Abstract: An activated composite web includes a nonwoven layer, and a formed film layer attached to the nonwoven layer. The formed film layer includes a plurality of first apertured protuberances having a mesh count of at least 35, and a plurality of second apertured protuberances. Each of the second apertured protuberances has a cross-sectional area larger than each of the first apertured protuberances. A plurality of first lanes are aligned in a first direction and have a first width extending in a second direction substantially perpendicular to the first direction. The first apertured protuberances are located in the first lanes. A plurality of second lanes are aligned in the first direction and have a second width, less than the first width, extending in the second direction. The first lanes and the second lanes alternate with each other in the second direction. The second apertured protuberances are located in the second lanes.

Abstract: A method for hydroforming a spun bonded nonwoven web includes applying a plurality of pressurized liquid jets onto an original unexpanded spun bonded nonwoven web having an original loft while the web passes over a forming structure. A plurality of spun bonded fibers in the original unexpanded spun bonded nonwoven web are reoriented from a closely packed substantially horizontal orientation to a more loosely packed orientation with greater vertical spacing between the fibers to produce a hydroformed expanded spun bonded nonwoven web having a loft of at least about 1.3 times greater than the original loft of the original unexpanded spun bonded nonwoven web, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed expanded spun bonded nonwoven web has a surface with a plurality of protuberances in a pattern corresponding to the pattern of apertures in the forming structure.

Abstract: A process of constructing a forming screen through metal deposition in a nonconductive preform structure to achieve a desired aspect ratio of the forming screen thickness to open area.

Abstract: A method for hydroforming a composite precursor material includes forming a composite precursor material comprising an original spun bonded nonwoven web and a polymer film layer. The method also includes applying a plurality of pressurized liquid jets onto an outer surface of the original spun bonded nonwoven web while the composite precursor material passes over a forming structure to push and reorient a plurality of spun bonded fibers from a closely packed substantially horizontal orientation to a more loosely packed orientation with greater vertical spacing between the fibers to produce a hydroformed composite material comprising an expanded spun bonded nonwoven layer having a loft of at least about 1.3 times greater than the original loft of the original spun bonded nonwoven web, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web.

Abstract: A fluid distribution material for use in an absorbent article includes a formed film layer, with a basis weight of between about 10 gsm and about 25 gsm, a user-facing side, and a garment-facing side. The formed film layer includes a plurality of apertured protuberances, numbering 10 to 40 per linear inch. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances, with land areas therebetween. A nonwoven layer, with a basis weight of between about 10 gsm and about 15 gsm, is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of fibers adjacent the land areas. Fibers adjacent the land areas are gathered a higher density than fibers located adjacent the plurality of apertures. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.

Abstract: A formed film with micro-cells and macro-cells or depressions may be disclosed. For example, the film may include a lands. Each of the lands may include micro-cells thereon. The micro-cells may have a first orientation. The film may further include macro-depressions adjacent to at least one respective land. Each of the macro depressions may include additional second micro-cells. Those additional micro-cells may have a second orientation. The second orientation includes an orientation that is an inverse of the first orientation (e.g., is in an opposite direction of the first orientation).

Abstract: A method of processing a polymeric web includes providing a forming screen configured for supporting and moving with the web in a machine direction. The forming screen has a plurality of elliptical screen openings, each having a major axis perpendicular to the machine direction and a minor axis parallel to the machine direction. The method includes continuously depositing the web onto the forming screen and passing the web and forming screen through a water stream having a pressure level sufficient to cause the web to be forced into the screen openings, thereby forming protrusions extending from the planar surface of the web. Each protrusion has an apex, an opening at the apex, and an elliptical cross-section parallel to the planar surface of the web. The elliptical cross-section has a protrusion axis ratio that may be selected so as to produce a desired protrusion axis ratio.

Abstract: A fluid distribution material for use in an absorbent article includes a formed film layer having first and second sides and a basis weight of between about 10 gsm and about 25 gsm, and a nonwoven layer having a basis weight of between about 10 gsm and about 15 gsm and laminated to the formed film layer. The formed film layer includes a plurality of apertured protuberances arranged in a pattern having 10 to 40 protuberances per linear inch. Each of the protuberances includes a continuous sidewall extending from the first side, and the second side has a plurality of apertures aligned with the plurality of protuberances, and land areas in between the apertures. The nonwoven layer includes a plurality of fibers attached to the formed film layer at the land areas. The material has a rewet value of less than 0.075 grams in accordance with the Rewet Test Method.

Abstract: An absorbent article with a three-dimensional film transfer layer having an open lattice structure formed from a single film for improved user properties.

Abstract: An illustrative aspect of the invention provides a film comprising a release layer defining a first outer film surface and an adhesion layer defining a second outer film surface opposite the first outer film surface. The adhesion layer comprises a hydrogenated styrene block copolymer with a styrene content in a range of about 30% to 40% by weight. In some embodiments, the adhesion layer may further comprise low density polyethylene (LDPE). In some embodiments, the adhesion layer may further comprise LDPE and high density polyethylene (HDPE).

Abstract: A three-dimensional film for use as a transfer layer in an absorbent article has a continuous surface and a discontinuous surface disposed generally parallel to and spaced from said continuous surface; both the continuous surface and the discontinuous surface have large scale apertures defined by sidewalls originating on the surface and extending outwardly therefrom and sized to permit acquisition of fluids by gravity, and optionally each surface also includes small scale apertures sized to acquire fluids by capillary action.

Abstract: Films (10) for use in protecting surfaces are disclosed and comprise at least one release layer (14) and optionally an adhesion layer (12) and/or an intermediate layer, the release layer (14) having a plurality of three-dimensional protrusions (13) that are either formed integral with the release layer or are discrete polymer beads applied to the release layer.

Abstract: A composite material includes a nonwoven layer having a plurality of fibers and a polymer film layer with a plurality of extended cells. Each of the extended cells are contemplated to include continuous sidewalls extending away from the nonwoven layer. At least one of the fibers extends into one or more of the extended cells.

Abstract: A hydroformed expanded spun bonded nonwoven web has a first substantially planar surface on one side thereof and a second surface on an opposite side thereof. The second surface includes a plurality of protuberances in a pattern. The hydroformed expanded spun bonded web has an average loft of at least about 1.3 times greater than an original average loft of an original unexpanded spun bonded nonwoven web from which the hydroformed expanded spun bonded nonwoven web was created, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web.

Abstract: A hydroformed composite material includes an expanded spun bonded nonwoven layer having a loft of at least about 1.3 times greater than an original loft of an original unexpanded spun bonded nonwoven web from which the expanded spun bonded nonwoven layer was created, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed composite material includes a formed film layer that includes a plurality of extended cells containing continuous fibers and/or fibrils of the expanded spun bonded nonwoven layer.

Abstract: An apertured film with a reduced gloss through the use of light trap micro-pits uniformly distributed on the lands of the film in a random pattern and a method of making the same.

Abstract: A film particularly suited for use as a transfer layer in an absorbent article has a plurality of capillaries and a plurality of drains, said capillaries comprising side walls depending from a female side of the film and terminating in an aperture on a male side of the film; said drains comprising side walls that depending from the female side of the film and terminating in an aperture on the male side of the film, wherein the drains are disposed at an obtuse angle relative to a base plane of the film.

Abstract: A process of constructing a forming screen through metal deposition in a nonconductive preform structure to achieve a desired aspect ratio of the forming screen thickness to open area.

Abstract: Systems and methods for forming a vacuum formed, apertured film with micro-aberrations may be disclosed. For example, a polymer web such as a molten polymer web may be received at an engagement point between a screen with a positive aberration and a roller comprising a surface with a negative depression. The roller may have a diameter of no more than about 5.5 inches. A micro-aberration may be expanded, for example, on a land of the polymer web at the engagement point by inserting the positive aberration on the screen into the negative depression on the surface of the roller at a pressure of about 1.5 to about 3.5 pounds per linear inch (PLI). Additionally, one or more apertures are formed in the polymer web adjacent to a micro-aberration on a land.