Abstract: A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend through at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

Abstract: Methods, apparatus and articles of manufacture are shown for creating a soft textile expanded apertured film.

Abstract: A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend through at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

Abstract: A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend though at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

Abstract: A wrapper for an absorbent article, including a wrapper material including at least one microapertured film layer. The wrapper material has opposite longitudinal sides between first and second ends, and is folded at a first fold axis such that the longitudinal sides are aligned with one another. The wrapper material is bonded along the aligned longitudinal sides to define a pouch having bonded sides and a size for carrying an individual absorbent article therein. The first end of the wrapper material is folded at a second fold axis back over onto a front surface of the pouch to define a flap, the flap having opposite sides bonded with the pouch sides.

Abstract: Methods, apparatus and articles of manufacture are shown for creating a soft textile expanded apertured film.

Abstract: Methods, apparatus and articles of manufacture are shown for creating a soft textile expanded apertured film.

Abstract: A topsheet made of a fibrous web or a perforated film and having a clear top layer containing about 5% to about 50% of jade particles. The jade particles having a mean diameter of from about 50 to about 600 microns and an aspect ratio from about 1 to about 5. Also disclosed is method for manufacturing the topsheet, as well as absorbent articles and facial protection masks containing the topsheet.

Abstract: An elastic laminate for use as a tear resistant diaper side panel. The elastic laminate comprises an elastic substrate bonded to at least one layer of a tensioned spunbond nonwoven web comprising thermoplastic filaments comprising at least about 10% by weight polyethylene. The laminate is then incrementally stretched in the transverse direction to provide a service stretch greater than 100% and a strength ratio greater than 0.35. In one embodiment, the elastic substrate is bonded between the tensioned nonwoven webs by point bonding or hot melt adhesives.

Abstract: A method of thermo-mechanically forming macrotextures in a microtextured film wherein a heat shield is utilized to thermally insulate the microtexture during the forming process.

Abstract: Methods, apparatus and articles of manufacture are shown for creating a soft textile expanded apertured film.

Abstract: A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend though at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

Abstract: A perforated laminate comprising at least first and second layers and apertures extending through at least the first layer. The first layer is a nonwoven or formed film material, and the second layer comprises an absorbent structure. The at least first and second layers are primarily joined at the periphery of the perforated apertures. The laminate is particularly useful as a topsheet for an absorbent article, such as a disposable diaper or sanitary napkin. Also described are various materials and methods used to create such laminates.

Abstract: An elastomeric film is bonded between two or more layers of nonwoven webs formed of nonelastomeric thermoplastic fibers. The laminate has, in a predefined transverse direction, an elastic elongation value greater than the predefined elastic elongation value of the nonwoven webs, and an ultimate force to break in the predefined transverse direction of at least 3000 g/in. The laminate advantageously provides a tear resistant, multiple ply, fabric that is soft to the touch as a result of the outwardly disposed nonwoven webs, and has a high elastic modulus. The laminate is particularly useful in applications where closure portions of a product must be stretched to keep the product in place when worn.

Abstract: An absorbent article having a topsheet, an intermediate layer, an absorbent core, and a backsheet, wherein the intermediate layer is formed of an apertured nonwoven. The intermediate layer may include stiffening means such as apertured film or an additional nonwoven layer.

Abstract: An elastic laminate for use as a tear resistant diaper side panel. The elastic laminate comprises an elastic substrate bonded to at least one layer of a tensioned spunbond nonwoven web comprising thermoplastic filaments comprising at least about 10% by weight polyethylene. The laminate is then incrementally stretched in the transverse direction to provide a service stretch greater than 100% and a strength ratio greater than 0.35. In one embodiment, the elastic substrate is bonded between the tensioned nonwoven webs by point bonding or hot melt adhesives.

Abstract: An elastic laminate comprising an elastic substrate bonded by point bonding to at least one extensible nonwoven web comprising thermoplastic fibers or filaments bonded by point bonding. The bonding points of the extensible nonwoven web are disposed in concentrated areas that are combined with areas having a substantially lower density of bonding points. Also disclosed is a method of making an elastic laminate comprising the steps of forming the nonwoven web, providing an elastic substrate adjacent the nonwoven web, and point bonding the elastic substrate and the nonwoven web to provide the elastic laminate.

Abstract: A method of making a composite intermediate layer by forming a resilient three dimensional apertured formed film; forming a nonwoven web of fibers; joining the nonwoven web with the apertured formed film; and aperturing the joined nonwoven web and formed film to create large scale apertures in the joined nonwoven web and formed film.

Abstract: An elastomeric film is bonded between two or more layers of nonwoven webs formed of nonelastomeric thermoplastic fibers. The laminate has, in a predefined transverse direction, an elastic elongation value greater than the predefined elastic elongation value of the nonwoven webs, and an ultimate force to break in the predefined transverse direction of at least 3000 g/in. The laminate advantageously provides a tear resistant, multiple ply, fabric that is soft to the touch as a result of the outwardly disposed nonwoven webs, and has a high elastic modulus. The laminate is particularly useful in applications where closure portions of a product must be stretched to keep the product in place when worn.

Abstract: An absorbent article has a body facing side which is positioned against the users body. The absorbent article is made of, at least, a backsheet, an absorbent core, and a composite topsheet. The backsheet is opposite the body facing side. The absorbent core is between the backsheet and the body facing side. The composite topsheet is between the absorbent core and the body facing side. The composite topsheet includes a resilient three dimensional apertured formed film, a nonwoven web small scale apertures, and large scale apertures. The formed film is between the absorbent core and the body facing side. The formed film has a male side and a female side opposite the male side, and small scale apertures with a mesh count. The nonwoven web of fibers is between the formed film and the body facing side of the absorbent article. The large scale apertures extend through the nonwoven web and the formed film. The large scale apertures have a mesh count which is less than the mesh count of the small scale apertures.