Apparatus for making a polymeric web exhibiting a soft and silky tactile impression

Abstract

A polymeric web exhibiting a soft and silky tactile impression on at least one side thereof is disclosed. The silky feeling side of the web exhibits a pattern of discrete hair-like fibrils, each of the hair-like fibrils being a protruded extension of the web surface and having a side wall defining an open proximal portion and a closed distal portion. The hair-like fibrils exhibit a maximum lateral cross-sectional diameter of between 2 and 5 mils, and an aspect ratio from 1 to 3. Methods and apparatus for making the polymeric web utilize a three-dimensional forming structure having a plurality of protrusions being generally columnar forms having an average aspect ratio of at least about 1.

What is claimed is:  
     
         1 . A forming structure for use in making macroscopically expanded, three-dimensional, apertured polymeric webs; said forming structure comprising: 
 a. a plurality of forming structure interconnecting members that define a plurality of forming structure apertures, said forming structure apertures permitting fluid communication between opposing first and second surfaces of said forming structure;    b. a plurality of protrusions extending from said first surface of said forming structure; and    c. said protrusions being generally columnar forms having an average aspect ratio of at least about 1.    
     
     
         2 . The forming structure of  claim 1 , wherein said forming structure comprises polymeric material.  
     
     
         3 . The forming structure of  claim 2 , wherein said polymeric material is a thermoplastic.  
     
     
         4 . The forming structure of  claim 2 , wherein said polymeric material is a thermoset.  
     
     
         5 . The forming structure of  claim 1 , wherein said protrusions have an average aspect ratio of at least 2.  
     
     
         6 . The forming structure of  claim 1 , wherein said protrusions have an average aspect ratio of at least 3.  
     
     
         7 . The forming structure of  claim 1 , wherein said protrusions are substantially cylindrical.  
     
     
         8 . The forming structure of  claim 1 , wherein said protrusions have an amplitude measured from said first surface of said forming structure to a distal end of said protrusion, said protrusions being shaped such that a maximum dimension of any lateral cross-section is greater than a similar dimension of a lateral cross-section at a greater amplitude.  
     
     
         9 . The forming structure of  claim 1 , wherein at least a portion of said plurality of forming structure apertures is generally polygonal shaped.  
     
     
         10 . The forming structure of  claim 1 , wherein at least a portion of said interconnecting members are linear, and at least a portion of said plurality of forming structure apertures are generally polygonal shaped.  
     
     
         11 . The forming structure of  claim 1 , wherein at least a portion of said interconnecting members are curvilinear, and at least a portion of said plurality of forming structure apertures are generally curvilinearly shaped.  
     
     
         12 . The forming structure of  claim 1 , wherein said interconnecting members define forming structure apertures having shapes chosen from the group consisting of: ovals, circles, tear-drop shapes; ellipses, hour-glass shapes, and heart-shapes.  
     
     
         13 . The forming structure of  claim 1 , wherein said forming structure is a belted forming structure.