Apertured material for use in absorbent articles and method of making the same

Abstract

A film for use in absorbent articles is first microscopically textured and then macroscopically apertured while maintaining the microscopic texture. The micro-texturing may be done by a variety of means including vacuum forming, and may include micro-apertures. The macroscopic texture may be done by a variety of means including thermo-mechanical means with a heat shielding means. Where heated pins are used, the heat shielding means protects the micro-texture from the heat so that the heat does not deform the micro-texture.

What is claimed is:  
     
         1 . A method for manufacturing a formed film, the method comprising: 
 extruding a thermoplastic material to form a film;    forming micro-textures soon after extrusion, while the thermoplastic material is still in a maleable state; and    forming three-dimensional macro-apertures after micro-textures have been formed.    
     
     
         2 . The method of  claim 1  wherein the micro-textures are formed with a differential pressure means.  
     
     
         3 . The method of  claim 1  wherein the micro-textures are formed by pulling the thermoplastic material onto a screen with a vacuum.  
     
     
         4 . The method of  claim 1  wherein the macro-apertures are formed with a thermo-mechanical forming process.  
     
     
         5 . The method of  claim 4  wherein the thermo-mechanical forming process includes use of a heat shielding material to maintain the micro-textures in the film while the film is in a nip of the thermo-mechanical means.  
     
     
         6 . The method of  claim 4  wherein the thermo-mechanical forming process includes use of a layer of nonwoven fabric with a higher melting point than the film as the heat shielding material.  
     
     
         7 . The method of  claim 1  wherein a nonwoven material is bonded to the film concurrently with the forming of macro-textures.  
     
     
         8 . An apertured thermoplastic film with a body facing surface and an absorbent core facing surface that comprises: 
 a micro-textured surface comprising a high density of elongated micro-funnels extending perpendicular to the surface's plane to form protrusions; and    three dimensional macro-apertures extending perpendicular to its plane to form protrusions on the film's absorbent core facing surface.    
     
     
         9 . The film of  claim 8  wherein the protrusions formed by the micro-funnels protrude from the same surface as the protrusions formed by the macro-apertures.  
     
     
         10 . The film of  claim 8  wherein the protrusions formed by the micro-funnels is in the opposite direction as the protrusions formed by the macro-apertures.  
     
     
         11 . The film of  claim 8  wherein the micro-funnels have a mesh of about 30 to about 100 micro funnels per linear inch.  
     
     
         12 . The film of  claim 8  wherein the micro-funnels have a mesh of about 40 to about 60 micro funnels per linear inch.  
     
     
         13 . The film of  claim 8  wherein the macro-apertures have a density of between 4 holes per square centimeter and 15 holes per square centimeter.  
     
     
         14 . The film of  claim 8  wherein the macro-apertures have a density of between 5 holes per square centimeter and 12 holes per square centimeter.  
     
     
         15 . The film of  claim 8  further comprising a nonwoven layer bonded to the absorbent facing side of the film with apertures aligned with the macro-protrusions on the absorbent facing side of the film.  
     
     
         16 . An absorbent article comprising: 
 a topsheet; and    an absorbent core;    wherein the topsheet is a film with apertures forming lands on a surface, the apertures being three dimensional and extending perpendicular to the surface, the lands having micro-apertures, the micro-apertures being three dimensional and extending perpendicular to the surface.    
     
     
         17 . The absorbent article of  claim 16  wherein the apertures and the micro-apertures extend opposite one another.  
     
     
         18 . The absorbent article of  claim 16  wherein the apertures and the micro-apertures extend in the same direction.  
     
     
         19 . The absorbent article of  claim 16  wherein the film is bonded to a nonwoven layer having openings aligned with the apertures.  
     
     
         20 . The film of  claim 16  wherein the micro-apertures have a mesh of about 30 to about 100 micro funnels per linear inch.  
     
     
         21 . The film of  claim 16  wherein the micro-apertures have a mesh of about 40 to about 60 micro funnels per linear inch.  
     
     
         22 . The film of  claim 16  wherein the apertures have a density of between 4 holes per square centimeter and 15 holes per square centimeter.  
     
     
         23 . The film of  claim 16  wherein the apertures have a density of between 5 holes per square centimeter and 12 holes per square centimeter.  
     
     
         24 . An absorbent article comprising: 
 a topsheet; and    an absorbent core;    wherein the topsheet is a film with apertures forming lands on a surface, the apertures being three dimensional and extending perpendicular to the surface, the lands having micro-textures, the micro-textures being three dimensional and extending perpendicular to the surface.    
     
     
         25 . The absorbent article of  claim 24  wherein the micro-textures extend opposite the apertures.  
     
     
         26 . The absorbent article of  claim 24  wherein the micro-textures are one of a group consisting of microdots, micro-ridges, random matte, and micro-apertures.  
     
     
         27 . The absorbent article of  claim 24  wherein the film is bonded to a nonwoven layer having openings aligned with the apertures.  
     
     
         28 . The film of  claim 24  wherein the apertures have a density of between 4 holes per square centimeter and 15 holes per square centimeter.  
     
     
         29 . The film of  claim 24  wherein the apertures have a density of between 5 holes per square centimeter and 12 holes per square centimeter.  
     
     
         30 . A method for making a formed film comprising: 
 extruding a resin onto a forming screen imparted with a micro-texture so that the resin forms to the screen and forms a film with the micro-texture;    aperturing the film with heated pins to create three dimensional macro-apertures with lands between the macro-apertures; and    shielding the lands between the macro apertures during the aperturing process with a protective layer to prevent the heating of the lands to a point where the micro-texture loses its form.    
     
     
         31 . The method of  claim 30  wherein the protective layer is a nonwoven material with a melting point higher than the resin.  
     
     
         32 . The method of  claim 30  further comprising: 
 bonding a nonwoven layer to the film during the aperturing process such that the heated pins extend through the nonwoven layer so that the nonwoven layer does not obstruct fluid flow through the apertures.  
 
     
     
         33 . The method of  claim 32  wherein a vacuum is applied to the forming screen to create micro-apertures as the micro-texture in the film.  
     
     
         34 . An absorbent article comprising: 
 a topsheet;    an absorbent core; and    an intermediate layer between the topsheet and the absorbent core;    wherein the intermediate layer is a film with apertures forming lands on a surface, the apertures being three dimensional and extending perpendicular to the surface, the lands having micro-textures, the micro-textures being three dimensional and extending perpendicular to the surface.    
     
     
         35 . The absorbent article of  claim 34  wherein the micro-textures extend opposite the apertures.  
     
     
         36 . The absorbent article of  claim 34  wherein the micro-textures are one of a group consisting of microdots, micro-ridges, random matte, and micro-apertures.  
     
     
         37 . The absorbent article of  claim 34  wherein the film is bonded to a nonwoven layer having openings aligned with the apertures.  
     
     
         38 . The film of  claim 34  wherein the apertures have a density of between 4 holes per square centimeter and 15 holes per square centimeter.  
     
     
         39 . The film of  claim 34  wherein the apertures have a density of between 5 holes per square centimeter and 12 holes per square centimeter.