Breathable and liquid impermeable web and method of making the web

Abstract

A web modified according to the disclosed method has desirable breathability and liquid impermeability, as well as extensibility and a soft, cloth-like textured surface.

What is claimed is: 
     
         1 . A disposable absorbent article comprising:
 a) a vapor permeable, liquid impervious, backsheet laminate;   b) a liquid pervious topsheet which is positioned in facing relation with said backsheet;   c) an absorbent core located between the backsheet laminate and the topsheet;   d) a first side panel and a second side panel, each disposed in a back waist region;   e) an elastic waist feature;   f) laterally opposed leg cuff elastics;   wherein a backsheet film is joined to a nonwoven on a garment-facing side to form the vapor permeable, liquid impermeable, microporous backsheet laminate;   wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has a dynamic fluid impact value of less than about 10 g/m 2 ;   wherein the backsheet film comprises a plurality pores and a plurality of capillaries running therebetween and connecting the plurality of pores, and wherein the backsheet is joined to the topsheet on a wearer-facing side of the backsheet;   wherein the laterally opposed leg cuff elastics are disposed parallel to each other and parallel with a longitudinal axis of the absorbent article, and wherein the leg cuff elastics are joined to the backsheet;   wherein side edges of the waist elastic feature extend laterally outboard of the side edges of the absorbent core in the back waist region;   wherein the plurality of capillaries extend between the wearer-facing side of the backsheet film and the garment-facing side of the backsheet film;   wherein the backsheet film is from about 0.25 mils to about 2.5 mils;   wherein the first and second side panels comprise a nonwoven; and   wherein the waist elastic feature does not overlap with the absorbent core.   
     
     
         2 . The disposable absorbent article of  claim 1 , wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has an air flow rate of at least about 2 liters/m 2 /s. 
     
     
         3 . The disposable absorbent article of  claim 1 , wherein the backsheet film comprises pore forming agents and has a mean pore size less than about 0.3 microns. 
     
     
         4 . The disposable absorbent article of  claim 1 , wherein the backsheet film comprises a thermoplastic polymer selected from the group consisting of polyolefins and copolymers, polyesters and copolymers, polyurethanes and copolymers, polyamides and copolymers and mixtures thereof. 
     
     
         5 . The disposable absorbent article of  claim 1 , wherein the vapor permeable, liquid impermeable, microporous backsheet laminate comprises fibers selected from the group consisting of polyolefins and copolymers, polyesters and copolymers, polyamide and copolymers, cellulose derivatives, and mixtures thereof. 
     
     
         6 . The disposable absorbent article of  claim 1 , wherein a plurality of micropores of the backsheet film are elongated. 
     
     
         7 . The disposable absorbent article of  claim 6 , wherein the plurality of micropores are elongated in the machine direction. 
     
     
         8 . The disposable absorbent article of  claim 1 , wherein the plurality of capillaries of the backsheet film is less than 0.1 micron. 
     
     
         9 . The disposable absorbent article of  claim 1 , wherein the backsheet film has been modified by being incrementally stretched. 
     
     
         10 . The disposable absorbent article of  claim 1 , wherein a plurality of capillaries of the backsheet film are hydrophobic. 
     
     
         11 . The disposable absorbent article of  claim 1 , wherein the vapor permeable, liquid impervious microporous backsheet laminate comprises a dynamic fluid impact value of less than about 7 g/m 2 . 
     
     
         12 . The disposable absorbent article of  claim 1 , wherein a majority of the capillaries run in a common direction. 
     
     
         13 . A disposable absorbent article comprising:
 a) a vapor permeable, liquid impervious, backsheet laminate;   b) a liquid pervious topsheet which is positioned in facing relation with said backsheet;   c) an absorbent core located between the backsheet laminate and the topsheet;   d) a first side panel and a second side panel, each disposed in a back waist region;   e) an elastic waist feature;   f) laterally opposed leg cuff elastics;   g) a landing zone;   wherein a backsheet film is joined to a nonwoven on a garment-facing side to form the vapor permeable, liquid impermeable, microporous backsheet laminate;   wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has a dynamic fluid impact value of less than about 10 g/m 2 ;   wherein the backsheet film comprises a plurality pores and a plurality of capillaries running therebetween and connecting the plurality of pores, and wherein the backsheet is joined to the topsheet on a wearer-facing side of the backsheet;   wherein the laterally opposed leg cuff elastics are disposed parallel to each other and parallel with a longitudinal axis of the absorbent article;   wherein side edges of the waist elastic feature extend laterally outboard of the side edges of the absorbent core in the back waist region;   wherein the plurality of capillaries extend between the wearer-facing side of the backsheet film and the garment-facing side of the backsheet film;   wherein the backsheet film is from about 0.25 mils to about 2.5 mils; and   wherein the first and second side panels comprise a nonwoven.   
     
     
         14 . The disposable absorbent article of  claim 13 , wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has an air flow rate of at least about 2 liters/m 2 /s. 
     
     
         15 . The disposable absorbent article of  claim 13 , wherein the backsheet film comprises pore forming agents and has a mean pore size less than about 0.3 microns. 
     
     
         16 . The disposable absorbent article of  claim 13 , wherein a plurality of micropores of the backsheet film are elongated. 
     
     
         17 . The disposable absorbent article of  claim 16 , wherein the plurality of micropores are elongated in the machine direction. 
     
     
         18 . The disposable absorbent article of  claim 13 , wherein the plurality of capillaries of the backsheet film is less than 0.1 micron. 
     
     
         19 . The disposable absorbent article of  claim 13 , wherein the backsheet film has been modified by being incrementally stretched. 
     
     
         20 . The disposable absorbent article of  claim 13 , wherein a plurality of capillaries of the backsheet film are hydrophobic. 
     
     
         21 . The disposable absorbent article of  claim 13 , wherein the vapor permeable, liquid impervious microporous backsheet laminate comprises a dynamic fluid impact value of less than about 7 g/m 2 . 
     
     
         22 . A disposable absorbent article comprising:
 a) a vapor permeable, liquid impervious, backsheet laminate;   b) a liquid pervious topsheet which is positioned in facing relation with said backsheet;   c) an absorbent core located between the backsheet laminate and the topsheet;   d) a first side panel and a second side panel, each disposed in a back waist region;   e) an elastic waist feature;   f) laterally opposed leg cuff elastics;   g) a landing zone;   wherein a backsheet film is joined to a nonwoven on a garment-facing side to form the vapor permeable, liquid impermeable, microporous backsheet laminate;   wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has a dynamic fluid impact value of less than about 10 g/m 2 ;   wherein the backsheet film comprises a plurality pores and a plurality of capillaries running therebetween and connecting the plurality of pores, and wherein the backsheet is joined to the topsheet on a wearer-facing side of the backsheet;   wherein the laterally opposed leg cuff elastics are disposed parallel to each other and parallel with a longitudinal axis of the absorbent article, and wherein the leg cuff elastics are joined to the backsheet;   wherein side edges of the landing zone extend laterally outboard of side edges of the absorbent core;   wherein the plurality of capillaries extend between the wearer-facing side of the backsheet film and the garment-facing side of the backsheet film;   wherein the backsheet film is from about 0.25 mils to about 2.5 mils;   wherein the first and second side panels comprise a nonwoven; and   wherein the waist elastic feature does not overlap with the absorbent core.   
     
     
         23 . The disposable absorbent article of  claim 22 , wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has an air flow rate of at least about 2 liters/m 2 /s. 
     
     
         24 . The disposable absorbent article of  claim 22 , wherein the backsheet film comprises pore forming agents and has a mean pore size less than about 0.3 microns. 
     
     
         25 . The disposable absorbent article of  claim 22 , wherein a plurality of micropores of the backsheet film are elongated in the machine direction. 
     
     
         26 . The disposable absorbent article of  claim 22 , wherein the plurality of capillaries of the backsheet film is less than 0.1 micron. 
     
     
         27 . The disposable absorbent article of  claim 22 , wherein the backsheet film has been modified by being incrementally stretched. 
     
     
         28 . The disposable absorbent article of  claim 22 , wherein a plurality of capillaries of the backsheet film are hydrophobic. 
     
     
         29 . The disposable absorbent article of  claim 22 , wherein the vapor permeable, liquid impervious microporous backsheet laminate comprises a dynamic fluid impact value of less than about 7 g/m 2 . 
     
     
         30 . A disposable absorbent article comprising:
 a) a vapor permeable, liquid impervious, backsheet laminate;   b) a liquid pervious topsheet which is positioned in facing relation with said backsheet;   c) an absorbent core located between the backsheet laminate and the topsheet;   d) a first side panel and a second side panel, each disposed in a back waist region;   e) an elastic waist feature;   f) laterally opposed leg cuff elastics;   g) a landing zone;   wherein a backsheet film is joined to a nonwoven on a garment-facing side to form the vapor permeable, liquid impermeable, microporous backsheet laminate;   wherein the vapor permeable, liquid impermeable, microporous backsheet laminate has a dynamic fluid impact value of less than about 10 g/m 2 ;   wherein the backsheet film comprises a plurality pores and a plurality of capillaries running therebetween and connecting the plurality of pores, and wherein the backsheet is joined to the topsheet on a wearer-facing side of the backsheet;   wherein the laterally opposed leg cuff elastics are disposed parallel to each other and parallel with a longitudinal axis of the absorbent article, and wherein the leg cuff elastics are joined to the backsheet;   wherein side edges of the landing zone extend laterally outboard of side edges of the absorbent core;   wherein side edges of the waist elastic feature extend laterally outboard of the side edges of the absorbent core in the back waist region;   wherein the plurality of capillaries extend between the wearer-facing side of the backsheet film and the garment-facing side of the backsheet film;   wherein the backsheet film is from about 0.25 mils to about 2.5 mils; and   wherein the first and second side panels comprise a nonwoven.