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 forming structure includes an outer surface configured to receive a polymer web, an inner surface, a thickness between the outer surface and the inner surface, and a plurality of openings extending through the thickness at an acute angle relative to a plane tangential to the outer surface. Each of the plurality of openings has a shape at the outer surface defined by a first ellipse having a first major axis and a first minor axis and a second ellipse having a second major axis and a second minor axis. The first major axis is substantially parallel to a machine direction and coincides with the second minor axis. The second major axis is substantially parallel to a transverse direction orthogonal to the machine direction and is offset from the first minor axis.

Abstract: A formed film that may be used in an absorbent article. The formed film includes a plurality of wavy ridges extending generally in a machine direction. The plurality of wavy ridges form a repeating pattern of peaks and valleys. A plurality of gathering pockets are in between adjacent wavy ridges and have an apertured bottom surface offset from top surfaces of the wavy ridges in a z-direction. Each of the gathering pockets has a length in the machine direction greater than a width in a cross direction, orthogonal to the machine direction.

Abstract: A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

Abstract: A method for manufacturing an elastic laminate includes conveying an elastic laminate precursor material comprising an elastic film layer and a nonwoven layer in a machine direction to an activation station, activating, at the activation station, a first zone of the elastic laminate precursor material to create a first stretch zone of the elastic laminate, and activating a second zone of the elastic laminate precursor material to create a second stretch zone of the elastic laminate having at least one stretch property different from the first stretch zone of the elastic laminate.

Abstract: An apparatus for manufacturing a formed film includes a first forming station configured to receive a polymer web and a second forming station configured to receive the polymer web from the first forming station after the polymer web has been apertured. The first forming station has a first forming structure with a plurality of first openings configured to form a plurality of apertures in the polymer web. The second forming station includes a second forming structure with a plurality of second openings and an overlying pattern configured to form raised areas in the polymer web to create a three-dimensional formed film.

Abstract: An apertured extrusion coated nonwoven web for use as a topsheet in an absorbent article includes a nonwoven material having a user-facing side and a garment-facing side opposite the user-facing side. The nonwoven material includes a plurality of fibers. The apertured extrusion coated nonwoven web also includes a polymer coating on the garment-facing side of the nonwoven material, the polymer coating having a basis weight of about 2 gsm to about 6 gsm, and a plurality of three-dimensional apertures that extend through the nonwoven material and the polymer coating. Each of the plurality of three-dimensional apertures includes a continuous sidewall extending from a garment-facing side of the polymer coating. The apertured extrusion coated nonwoven web has an open area of greater than 5% when subjected to a pressure of 0.6 psi.

Abstract: A formed film includes a first surface generally located in a first plane, a second surface generally located in a second plane parallel to and spaced from the first plane, and a third surface generally located in a third plane parallel to and spaced from the first plane and the second plane, in between the first plane and the second plane. A porous structure extends between the second surface and the third surface. A plurality of raised areas have sidewalls that extend between the first surface and the third surface, and top portions that define the first surface. The plurality of sidewalls, the porous structure, and the first plane define a plurality of gathering volumes.

Abstract: A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

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 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: 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 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.