Abstract: A hydro-enlarged apertured non-woven web includes a plurality of fibers with a plurality of bond points, a first surface defining a planar top, and a second surface defining a planar bottom. The second surface is separated from the first surface by a first distance defining a loft. A plurality of apertures extending through the non-woven web. The plurality of apertures is formed by spraying a fluid against an unapertured precursor web, causing a plurality of pins disposed on a pinned roller to punch through the unapertured precursor web. The unapertured precursor web has a third surface defining a planar top and a fourth surface defining a planar bottom, where the third surface is separated from the fourth surface by a second distance defining a precursor loft. The loft is greater than the precursor loft by a loft increase within a range of 50-110%.

Abstract: A hydroformed expanded spun bonded nonwoven 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 nonwoven 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. The hydroformed expanded spun bonded nonwoven web includes bicomponent fibers combining a polymer with PLA in a ratio of polymer/PLA within a range of about 20/80 to 80/20.

Abstract: A fluid distribution material for use in an absorbent article includes a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side. 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 user-facing side. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. A nonwoven layer is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of continuous fibers extending across the land areas and the plurality of apertures of the formed film layer and attached to the land areas at bond sites. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.

Abstract: A fluid distribution material for use in an absorbent article includes a formed film layer having a user-facing side and a garment-facing side opposite the user-facing side. 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 user-facing side. The garment-facing side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. A nonwoven layer is laminated to the garment-facing side of the formed film layer. The nonwoven layer includes a plurality of continuous fibers extending across the land areas and the plurality of apertures of the formed film layer and attached to the land areas at bond sites. The fluid distribution material has a compressibility of less than 10% between pressures of 0.21 psi and 0.60 psi.

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 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 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 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: 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 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.