Patent ID: 7655176

Claim:
A method for making a macroscopically expanded, three-dimensional, apertured polymeric web from a substantially planar polymeric precursor web, said method comprising the steps of: a. providing said precursor web; said precursor web being a thermoplastic film having a thickness; b. providing a rotating forming drum; c. providing a flexible belted forming structure having opposed surfaces; said forming structure comprising a plurality of protrusions, said protrusions having an aspect ratio of at least 1; said forming structure comprising a multiplicity of forming structure apertures; said apertures placing said opposed surfaces of said forming structure in fluid communication with one another; d. guiding said belted forming structure onto said rotating forming drum; e. supporting said precursor web on said belted forming structure; f. applying at least one high pressure liquid jet(s) to said precursor web, said liquid jet(s) having sufficient mass and velocity to cause said precursor web to be formed into a macroscopically expanded, three-dimensional, apertured polymeric web comprising hair-like fibrils and apertures; g. removing said belted forming structure and said apertured polymeric web from said rotating forming drum; h. providing drying means for removing liquid from said apertured polymeric web; i. drying said apertured polymeric web directly on said forming structure; and j. removing said apertured polymeric web from said belted forming structure.