM>. The illustrated embodiment is not intended to be limiting in any way.

A series of films <NUM> was created using the apparatus <NUM> described above. The forming structure <NUM> had a pattern of apertures arranged with <NUM> apertures per linear <NUM> (inch) in at least one direction (i.e. <NUM> mesh). Different blends were used to create films having different melt index values, but with the same target basis weight of <NUM> grams per square meter (gsm). The Comparative Example was a typical blend of polyethylenes and masterbatches that included a surfactant and white pigment that is used to make vacuum formed films. The resulting film formed for the Comparative Example was measured to have an air permeability of <NUM><NUM>/m<NUM>/min, which indicates that very few apertures were created using the <NUM> mesh forming structure. It was difficult to measure the melt index of the actual blend of materials, so the melt index of the resulting film was measured instead, which was found to be <NUM>/<NUM>.

Without being bound by theory, it was postulated that increasing the melt index of the blend of materials used may provide better flow of the melt curtain into the apertures of the <NUM> mesh forming structure <NUM> and result in more apertures being formed in the film and therefore result in higher air permeability. To increase the melt index of the blend for the film <NUM>, three different series of blends (Examples <NUM>-<NUM>; Examples <NUM>-<NUM>; Examples <NUM>-<NUM>) were investigated, with each blend including the same masterbatches that included a surfactant and white pigment that is used to make the Comparative Example. Each film was measured for film melt index and air permeability. A summary of the test results is listed in Table I below:.

The results indicate that for each series of blends, increasing the melt index of the film by increasing the melt index of the blend resulted in films with increased air permeability, which improves the fluid handling properties and softness of the films.

Film samples of Examples <NUM>, <NUM> and <NUM>, as well as the Comparative Example were used as topsheets, with the apertured protuberances <NUM> facing outward, and assembled into feminine hygiene pads for a panel test to determine relative softness of the samples. A total of ten panelists ranked each set of four sample in order of perceived softness, with <NUM> being least soft and <NUM> being most soft. A summary of the results is listed in Table II below:.

The panel results indicate that the Comparative Example, which had the lowest film melt index, was ranked by each of the ten panelists as least soft, and Example <NUM>, which had the highest film melt index was ranked, on average, the softest.

<FIG> is a microphotograph of a portion of one side of a film/nonwoven laminate <NUM> in accordance with an embodiment of the invention, which may be used as the topsheet <NUM> for the absorbent article of <FIG>, with a nonwoven layer <NUM> of the film/nonwoven laminate <NUM> on top. <FIG> is an enlarged microphotograph of a portion of the film/nonwoven laminate <NUM> with a film layer <NUM> on top, and <FIG> is a schematic illustration of a cross section of the film/nonwoven laminate <NUM> taken along lines 4C-4C.

As illustrated in <FIG>, the film layer <NUM> has a first side <NUM> and a second side <NUM> that is opposite the first side <NUM>. The film layer <NUM> includes a plurality of apertured protuberances <NUM>. Each of the apertured protuberances <NUM> includes a continuous sidewall <NUM> extending from the first side <NUM> of the film layer <NUM> to a distal end <NUM> that includes a secondary aperture <NUM>, as illustrated. The first side <NUM> of the film layer <NUM> also includes land areas <NUM> in between the apertured protuberances <NUM>.

The second side <NUM> of the film layer <NUM> has a plurality of primary apertures <NUM> aligned with the plurality of protuberances <NUM>. As such, the primary apertures <NUM> in the second side <NUM> of the film layer <NUM> are also considered to be proximal apertures <NUM> of the apertured protuberances <NUM>, while the secondary apertures <NUM> at the distal ends <NUM> of the apertured protuberances <NUM> may also be considered to be distal apertures <NUM> of the apertured protuberances <NUM>. The second side <NUM> of the film layer <NUM> also includes land areas <NUM> in between the proximal apertures <NUM>. The film layer <NUM> may include one or more of the polymers listed about with respect to the film <NUM>, and may have a basis weight between about <NUM> gsm and about <NUM> gsm.

In an embodiment, the apertured protuberances <NUM> may be arranged in a pattern having about <NUM> to about <NUM> protuberances per linear <NUM> (inch) or "mesh," i.e., about <NUM> mesh to about <NUM> mesh in at least one direction. The pattern may be a hexagonal pattern, a square pattern, a staggered pattern, or any other type of pattern or design. In an embodiment, the proximal apertures <NUM> may be hexagonal in shape and have approximately the same size.

The nonwoven layer <NUM> has a first side <NUM> and a second side <NUM> opposite the first side <NUM>. In the illustrated embodiment, the first side <NUM> of the nonwoven layer <NUM> contacts the second side <NUM> of the film layer <NUM>. The nonwoven layer <NUM> includes a plurality of fibers <NUM>.

Nonwoven webs that may be used for the nonwoven layer <NUM> may be formed from many processes, including but not limited to spunbonding processes, melt-blowing processes, hydroentangling processes, spunlacing processes, air-laying, and bonded carded web processes, or combinations thereof, as are known in the nonwoven art. In an embodiment, the nonwoven layer <NUM> may be a spunbonded nonwoven web. In an embodiment, the fibers <NUM> in the nonwoven layer <NUM> may be polypropylene fibers. In an embodiment, the nonwoven layer <NUM> may include natural fibers, such as cotton. In an embodiment, the nonwoven layer <NUM> may include bio-based fibers that include polymers that are produced from plants, including but not limited to sugarcane, or polylactic acid ("PLA"). The nonwoven layer <NUM> may have a basis weight of between about <NUM> gsm and about <NUM> gsm.

The film layer <NUM> is attached to the nonwoven layer <NUM> at bond sites <NUM> where the first side <NUM> of the nonwoven layer <NUM> contacts the land areas <NUM> of the second surface <NUM> of the film layer <NUM>. In an embodiment, the fibers <NUM> at the bond sites <NUM> are embedded into the land areas <NUM> of the film layer <NUM>, which may be accomplished by a vacuum formed lamination process, as described in further detail below. The bond sites <NUM> are contemplated to be distributed in a pattern, commensurate with some or all of the land areas <NUM>.

<FIG> illustrates an embodiment of an apparatus <NUM> that may be used to manufacture the film/nonwoven laminate <NUM> of <FIG>. The apparatus <NUM> includes many of the same parts as the apparatus <NUM> of <FIG>. A nonwoven web <NUM> is unwound from a roll <NUM> over a laminating roller <NUM> and directed to the melt curtain <NUM> while the melt curtain <NUM> is still molten at an impingement point <NUM> between the rotating forming structure <NUM> and the laminating roller <NUM>. In an embodiment, the laminating roller <NUM> may be a point bond roller that includes a plurality of protrusions extending from a cylindrical surface of the roller <NUM>.

The fibers of the nonwoven web <NUM> adjacent to the melt curtain <NUM> embed in the surface of the melt curtain <NUM> as the two layers cross over the vacuum slot <NUM> together, where the apertured protuberances are formed in the polymer web (i.e., the solidified melt curtain <NUM>) in substantially the same pattern that is provided by the forming structure <NUM>. As the polymer web (which solidifies to form, for example, the film layer <NUM> of <FIG>) is apertured, air flow is initiated through the apertured protuberances (e.g., <NUM>) which cools and solidifies the apertured protuberances (e.g., <NUM>). The polymer web is also cooled by the forming structure <NUM> as the fibers (e.g., <NUM>) of the nonwoven are embedded in the land areas (e.g., <NUM>) between the apertured protuberances (e.g., <NUM>) so that the nonwoven is bonded to the film layer (e.g., <NUM>) at the land areas (e.g., <NUM>). The resulting vacuum formed film/nonwoven laminate <NUM> is pulled off of forming structure <NUM> by the peel roller <NUM> and travels to one or more subsequent rollers <NUM> until it may be wound by the winder <NUM> into a roll <NUM>. Additional rollers and/or other pieces of equipment may be used in the apparatus <NUM>.

The illustrated embodiment is not intended to be limiting in any way. For example, other lamination techniques may be used to create the film/nonwoven laminate <NUM>. In an embodiment, the film layer may be manufactured using the apparatus <NUM> of <FIG> and later attached to a nonwoven web using known techniques, such as applying an adhesive to the film and/or nonwoven and then applying pressure to the two layers of materials, or using sonic or ultrasonic bonding techniques.

In an embodiment, either apparatus <NUM>, <NUM> may also include additional equipment, such as intermeshing gears that may be used to activate the film <NUM> or the film/nonwoven laminate <NUM> in the machine direction or the transverse direction, if desired. Other equipment that may be included in the apparatus <NUM>, <NUM> include, but are not limited to, corona treatment apparatus, printers, festooning equipment, spooling equipment, and additional processing equipment that may emboss or provide additional apertures to the film <NUM> or film/nonwoven laminate <NUM>, as described in further detail below.

<FIG> illustrates and embodiment of a film/nonwoven laminate <NUM> that started as the film/nonwoven laminate <NUM> of <FIG> and then was further processed to form a plurality of macro apertures <NUM> in a pattern. The macro apertures <NUM> may be arranged in a pattern having between <NUM> apertures per linear <NUM> (inch) and <NUM> apertures per linear <NUM> (inch) (i.e., <NUM>-<NUM> mesh), desirably less than <NUM> apertures per linear <NUM> (inch) (i.e. <NUM> mesh).

<FIG> illustrates an apparatus <NUM> that may be used to create the macro apertures <NUM>. 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 the film/nonwoven laminate <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 laminate between the rolls <NUM>, <NUM> is perforated by the pins <NUM>, thereby forming the macro apertures <NUM>. The resulting laminate <NUM> may be wound into a roll <NUM> for later conversion into, for example, a topsheet or other layer, in an absorbent article. In an embodiment, the apparatus <NUM> may be "in-line" with the apparatus of <FIG>, such as between the roller <NUM> and the winder <NUM>.

<FIG> is a photograph of an embodiment of an embossed laminate <NUM> that started as the film/nonwoven laminate <NUM> of <FIG> and was embossed with a pattern. As illustrated in <FIG>, macro apertures <NUM> may be formed in the pattern, although the illustrated embodiment is not intended to be limiting in any way. In an embodiment, the embossed laminate <NUM> only includes the plurality of microapertures that were formed in the original laminate before embossing. In an embodiment, additional macro apertures <NUM> may be formed in the film/nonwoven laminate <NUM> using the embossing process.

<FIG> illustrates and apparatus <NUM> that may be used to create the embossed laminate <NUM> of <FIG>. As illustrated, the apparatus <NUM> includes matching embossing rolls <NUM>, <NUM> that are configured to provide the pattern illustrated in <FIG>. After the film/nonwoven laminate <NUM> passes between the embossing rolls <NUM>, <NUM>, the embossed laminate <NUM> may be rolled into a roll <NUM> for further processing. In embodiments in which it is desirable to form macro apertures, at least one of the embossing rolls <NUM>, <NUM> may having suitable structures to pierce the laminate <NUM> and form the macro apertures <NUM>. In an embodiment, the apparatus <NUM> may be "in-line" with the apparatus of <FIG>, such as between the roller <NUM> and the winder <NUM>.

<FIG> are photographs illustrating an embodiment of a film/nonwoven laminate <NUM> that was made using the apparatus <NUM> illustrated in <FIG>, and embossed with the apparatus of <FIG>. In the illustrated embodiment, the nonwoven layer of the film/nonwoven laminate <NUM> is the top layer and the film layer is beneath the nonwoven layer. The embossing rolls <NUM>, <NUM> were designed to create a plurality of narrow, wavy ridges <NUM> on one side of the film/nonwoven laminate <NUM>, as well as a plurality of narrow ridges that outline individual hearts <NUM>, as illustrated. Other shapes may be created in the film/nonwoven laminate <NUM>. The illustrated embodiment is not intended to be limiting in any way.

<FIG> schematically illustrates a cross-section of a portion of a film/film laminate <NUM>, which may be used as the topsheet <NUM> for the absorbent article <NUM> of <FIG>, or as a combination of the topsheet <NUM> and fluid distribution material <NUM> for the absorbent article <NUM> of <FIG>. As illustrated in <FIG>, the film/film laminate <NUM> includes a first film layer <NUM> attached to a second film layer <NUM>. The first film layer <NUM> has a first side <NUM> and a second side <NUM> that is opposite the first side <NUM>. The first film layer <NUM> includes a plurality of apertured protuberances <NUM>. Each of the apertured protuberances <NUM> includes a continuous sidewall <NUM> extending from the first side <NUM> of the first film layer <NUM> to a distal end <NUM> that includes a secondary aperture <NUM>, as illustrated. The first side <NUM> of the first film layer <NUM> also includes land areas <NUM> in between the apertured protuberances <NUM>.

The second side <NUM> of the first film layer <NUM> has a plurality of primary apertures <NUM> aligned with the plurality of protuberances <NUM>. As such, the primary apertures <NUM> in the second side <NUM> of the first film layer <NUM> are also considered to be proximal apertures <NUM> of the apertured protuberances <NUM>, while the secondary apertures <NUM> at the distal ends <NUM> of the apertured protuberances <NUM> may also be considered to be distal apertures <NUM> of the apertured protuberances <NUM>. The second side <NUM> of the first film layer <NUM> also includes land areas <NUM> in between the proximal apertures <NUM>. The first film layer <NUM> may include one or more of the polymers listed about with respect to the film <NUM>, and may have a basis weight between about <NUM> gsm and about <NUM> gsm.

In an embodiment, the apertured protuberances <NUM> may be arranged in a pattern having about <NUM> to about <NUM> protuberances per linear <NUM> (inch) or "mesh," i.e., about <NUM> mesh to about <NUM> mesh in at least one direction (e.g., in the machine direction of the film/film laminate <NUM> and/or the transverse direction of the film/film laminate <NUM>, which is orthogonal to the machine direction). The pattern may be a hexagonal pattern, a square pattern, a staggered pattern, or any other type of pattern or design. In an embodiment, the proximal apertures <NUM> may be hexagonal in shape and have approximately the same size.

The second film layer <NUM> has a first side <NUM> and a second side <NUM> that is opposite the first side <NUM>. The second film layer <NUM> includes a plurality of apertured protuberances <NUM>. Each of the apertured protuberances <NUM> includes a continuous sidewall <NUM> extending from the first side <NUM> of the second film layer <NUM> to a distal end <NUM> that includes a secondary aperture <NUM>, as illustrated. The first side <NUM> of the second film layer <NUM> also includes land areas <NUM> in between the apertured protuberances <NUM>.

The second side <NUM> of the second film layer <NUM> has a plurality of primary apertures <NUM> aligned with the plurality of protuberances <NUM>. As such, the primary apertures <NUM> in the second side <NUM> of the second film layer <NUM> are also considered to be proximal apertures <NUM> of the apertured protuberances <NUM>, while the secondary apertures <NUM> at the distal ends <NUM> of the apertured protuberances <NUM> may also be considered to be distal apertures <NUM> of the apertured protuberances <NUM>. The second side <NUM> of the second film layer <NUM> also includes land areas <NUM> in between the proximal apertures <NUM>. The second film layer <NUM> may include one or more of the polymers listed about with respect to the film <NUM>, and may have a basis weight between about <NUM> gsm and about <NUM> gsm.

The first film layer <NUM> is attached to the second film layer <NUM> at bond sites <NUM> where the land areas <NUM> of the second side <NUM> of the second film layer <NUM> contact the land areas <NUM> of the second side <NUM> of the first film layer <NUM>. In an embodiment, the first film layer <NUM> and the second film layer <NUM> may be attached by a vacuum formed lamination process, as described in further detail below.

<FIG> illustrates an embodiment of an apparatus <NUM> that may be used to manufacture the film/film laminate <NUM> of <FIG>. The apparatus <NUM> includes many of the same parts as the apparatus <NUM> of <FIG>. An apertured film <NUM>, which is to become the second film layer <NUM> of the film/film laminate <NUM>, is unwound from a roll <NUM> over the laminating roller <NUM> and directed to the melt curtain <NUM> while the melt curtain <NUM> is still molten at the impingement point <NUM> between the rotating forming structure <NUM> and the laminating roller <NUM>.

The side of the apertured film <NUM> adjacent to the melt curtain <NUM>, which coincides with the second side <NUM> of the second film layer <NUM>, contacts the surface of the melt curtain <NUM> as the two layers cross over the vacuum slot <NUM> together, where the apertured protuberances are formed in the polymer web (i.e., the solidified melt curtain <NUM>) in substantially the same pattern that is provided by the forming structure <NUM>. As the polymer web (which solidifies to form, for example, the first film layer <NUM> of <FIG>) is apertured, air flow is initiated through the apertured protuberances (e.g., <NUM>) which cools and solidifies the apertured protuberances (e.g., <NUM>). The polymer web is also cooled by the forming structure <NUM> as the land areas (e.g., <NUM>) of the apertured film <NUM> bond to the land areas (e.g., <NUM>) between the apertured protuberances (e.g., <NUM>) so that the apertured film <NUM> is bonded to the first film layer (e.g., <NUM>) at the land areas (e.g., <NUM>). The resulting vacuum formed film/film laminate <NUM> is pulled off of the forming structure <NUM> by the peel roller <NUM> and travels to one or more subsequent rollers <NUM> until it may be wound by the winder <NUM> into a roll <NUM>. Additional rollers and/or other pieces of equipment may be used in the apparatus <NUM>.

The illustrated embodiment is not intended to be limiting in any way. For example, other lamination techniques may be used to create the laminate <NUM>. In an embodiment, the first film layer <NUM> and the second film layer <NUM> may be manufactured separately using the apparatus <NUM> of <FIG> and later attached to each other known techniques, such as applying an adhesive to the one of the film layers <NUM>, <NUM> and then applying pressure to the two film layers <NUM>, <NUM>, or using sonic or ultrasonic bonding techniques. In an embodiment, the first film layer <NUM> may be made first and then vacuum laminated to the second film layer <NUM> as the second film layer <NUM> is vacuum formed (i.e., the reverse of what is illustrated in <FIG>).

In an embodiment, the apparatus <NUM> may also include additional equipment, such as intermeshing gears that may be used to activate the film/film laminate <NUM> in the machine direction or the transverse direction, if desired. Other equipment that may be included in the apparatus <NUM> include, but are not limited to, corona treatment apparatus, printers, festooning equipment, spooling equipment, and additional processing equipment that may emboss or provide additional apertures to the film/film laminate <NUM>, as described above.

Claim 1:
A film for use in an absorbent article, the film comprising:
a first side and a second side opposite the first side,
a plurality of apertured protuberances arranged in a pattern having <NUM> to <NUM> protuberances per linear <NUM> (inch) in at least one direction, each of the protuberances comprising a continuous sidewall extending from the first side, the second side having a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures,
wherein the film has a melt index of at least <NUM>/<NUM> and an air permeability of at least <NUM><NUM>/m<NUM>/min.