Patent ID: 7390553

Claim:
A laminate with a perforated thermoplastic structure, said laminate having a machine direction of manufacture (MD) and a cross direction of manufacture (CD), and said product comprising a first layer forming an outer surface of the laminate, the first layer comprising a spunbond nonwoven fabric containing filaments of a thermoplastic material, a plurality of perforations which extend through the first layer, with the perforations having a three-dimensional shape and a hole diameter in the MD of between 1 and 1.8 mm and in the CD of between 0.8 and 1.7 mm, and a second layer comprising a thermoplastic material forming an inner surface of the laminate and at least partially forming a surface of the laminate, the second layer being joined at least partly with the first layer, and also containing the plurality of perforations which extend through the second layer, wherein the first and the second layer have fibers which are intermixed at least partially in the region of the perforations, portions of the second layer surrounding the three-dimensionally shaped perforations extend into the perforations through the first layer; portions of the first and second layers surrounding the three-dimensionally shaped perforations project from the surface of the first layer; and the first layer comprises a thermoplastic material whose melting point is lower than the melting point of the thermoplastic material of the second layer and the first layer is at least partly melted in the region of the perforations which stabilizes the structure of the laminate, and the second layer is substantially not melted in the region of the perforations.