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 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 manufacturing a composite material includes forming a composite precursor material comprising a nonwoven layer comprising a plurality of fibers and a polymer film layer laminated to the nonwoven layer; forming a plurality of apertured extended cells in the polymer film layer, each of the apertured extended cells having a continuous sidewall extending away from the nonwoven layer that terminates in an aperture at a distal end; and, while forming the plurality of apertured extended cells, pushing, with a fluid, at least one of the fibers into at least one of the apertured extended cells so that a portion of the at least one of the fibers extends into the at least one of the apertured extended cells and through the aperture at the distal end.

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 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 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 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 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 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 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: A polymeric film is provided, the film comprising one or more land portions that are substantially coplanar in a base plane and a plurality of distended portions separated from one another by the one or more land portions. The distended portions bow distally outward from the base plane. The polymeric film further comprises a plurality of annular micro-protrusions extending outward from the distal film surface, each protrusion having an apex. A portion of the plurality of annular micro-protrusions extends from each of the one or more land portions of the polymeric film and from each of the distended portions of the polymeric film.

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: 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: An apertured formed film particularly suited for use as a topsheet or transfer layer in an absorbent article comprises at least one thermoplastic olefin polymer and a fatty alcohol in an amount sufficient to increase the hydrophilic affinity of the film.

Abstract: An apertured material comprising a web and a plurality of apertures in the web, each aperture having at least two vertices with a convex flap of the web spanning a pair of the vertices.

Abstract: An apertured material comprising a web and a plurality of apertures in the web, each aperture having at least two vertices with a convex flap of the web spanning a pair of the vertices.

Abstract: The invention relates to a method of making a film, and to a die for making the film. The fluid die includes a fluid feed manifold connected to a housing having positioned therein at least one fluid feed channel in fluid communication with the fluid feed manifold. The housing also includes at least one profiling block within the fluid feed channel.

Abstract: The invention relates to a method of making a film, and to a die for making the film. The fluid die includes a fluid feed manifold connected to a housing having positioned therein at least one fluid feed channel in fluid communication with the fluid feed manifold. The housing also includes at least one profiling block within the fluid feed channel.