High-elongation apertured nonwoven web and method for making

Abstract

An extensible apertured nonwoven web, and a method for making such an apertured nonwoven web. In one embodiment the method comprises the steps of providing an apertured nonwoven web, incrementally stretching it in a direction substantially parallel to the cross machine direction, and applying tension in the machine direction such that the web width after applying tension is less than the web width after incremental stretching. In another embodiment the method comprises the steps of providing a nonwoven web; weakening the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations; applying a first tensioning force to the nonwoven web to cause the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of apertures in the nonwoven web coincident with the weakened, melt-stabilized locations, incrementally stretching the nonwoven web in a direction substantially parallel to the cross machine direction, and applying tension in the machine direction such that the web width after applying machine direction tension is less than the web width after incremental stretching. An apparatus for producing a web of the present invention by this method is also disclosed. The extensible apertured nonwoven web produced has a plurality of apertures each having a hole size greater than 2 mm 2 , and a hole aspect ratio less than 6, the nonwoven web having an open area greater than 15% and being capable of at least 70% extension in the cross machine direction at a loading of 10 g/cm.

What is claimed is:  
     
         1 . A nonwoven web comprising a plurality of apertures each having a hole size greater than 2 mm 2 , and a hole aspect ratio less than 6, said nonwoven web having an open area greater than 15% and being capable of at least 70% extension in the cross machine direction at a loading of 10 g/cm.  
     
     
         2 . The nonwoven web of  claim 1 , wherein said nonwoven web has a basis weight between 15 and 70 gsm.  
     
     
         3 . The nonwoven web of  claim 1 , wherein said nonwoven web has a basis weight between 40 and 50 gsm.  
     
     
         4 . The nonwoven web of  claim 1  wherein said nonwoven web is a web selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.  
     
     
         5 . The nonwoven web of  claim 4  wherein said web of meltblown fibers includes meltblown microfibers.  
     
     
         6 . The nonwoven web of  claim 1 , wherein said nonwoven web is a topsheet on a disposable absorbent article.  
     
     
         7 . A nonwoven web comprising a plurality of apertures formed by application of a tensioning force, said apertures coincident with a plurality of weakened, melt-stabilized locations, said apertures having a circumferential edge, a portion of said circumferential edge being defined by a remnant of said melt-stabilized locations, said nonwoven web capable of extension in the cross machine direction of at least 70% at a loading of 10 g/cm.  
     
     
         8 . The nonwoven web of  claim 7 , wherein said nonwoven web comprises an open area greater than 15% and an average aperture size greater than 2.0 mm 2 .  
     
     
         9 . The nonwoven web of  claim 7 , wherein said nonwoven web has a basis weight between 15 and 60 gsm.  
     
     
         10 . The nonwoven web of  claim 7 , wherein said nonwoven web is a topsheet on a disposable absorbent article.  
     
     
         11 . A method for making a highly extensible apertured nonwoven web comprising the steps of: 
 a) providing a nonwoven web having a length measured in a machine direction and a first width measured in a cross machine direction;    b) weakening said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;    c) applying a first tensioning force to said nonwoven web to cause said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations creating a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations, said first tensioning force causing said nonwoven web to have a second width;    d) incrementally stretching said nonwoven web to locally extend portions of said nonwoven web in a direction substantially parallel to said cross machine direction to a third width that is greater than the second width;    e) applying tension to said nonwoven web in the machine direction such that said nowoven web has a width less than said -third width.    
     
     
         12 . The method of  claim 11  wherein said nonwoven web is a web having a peak CD extensibility of at least 150%, and being selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.  
     
     
         13 . The method of  claim 12  wherein said meltblown web includes meltblown microfibers.  
     
     
         14 . The method of  claim 11  wherein said nonwoven web comprises an elastic nonwoven web.  
     
     
         15 . The method of  claim 11  wherein said nonwoven web comprises a nonelastic nonwoven web.  
     
     
         16 . The method of  claim 11  wherein said second tensioning step causes said nonwoven web to exhibit extension in the cross machine direction of at least 70% at 10 g/cm loading.  
     
     
         17 . A method for making a highly extensible apertured nonwoven web comprising the steps of: 
 a) providing an apertured nonwoven web having a length measured in a machine direction and a first width measured in a cross machine direction;    b) incrementally stretching said nonwoven web to locally extend portions of said nonwoven web in a direction substantially parallel to said cross machine direction to a second width that is greater than the first width;    e) applying tension to said nonwoven web in the machine direction such that said nowoven web has a width less than said second width.    
     
     
         18 . The method of  claim 17  wherein said nonwoven web is a web having a peak CD extensibility of at least 150%, and being selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.  
     
     
         19 . The method of  claim 17  wherein said nonwoven web is a composite material comprising a mixture of fibers and one or more other materials selected from the group consisting of wood pulp, staple fibers, particulates and superabsorbent materials.  
     
     
         20 . The method of  claim 17  wherein said tensioning step causes said nonwoven web to exhibit extension in the cross machine direction of at least 70% at 10 g/cm loading.