Process for concurrently aperturing, bonding and texturing nonwoven materials and products made therefrom

Abstract

A process is disclosed for simultaneously aperturing, bonding and texturizing nonwoven webs. In one embodiment, the process can be used to combine two material layers together without using an adhesive. For instance, a nonwoven web can be apertured, texturized and bonded to an opposing web containing superabsorbent materials.

Description

[0001] PROCESS FOR CONCURRENTLY APERTURING, BONDING AND TEXTURING NONWOVEN MATERIALS AND PRODUCTS MADE THEREFROM

[0002] CROSS-REFERENCE TO RELATED APPLICATION

[0003] The present application is related and has right of priority to U.S. Provisional Patent Application No. 63 / 604,258 filed on November 30, 2023, which is incorporated by reference in its entireties for all purposes.

[0004] BACKGROUND

[0005] Nonwoven webs can be made according to various different processes and can be incorporated into many different products based upon the properties of the webs. For instance, nonwoven webs and laminates made from the webs are well suited for use in constructing articles that absorb, distribute, and / or retain fluids, such as liquids. For instance, many different types of nonwoven materials are incorporated into personal care products, such as disposable diapers, adult incontinence products, feminine hygiene products, child pants, training pants, and the like.

[0006] For instance, nonwoven materials, such as spunbond webs, meltblown webs, carded webs, and the like, have been used as bodyside liners in disposable absorbent articles. Typically, very open and porous liner structures have been employed to allow liquids to pass through them rapidly, thereby keeping the wearer’s skin separate from the wetted absorbent core underneath the liner. Also, other layers of material, such as those constructed with thick, lofty fabric structures, have been interposed between the liner and the absorbent core for the purposes of handling surges of liquids and reducing the flowback of liquids.

[0007] In order to increase the liquid porosity of nonwoven materials, the materials have been apertured in the past. For instance, bodyside liners made from nonwoven materials have been apertured for creating openings which are larger than the spaces between the fibers in the nonwoven webs. The prior methods and apparatus have often included the use of rotating rolls having projections extending therefrom. The projections are used to pierce the webs to form the apertures.

[0008] In order to incorporate the apertured material into a product, such as an absorbent article, the apertured layer was typically adhered to other layers in the article using an adhesive in a converting process. Applying an adhesive to the materials, however, not only adds an extra process step but can also create issues related to adhesive bleed through, glue buildup, and the like. The adhesive can also increase stiffness and decrease the softness of the laminate being formed.

[0009] In view of the above, a need exists for a method of aperturing and bonding a nonwoven web. For instance, a need exists for a method of aperturing and bonding the nonwoven web to an adjacent material while eliminating the need to use an adhesive. A need also exists for a method of further improving the softness and feel of an apertured web by incorporating a three-dimensional conformation into the web.

[0010] SUMMARY

[0011] In general, the present disclosure is directed to a process for concurrently or simultaneously aperturing, bonding, and embossing a material, such as a nonwoven web. For instance, according to the process of the present disclosure, a pattern of apertures, a bonding pattern, and a pattern of raised areas can be formed into a nonwoven web all in a single process step. In one embodiment, a single layer of a nonwoven web is subjected to the process for aperturing the web, creating greater surface texture, and for bonding together fibers contained within the web. In an alternative embodiment, superimposed layers can be fed into a process in which the multiple layers are bonded together while being apertured and texturized without having to use any adhesive material. The process of the present disclosure is particularly well suited for producing nonwoven webs and laminates that may be used to construct personal care products, such as absorbent articles.

[0012] In one embodiment, the present disclosure is directed to a process for aperturing, bonding, and texturizing a nonwoven material. The process includes feeding a nonwoven web having a first surface and a second and opposite surface into a nip formed between complementary patterned rolls including a first patterned roll positioned opposite a second patterned roll. The nonwoven web comprises unbonded fibers. Within the nip, the nonwoven web is concurrently apertured and textured. The nonwoven web is also subjected to heat and pressure within the nip that causes the unbonded fibers to plasticize and form a pattern of bond sites. During the process, the nonwoven web is textured in the nip such that a pattern of discrete raised areas are formed on at least one surface of the nonwoven web.

[0013] The apertures formed in the nonwoven web can have an average diameter of from about 0.5 mm to about 3.5 mm, such as from about 0.75 mm to about 2.5 mm. The aperture density can be from about 1 aperture per cm2to about 5 apertures per cm2, such as from about 1 aperture per cm2to about 4 apertures per cm2. The bond sites, on the other hand, can be in a pattern that covers from about 1% to about 25% of the surface area of the nonwoven web, such as from about 2% to about 15% of the surface area of the nonwoven web, such as from about 3% to about 10% of the surface area of the nonwoven web. In one aspect, the bond sites can be separate from and / or located a distance from the apertures.

[0014] The discrete raised areas formed on one surface of the nonwoven web can have a height of greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 1 mm, and less than about 5 mm. The density of the raised areas on one surface of the nonwoven web can be from about 1 raised area per 4 cm2to about 20 raised areas per 4 cm2, such as from about 1 raised area per 4 cm2to about 15 raised areas per 4 cm2.

[0015] As described above, the nip is formed between a first patterned roll and a second patterned roll. The first patterned roll can include a pattern of aperture pins, bonding elements, and discrete depressions or recesses for forming the apertures, bond sites, and raised areas respectively. The second patterned roll can have a pattern that engages and mates with the aperture pins and discrete depressions on the first patterned roll. In one aspect, the second patterned roll can comprise a flat surface opposite the bonding elements. During the process, the patterned rolls can apply from about 100 pounds per linear inch to about 300 pounds per linear inch, such as from about 125 pounds per linear inch to about 225 pounds per linear inch. At least one of the patterned rolls can be heated. For instance, the surface of at least one of the patterned rolls can be at a temperature of from about 200°F to about 380° F, such as from about 220°F to about 320°F.

[0016] In one aspect, at least two superimposed layers are fed into the nip simultaneously. The two superimposed layers can include a first layer comprising the nonwoven web and a second layer. The second layer, for instance, can comprise a second nonwoven web or can comprise a polymer film. In one embodiment, the second layer can contain superabsorbent particles for forming an absorbent core in an absorbent article. For instance, the second layer can comprise a foam formed web containing the superabsorbent material.

[0017] When feeding more than one layer into the nip, the bond sites cause the layers to bond together without having to use an adhesive.

[0018] Other features and aspects of the present disclosure are discussed in greater detail below.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

[0021] Figure 1 is a cross-sectional view of one embodiment of a process in accordance with the present disclosure;

[0022] Figure 2 is a cross-sectional view of another embodiment of a process in accordance with the present disclosure;

[0023] Figure 3 is a plan view of one embodiment of the surface of a patterned roll for processing nonwoven webs in accordance with the present disclosure;

[0024] Figure 4a is a plan view of an aperture pin and bonding elements contained in the pattern illustrated in Figure 3;

[0025] Figure 4b is a cross-sectional view of the aperture pin and bonding elements illustrated in Figure 4a; Figure 5a is a plan view of an aperture pin and depression element contained in the pattern illustrated in Figure 3;

[0026] Figure 5b is a cross-sectional view of the aperture pin and depression element as shown in Figure 5a;

[0027] Figure 6 is a cross-sectional view of the aperture pin and bonding elements as shown in Figure 4b in conjunction with a partial cross-sectional view of a complementary patterned roll; and

[0028] Figure 7 is a cross-sectional view of the aperture pin and depression element as shown in Figure 5b in conjunction with a partial cross-sectional view of an opposing complementary patterned roll.

[0029] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

[0030] DEFINITIONS

[0031] As used herein the term “nonwoven fabric, material or web” refers to a web having a structure of individual fibers, filaments or threads (collectively referred to as “fibers” for sake of simplicity) which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, carded web processes, etc.

[0032] As used herein, the term “meltblown web” generally refers to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten fibers into converging high velocity gas (e.g. air) streams that attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin, et al., which is incorporated herein in its entirety by reference thereto for all purposes. Generally speaking, meltblown fibers may be microfibers that are substantially continuous or discontinuous, generally smaller than 10 microns in diameter, and generally tacky when deposited onto a collecting surface.

[0033] As used herein, the term “spunbond web" generally refers to a web containing small diameter substantially continuous fibers. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, usually circular, capillaries of a spinnerette with the diameter of the extruded fibers then being rapidly reduced as by, for example, eductive drawing and / or other well-known spunbonding mechanisms. The production of spunbond webs is described and illustrated, for example, in U.S. Pat. No. 4,340,563 to Appel, et al., U.S. Pat. No. 3,692,618 to Dorschner, et al., U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat. No. 3,338,992 to Kinney, U.S. Pat. No. 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat. No. 3,542,615 to Dobo, et al., and U.S. Pat. No. 5,382,400 to Pike, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers may sometimes have diameters less than about 40 microns, and are often between about 5 to about 20 microns. To provide additional web integrity the webs so formed can be subjected to additional fiber bonding techniques if so desired. See for example, U.S. Pat. No. 3,855,046 to Hansen et al., which is incorporated herein in its entirety by reference thereto for all purposes.

[0034] As used herein, the term "carded web” generally refers to a web containing natural or synthetic staple length fibers typically having fiber lengths less than 100 millimeters. Bales of staple fibers undergo an opening process to separate the fibers which are then sent to a carding process which separates and combs the fibers to align them in the machine direction after which the fibers are deposited onto a moving wire for further processing. Such webs usually are subjected to some type of bonding process such as thermal bonding using heat and / or pressure. In addition or in lieu thereof, the fibers may be subject to adhesive processes to bind the fibers together such as by the use of powder adhesives. Still further, the carded web may be subjected to fluid entangling such as hydroentangling to further intertwine the fibers and thereby improve the integrity of the carded web. Carded webs due to the fiber alignment in the machine direction, once bonded, will typically have more machine direction strength than cross machine direction strength.

[0035] As used herein, the term "fluid entangling” and "fluid-entangled” generally refers to a formation process for further increasing the degree of fiber entanglement within a given fibrous nonwoven web or between fibrous nonwoven webs and other materials so as to make the separation of the individual fibers and / or the layers more difficult as a result of the entanglement. Generally this is accomplished by supporting the fibrous nonwoven web on some type of forming or carrier surface which has at least some degree of permeability to the impinging pressurized fluid. A pressurized fluid stream (usually multiple streams) is then directed against the surface of the nonwoven web which is opposite the supported surface of the web. The pressurized fluid contacts the fibers and forces portions of the fibers in the direction of the fluid flow thus displacing all or a portion of a plurality of the fibers towards the supported surface of the web. The result is a further entanglement of the fibers in what can be termed the Z-direction of the web (its thickness) relative to its more planar dimension, its X-Y plane. When two or more separate webs or other layers are placed adjacent one another on the forming / carrier surface and subjected to the pressurized fluid, the generally desired result is that some of the fibers of at least one of the webs are forced into the adjacent web or layer thereby causing fiber entanglement between the interfaces of the two surfaces so as to result in the bonding or joining of the webs / l ayers together due to the increased entanglement of the fibers. The degree of bonding or entanglement will depend on a number of factors including, but not limited to, the types of fibers being used, their fiber lengths, the degree of pre-bonding or entanglement of the web or webs prior to subjection to the fluid entangling process, the type of fluid being used (liquids, such as water, steam or gases, such as air), the pressure of the fluid, the number of fluid streams, the speed of the process, the dwell time of the fluid and the porosity of the web or webs / other layers and the forming / carrier surface. One of the most common fluid entangling processes is referred to as hydroentangling which is a well-known process to those of ordinary skill in the art of nonwoven webs. Examples of fluid entangling process can be found in U.S. Pat. No. 4,939,016 to Radwanski et al., U.S. Pat. No. 3,485,706 to Evans, and U.S. Pat. Nos. 4,970,104 and 4,959,531 to Radwanski, each of which is incorporated herein in its entirety by reference thereto for all purposes.

[0036] As used herein, the terms “machine direction" or “MD” generally refers to the direction in which a material is produced. The term “cross-machine direction” or “CD” refers to the direction perpendicular to the machine direction.

[0037] As used herein, the term “elastomeric” and “elastic” and refers to a material that, upon application of a stretching force, is stretchable in at least one direction (such as the CD direction), and which upon release of the stretching force, contracts / returns to approximately its original dimension. For example, a stretched material may have a stretched length that is at least 50% greater than its relaxed unstretched length, and which will recover to within at least 50% of its stretched length upon release of the stretching force. A hypothetical example would be a one (1 ) inch sample of a material that is stretchable to at least 1.50 inches and which, upon release of the stretching force, will recover to a length of not more than 1.25 inches. Desirably, the material contracts or recovers at least 50%, and even more desirably, at least 80% of the stretched length.

[0038] As used herein, the term “thermal point bonding” generally refers to a process performed, for example, by passing a material between a patterned roll (e.g ., calender roll) and another roll (e.g., anvil roll), which may or may not be patterned. One or both of the rolls are typically heated.

[0039] As used herein, the term “foam formed product” means a product formed from a suspension including a mixture of a solid, a liquid, and dispersed gas bubbles.

[0040] As used herein, the term “foam forming process” means a process for manufacturing a product involving a suspension including a mixture of a solid, a liquid, and dispersed gas bubbles.

[0041] As used herein, the term “foaming fluid" means any one or more known fluids compatible with the other components in the foam forming process. Suitable foaming fluids include, but are not limited to, water. The term “absorbent article” refers herein to an article intended and / or adapted to be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Examples include, but are not limited to, diapers, diaper pants, training pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads or pants, incontinence products, medical garments, surgical pads and bandages, and so forth.

[0042] The term "superabsorbent material" as used herein refers to water-swellable, water-insoluble organic or inorganic materials including superabsorbent polymers and superabsorbent polymer compositions capable, under the most favorable conditions, of absorbing at least about 10 times their weight, or at least about 15 times their weight, or at least about 25 times their weight in an aqueous solution containing 0.9 weight percent sodium chloride.

[0043] The term "pulp" as used herein refers to fibers from natural sources such as woody and non- woody plants. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute, hemp, and bagasse. Pulp fibers can include hardwood fibers, softwood fibers, and mixtures thereof.

[0044] As used herein the term "staple fibers" means discontinuous fibers made from synthetic polymers or regenerated cellulose, such as polypropylene, polyester, post consumer recycle (PCR) fibers, polyester, nylon, viscose, rayon, and the like, and those not hydrophilic may be treated to be hydrophilic. Staple fibers may be cut fibers or the like. Staple fibers can have cross-sections that are round, bicomponent, multicomponent, shaped, hollow, or the like.

[0045] As used herein, “binder fibers" are fibers that can bond to other fibers in a substrate using chemical, mechanical, or thermal means. The binder fibers may comprise thermally bondable fibers that, when heated, form thermal bonds with other fibers at their point of intersection. In one aspect, the binder fibers include a surface polymer having a lower melting temperature. For instance, the binder fibers can be made from a polymer, such as a polyolefin, having a melting temperature of less than 200°C, such as less than 180°C, such as less than 160°C, such as less than 140°C, such as less than 120°C, such as less than 100°C, and greater than 80°C, such as greater than 90°C. In one aspect, the binder fibers comprise conjugate fibers, such as bicomponent fibers. The conjugate fibers can have a core and sheath structure, including a core polymer surrounded by a sheath polymer. The core polymer can have a higher melting temperature than the sheath polymer. The core polymer can be selected for its strength and high melting point and the sheath polymer can be made from a polymer selected for its lower melting temperature. The core polymer, for instance, can have a melting temperature higher than the sheath polymer. In this manner, the sheath polymer, when subjected to heat, melts and bonds to other fibers within the web at intersecting points. The core polymer, however, allows the bicomponent binder fiber to retain its shape and provide strength.

[0046] As used herein, “synthetic polymer fibers” refers to fibers made from polymers that may include binder fibers. Synthetic polymer fibers can include polyester fibers, such as fibers made from a polyethylene terephthalate polymer. Other polymer synthetic fibers include polyolefin fibers, such as polyethylene fibers, polypropylene fibers, and fibers made from copolymers of the above.

[0047] As used herein, the term “coform nonwoven web” or “coform material” means composite materials comprising a mixture or stabilized matrix of thermoplastic filaments and at least one additional material, usually called the “second material” or the “secondary material”. As an example, coform materials may be made by a process in which at least one meltblown die head is arranged near a chute through which the second material is added to the web while it is forming. The second material may be, for example, an absorbent material such as fibrous organic materials such as woody and non-wood pulp such as cotton, rayon, recycled paper, pulp fluff; superabsorbent materials such as superabsorbent particles and fibers; inorganic absorbent materials and treated polymeric staple fibers and the like; or a non-absorbent material, such as non-absorbent staple fibers or non-absorbent particles. Exemplary coform materials are disclosed in commonly assigned U.S. Pat. No. 5,350,624 to Georger et al.; U.S. Pat. No. 4,100,324 to Anderson et al.; and U.S. Pat. No. 4,818,464 to Lau et al.; the entire contents of each is hereby incorporated by reference in their entirety for all purposes.

[0048] DETAILED DESCRIPTION

[0049] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

[0050] In constructing sheet materials for use in making all different types of products, such as wiping products and / or absorbent articles, nonwoven webs are apertured, subjected to bonding processes, and subjected to various texturizing processes in order to improve the properties of the web. In some applications, different substrates are joined together in combination with carrying out the above processes for producing laminates having improved overall properties.

[0051] The present disclosure is directed to an efficient process for aperturing, bonding and texturizing sheet materials, including nonwoven webs and films. More particularly, in a single step, the process is capable of forming apertures, bond sites and texture into nonwoven materials. The process of the present disclosure can be used to change the properties of a single layer structure or can be used to process multiple layers of materials together. When processing multiple layers or multiple plies of sheet materials, the process is capable of bonding the different plies together simultaneously with aperturing and texturizing at least one of the plies. All different types of nonwoven webs and films can be processed in accordance with the present disclosure. Merely for exemplary purposes, in one embodiment, the process can be used to combine an absorbent core material containing superabsorbent particles with a liner material that can comprise a nonwoven web containing synthetic polymer fibers. Of particular advantage, the multiple plies, such as the absorbent core material and nonwoven web, can be apertured, texturized and bonded together without using an adhesive. Eliminating the necessity of using an adhesive to bond different plies together provides numerous advantages and benefits. For instance, not only does it eliminate the process steps of applying adhesive between different plies, but also eliminates problems associated with adhesives, such as adhesive bleed through, glue buildup, and the like. Further, by eliminating the use of an adhesive, the resulting properties of the laminated material can be enhanced. Eliminating the use of an adhesive, for instance, can dramatically increase the bulk of the resulting product. For instance, the bulk can be increased by greater than about 10%, such as greater than about 15%, such as greater than about 20%, such as even greater than about 25%. In addition, bonding and aperturing the different plies or layers together can improve the fluid handling properties of the resulting product. For instance, the resulting laminate can display a faster fluid intake rate according to FIFE Testing. For instance, the liquid intake rate can be improved by greater than 3 times, such as greater than 4 times, such as even greater than 5 times in comparison to products made in the past that were assembled using an adhesive. Finally, the texturizing performed on the nonwoven materials can create a three-dimensional texture that is retained even when the laminate is wetted.

[0052] Referring to FIG. 1, one embodiment of a process 10 in accordance with the present disclosure is shown in which a nonwoven web or material 12 is fed into a nip 14 formed between a first patterned roll 16 and a second patterned roll 18 in order to simultaneously aperture, bond and texturize the nonwoven web 12.

[0053] FIG. 2 illustrates a similar process in which like reference numerals have been used to indicate similar elements. In the process 10 illustrated in FIG. 2, instead of a single ply or layer of material, multiple plies of material are fed through a nip 14 formed between a first patterned roll 16 and a second patterned roll 18. In this embodiment, for instance, a nonwoven web 12 is fed with a second substrate 20 into the nip 14 to form a laminate 22. In the process illustrated in FIG. 2, in addition to thermally bonding, aperturing and texturizing the nonwoven web 12, the nonwoven web 12 is also bonded to the second substrate 20. The second substrate 20 can comprise a nonwoven web or film. In other embodiments, more than two plies of material can be fed into the process. For instance, in other embodiments, three plies, four plies, five plies or even six plies can be fed into the nip 14 in accordance with the present disclosure. As described above, the nonwoven web 12 according to the process of the present disclosure is simultaneously and concurrently apertured, bonded and texturized. The apertures can, in one embodiment, be used for improving the fluid handling characteristics of the web or the resulting laminate. The apertures, for instance, can significantly increase liquid absorbency intake speeds when incorporated into wipers and / or absorbent articles. The apertures can also provide texture, softness, improved handfeel, and / or aesthetic appeal to the single or multi-layer product.

[0054] In addition to a pattern of apertures, a pattern of bond sites are also incorporated into the nonwoven web. The bond sites can be formed by heat and pressure which causes fibers within the nonwoven web to plasticize and form the bond sites. For instance, the bond sites can form a thermal point bonded pattern. The pattern of bond sites provides high structural integrity within the nonwoven web without compromising the flexibility and / or the loftiness of the nonwoven web. As will be described in greater detail below, the bond sites are formed separate from the apertures and can be applied to the nonwoven web in a pattern. The bond sites can be used to not only form thermal point bonds within a single web but can also be used to attach a nonwoven web to a second substrate, such as another nonwoven web or film. When bonding two plies together, the bond sites provide high structural integrity without compromising flexibility, surface texture, or decreasing bulk. Ultimately, a product is made having improved liquid intake and distribution and air circulation characteristics that results in greater surface dryness and comfort when placed against or proximate to a user.

[0055] As described above, the nonwoven web is also simultaneously textured in accordance with the present disclosure. For instance, the nonwoven web can be texturized for providing a three- dimensional surface topology. In one aspect, the nonwoven web can be produced having a lofty, pillowed structure that is believed to improve softness, aesthetics, and provide a cushiony feel to the user. In addition, the three-dimensional structure incorporated into the nonwoven web can be relatively permanent and can remain even after the material is contacted with a liquid, such as water.

[0056] Referring to FIGS. 1, 2 and 3, FIG. 3 illustrates one embodiment of an embossing pattern 24 that can be incorporated into the surface of the first patterned roll 16 for concurrently forming apertures and bond sites into a nonwoven web while also texturizing the web. Referring to FIG. 3, the embossing pattern 24 includes aperture pins 26 designed to form apertures into a nonwoven web. In this embodiment, the aperture pins 26 form a diamond pattern with bonding elements 28 and 30. As shown, the bonding elements 28 and 30 have different shapes. The bonding elements 30 have an oval shape, while the bonding elements 28 have a circular shape. The bonding elements 28 and 30 are for forming a pattern of bond sites within a nonwoven web. The bonding elements 28 and 30 are also capable of bonding together two or more plies of material.

[0057] The embossing pattern 24 further includes depression elements 32. The depression elements 32 are for creating texture in a nonwoven web. In particular, the depression elements 32 comprise hollow cavities or recesses that form raised areas on a surface of the nonwoven web.

[0058] As shown in FIG. 3, each of the features or elements of the embossing pattern 24 are separate and discrete. For instance, the bonding elements 28 and 30 are separate and spaced from the aperture pins 26. In addition, the depression elements 32 are spaced from and separate from the apertures pins 26 and the bonding elements 28 and 30.

[0059] Referring to FIGS. 4A, 4B, 5A, and 5B, cross-sectional views of portions of the embossing pattern 24 are illustrated. FIG. 4A, for instance, is an isolated plan view of an aperture pin 26 spaced from bonding elements 28 and 30. FIG. 4B is a cross-sectional view of the embossing elements illustrated in FIG. 4A. As shown in FIG. 4B, for instance, the aperture pin 26 can have a pointed structure that extends from a surface of the patterned roll 16. The bonding elements 28 and 30 also have a height that extends from the surface of the patterned roll 16.

[0060] Referring to FIGS. 5A and 5B, a depression element 32 is shown in combination with an aperture pin 26. FIG. 5B illustrates a cross-sectional view of the aperture pin 26 and the depression element 32. As shown, the depression element 32 comprises, in this embodiment, a depression or cavity formed into the surface of the patterned roll 16. As shown in FIG. 5B, the aperture pin 26 extends from the surface of the patterned roll 16 while the depression element 32 forms a recess within the patterned roll 16. In this manner, when a nonwoven web is being apertured by the aperture pin 26 and bonded by the bonding elements 28 and 30, fibrous material accumulates within the depression element 32 and forms discrete raised areas on a surface of the nonwoven web. The raised areas become accentuated because, as shown in FIG. 3, apertures and bond sites are formed around the perimeter of the depression elements 32.

[0061] In accordance with the present disclosure, the second patterned roll 18 is designed to be complementary with the embossing pattern present on the first patterned roll 16. For instance, the second patterned roll 18 can form an intermeshing or mating engagement with the first patterned roll 16.

[0062] For example, referring to FIGS. 6 and 7, an engagement between the first patterned roll 16 and the second patterned roll 18 is illustrated. As shown in FIG. 6, for instance, the second patterned roll 18 can include pin recesses 34 that engage with the pin elements 26. Opposite the bonding elements 28 and 30, on the other hand, the second patterned roll 18 can form a flat surface. When the two rolls are brought together to form the nip 14, the bonding elements 28 and 30 press against the flat surface 36 while applying heat and pressure to a nonwoven web in a manner that not only embosses the web but causes fibers within the nonwoven web to plasticize and form bond sites.

[0063] Referring to FIG. 7, the second patterned roll 18 further illustrates another pin recess 34 for receiving the pin element 26. In addition, the second patterned roll 18 includes raised elements 38 that engage with the depression elements 32 for forming texture. As shown in FIG. 7, the pin recesses 34 can be shaped to contact the sides of the pin elements 26. The raised elements 38, however, may engage the depression elements 32 without contacting the far end or bottom surface of the depression elements 32. In this manner, bulk can be preserved while still forming texture.

[0064] The patterned rolls 16 and 18 can be made from any suitable metal, such as steel. One or both of the patterned rolls 16 and 18 can also include a heating apparatus for heating the surface of the rolls. In this manner, both heat and pressure are applied to the sheet materials fed through the nip 14. For instance, one or each surface of the patterned rolls 16 and 18 can be heated to a temperature of greater than about 200°F, such as greater than about 220°F, such as greater than about 240°F, such as greater than about 260°F, such as greater than about 280°F, such as greater than about 300°F, and less than about 380°F, such as less than about 320°F, such as less than about 300°F.

[0065] The pressure applied to the materials within the nip 14 can be greater than about 100 pounds per linear inch (PLI), such as greater than about 125 pli, such as greater than about 150 pli, such as greater than about 175 pli, such as greater than about 200 pli. The pressure applied to the nonwoven web can be less than about 300 pli, such as less than about 275 pli, such as less than about 250 pli, such as less than about 225 pli, such as less than 200 pli, such as less than about 175 pli.

[0066] It should be understood that the embossing pattern 24 as shown in FIG. 3 represents merely one embodiment that may be used in accordance with the present disclosure. In general, any suitable embossing pattern can be used that contains the aperture pins 26, the bonding elements 30 or 28, and the depressions 32. In addition, various different sizes of elements can be incorporated into the embossing pattern. For instance, the embossing pattern can include different aperture sizes and different depression element sizes. In addition, the pattern can include a single shape of bonding element or can include more than two different shaped bonding elements. The pattern can be varied and changed depending upon the particular application and the desired result.

[0067] In one embodiment, the process of the present disclosure can be configured to produce apertures within a nonwoven web that have a diameter of generally greater than about 0.5 mm, such as greater than about 0.75 mm, such as greater than about 1 mm, such as greater than about 1.25 mm, such as greater than about 1.5 mm, such as greater than about 1.75 mm. The average size of the apertures can generally be less than about 3.5 mm, such as less than about 3 mm, such as less than about 2.5 mm, such as less than about 2.25 mm, such as less than about 2 mm, such as less than about 1.75 mm, such as less than about 1.5 mm. The embossing pattern 24 can be configured such that the aperture density on the nonwoven web is greater than about 1 aperture per cm2, such as greater than about 1.5 apertures per cm2, such as greater than about 2 apertures per cm2, such as greater than about 2.5 apertures per cm2, such as greater than about 3 apertures per cm2. The aperture density can generally be less than about 5 apertures per cm2, such as less than about 4.5 apertures per cm2, such as less than about 4 apertures per cm2, such as less than about 3.5 apertures per cm2, such as less than about 3 apertures per cm2.

[0068] In one aspect, the bond sites formed into the nonwoven web are applied according to a thermal point bonding pattern. The bond sites, for instance, can occupy from about 1% of the surface area of the nonwoven web to about 50% of the surface area of the nonwoven web including all increments of 1% therebetween. In one aspect, the bond sites occupy less than about 25% of the surface area of the nonwoven web, such as less than about 20% of the surface area of the nonwoven web, such as less than about 15% of the surface area of the nonwoven web, such as less than about 10% of the surface area of the nonwoven web. The bond sites can occupy greater than about 2% of the surface area of the nonwoven web, such as greater than about 3% of the surface area of the nonwoven web, such as greater than about 4% of the surface area of the nonwoven web, such as greater than about 5% of the surface area of the nonwoven web.

[0069] The depression elements in the embossing pattern and present on the first patterned roll 16 can form raised areas on a surface of the nonwoven web. The raised areas, for instance, can have a height of greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 1 mm. The height of the raised area is generally less than about 3 mm, such as less than about 2 mm, such as less than about 1.8 mm, such as less than about 1.5 mm. The raised areas can have a density on a surface of the nonwoven web of from about 1 raised area per 4 cm2to about 20 raised areas per 4 cm2including all increments of 0.25 raised areas per 4 cm2therebetween. For instance, the density of the raised areas can be greater than about 1.5 raised areas per 4 cm2, such as greater than about 2 raised areas per 4 cm2, such as greater than about 3 raised areas per 4 cm2, and less than about 15 raised areas per 4 cm2, such as less than about 10 raised areas per 4 cm2, such as less than about 8 raised areas per 4 cm2, such as less than about 6 raised areas per 4 cm2, such as less than about 4 raised areas per 4 cm2, such as less than about 3 raised areas per 4 cm2.

[0070] All different types of nonwoven webs can be fed into the process 10 as shown in FIG .1. For instance, nonwoven webs that can be fed into the process include spunbond webs, meltblown webs, carded webs, foam formed webs, wetlaid webs, airlaid webs, hydroentangled webs, and combinations thereof.

[0071] The nonwoven web generally contains at least one fiber that plasticizes and begins flowing to form the bond sites, which is also known as non-reversible elastic deformation. The fibers that form the bond sites, for instance, can comprise polymer synthetic fibers including binder fibers. Monocomponent and / or multicomponent fibers may be used to form the nonwoven web material. Monocomponent fibers are generally formed from a polymer or blend of polymers extruded from a single extruder. Multicomponent fibers are generally formed from two or more polymers (e.g., bicomponent fibers) extruded from separate extruders. The polymers may be arranged in substantially constantly positioned distinct zones across the cross-section of the fibers. The components may be arranged in any desired configuration, such as sheath-core, side-by-side, pie, island-in-the-sea, three island, bull’s eye, or various other arrangements known in the art. and so forth. Multicomponent fibers having various irregular shapes may also be formed.

[0072] Although any combination of polymers may be used, the polymers of the multicomponent fibers are typically made from thermoplastic materials with different glass transition or melting temperatures where a first component (e.g., sheath) melts at a temperature lower than a second component (e.g., core). Softening or melting of the first polymer component of the multicomponent fiber allows the multicomponent fibers to form a tacky skeletal structure, which upon cooling, stabilizes the fibrous structure. For example, the multicomponent fibers may have from about 20% to about 80%, and in some embodiments, from about 40% to about 60% by weight of the low melting polymer. Further, the multicomponent fibers may have from about 80% to about 20%, and in some embodiments, from about 60% to about 40%, by weight of the high melting polymer. Some examples of known sheath-core bicomponent fibers available from KoSa Inc. of Charlotte, North Carolina under the designations T-255 and T-256, both of which use a polyolefin sheath, or T-254, which has a low melt co-polyester sheath. Still other known bicomponent fibers that may be used include those available from the Chisso Corporation of Moriyama, Japan or Fibervisions LLC of Wilmington, Delaware.

[0073] Fibers of any desired length may be employed, such as staple fibers, continuous fibers, etc. In one particular embodiment, for example, staple fibers may be used that have a fiber length in the range of from about 1 to about 150 millimeters, in some embodiments from about 5 to about 50 millimeters, in some embodiments from about 10 to about 40 millimeters, and in some embodiments, from about 10 to about 25 millimeters. Although not required, carding techniques may be employed to form fibrous layers with staple fibers as is well known in the art. For example, fibers may be formed into a carded web by placing bales of the fibers into a picker that separates the fibers. Next, the fibers are sent through a combing or carding unit that further breaks apart and aligns the fibers in the machine direction so as to form a machine direction-oriented fibrous nonwoven web. The carded web may then be bonded using known techniques to form a bonded carded nonwoven web.

[0074] In one embodiment, the nonwoven material 12 fed through the process as shown in FIG. 1 can be a multi-layered composite material. For instance, the nonwoven material can be a spunbond / meltblown / spunbond laminate or a spunbond / meltblown laminate.

[0075] A nonwoven web material may also contain an additional fibrous component such that it is considered a composite. For example, a nonwoven web may be entangled with another fibrous component using any of a variety of entanglement techniques known in the art (e.g., hydraulic, air, mechanical, etc.). In one embodiment, the nonwoven web is integrally entangled with cellulosic fibers using hydraulic entanglement. A typical hydraulic entangling process utilizes high pressure jet streams of water to entangle fibers to form a highly entangled consolidated fibrous structure, e.g., a nonwoven web. The cellulose fibrous component of the composite may contain any desired amount of the resulting substrate. The cellulose fibrous component may contain greater than about 50% by weight of the composite, and in some embodiments, from about 60% to about 90% by weight of the composite. Likewise, the nonwoven web may contain less than about 50% by weight of the composite, and in some embodiments, from about 10% to about 40% by weight of the composite.

[0076] In one embodiment, the nonwoven web can comprise a foam formed web. During a foam forming process, water is replaced with foam as the carrier for the fibers that form the web. The foam, which represents a large quantity of air, is blended with a fiber furnish. Foam forming processes are particularly well suited to processing and handling various different types of fibers, especially longer and / or crimped synthetic fibers alone or in combination with pulp fibers. The synthetic fibers can comprise polymer synthetic fibers and / or regenerated cellulose fibers.

[0077] In order to produce the nonwoven web, the fiber furnish is combined with a foaming agent. The foaming agent, for instance, may comprise any suitable surfactant. In one embodiment, for instance, the foaming agent may comprise sodium lauryl sulfate, which is also known as sodium laureth sulfate or sodium lauryl ether sulfate. In one embodiment, the foaming agent is a nonionic surfactant which may comprise an alkyl polyglycoside. The foaming agent, for instance, can be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.

[0078] Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other embodiments, the foaming agent may comprise any suitable cationic and / or amphoteric surfactant. For instance, other foaming agents include fatty acid amines, amides, amine oxides, fatty acid quaternary compounds, and the like.

[0079] The foaming agent is combined with water generally in an amount greater than about 0.1% by weight, such as in an amount greater than about 1% by weight, such as in an amount greater than about 2% by weight, such as in an amount greater than about 3% by weight. One or more foaming agents are generally present in an amount less than about 50% by weight, such as in an amount less than about 10% by weight, such as in an amount less than about 8% by weight, such as in an amount less than about 4% by weight. Residual amounts of the foaming agent may remain in the final web after drying.

[0080] Once the foaming agent and water are combined, the mixture is blended or otherwise subjected to forces capable of forming a foam. A foam generally refers to a porous matrix, which is an aggregate of hollow cells or bubbles which may be interconnected to form channels or capillaries.

[0081] The foam density can vary depending upon the particular application and various factors including the fiber furnish used. In one embodiment, for instance, the foam density of the foam can be greater than about 200 g / L, such as greater than about 250 g / L, such as greater than about 300 g / L. The foam density is generally less than about 600 g / L, such as less than about 500 g / L, such as less than about 400 g / L, such as less than about 350 g / L. In one embodiment, for instance, a lower density foam is used having a foam density of generally less than about 350 g / L, such as less than about 340 g / L, such as less than about 330 g / L. The foam will generally have an air content of greater than about 30%, such as greater than about 40%, such as greater than about 50%, such as greater than about 60%. The air content is generally less than about 80% by volume, such as less than about 70% by volume, such as less than about 65% by volume.

[0082] Once the fibers are suspended in the foam, the foam is then fed to a headbox and formed into a nonwoven web on a porous forming surface. Optionally, the foam formed web can be subjected to one or more hydroentangling steps. For instance, the nonwoven web can be hydroentangled on one side or can be hydroentangled on both sides of the web.

[0083] In one aspect, the foam formed nonwoven web is comprised of synthetic fibers alone or in combination with pulp fibers. For instance, the web can contain polymer synthetic fibers and / or regenerated cellulose fibers either alone or in combination with cellulose pulp fibers. The polymer synthetic fibers, for instance, can comprise polyester fibers having a denier of from about 0.3 to about 3. Alternatively, the synthetic fibers can comprise regenerated fibers such as lyocell fibers, viscose fibers, rayon fibers, and mixtures thereof. The synthetic fibers can have a fiber length of from about 4 mm to about 80 mm, such as from about 5 mm to about 20 mm.

[0084] Suitable cellulose pulp fibers include, but are not limited to, nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as Northern and / or Southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, and aspen. Pulp fibers can be prepared in high-yield or low- yield forms and can be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods can also be used, including the fibers and methods disclosed in U.S. Pat. No. 4,793,898, U.S. Pat. No. 4,594,130, U.S. Pat. No. 3,585,104. Useful fibers can also be produced by anthraquinone pulping, exemplified by U.S. Pat. No. 5,595,628.

[0085] Chemically treated natural cellulosic fibers can be used such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers. For good mechanical properties, it can be desirable that the fibers be relatively undamaged and largely unrefined or only lightly refined. Suitable cellulose pulp fibers can also include recycled fibers, virgin fibers, or mixes thereof. In certain embodiments capable of high bulk and good compressive properties, the fibers can have a Canadian Standard Freeness of at least 200, more specifically at least 300, more specifically still at least 400, and most specifically at least 500.

[0086] Other cellulose fibers that can be used in the present disclosure include high yield fibers. High yield pulp fibers are those papermaking fibers produced by pulping processes providing a yield of about 65% or greater, more specifically about 75% or greater, and still more specifically about 75% to about 95%. Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass. Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure / pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which leave the resulting fibers with high levels of lignin. High yield fibers are well known for their stiffness in both dry and wet states relative to typical chemically pulped fibers.

[0087] The cellulose pulp fibers can be present in the nonwoven web generally in an amount from about 5% by weight to about 90% by weight including all increments of 1% by weight therebetween.

[0088] The basis weight of the nonwoven web material may generally vary, such as from about 5 grams per square meter (“gsm”) to 120 gsm, in some embodiments from about 10 gsm to about 70 gsm, and in some embodiments, from about 15 gsm to about 35 gsm. When multiple nonwoven web materials, such materials may have the same or different basis weights.

[0089] As shown in FIG. 2, in one embodiment, more than one ply of material, such as two or three plies of material are fed through the process of the present disclosure. During the process, the sheet materials are concurrently perforated, bonded, and texturized. In general, the different plies of material can comprise combinations of any of the nonwoven materials described above. For instance, a spunbond web, a meltblown web, or a coform web can be combined with a foam formed web using the process illustrated in FIG. 2. Alternatively, multiple layers of spunbond webs or spunbond webs and meltblown webs can be fed together into the process. In still another embodiment, a spunbond web and / or a meltblown web can be combined with a hydroentangled web.

[0090] In one particular embodiment, the process illustrated in FIG. 2 can be configured to combine a meltspun web such as a spunbond web with a nonwoven web containing superabsorbent particles. The top layer, for instance, can comprise a liner material, while the nonwoven web containing the superabsorbent particles can comprise an absorbent structure or core. The two materials can be combined together and then incorporated into an absorbent article, such as a diaper, adult incontinence product, feminine care product, or child pant. The apertures formed into the liner material can allow liquids to be quickly absorbed into the nonwoven web containing the superabsorbent material. Of particular advantage, the nonwoven web containing the superabsorbent material can be bonded to the liner material without using an adhesive.

[0091] The absorbent layer or structure can contain the superabsorbent material in an amount from about 10% by weight to about 100% by weight, including all increments of 1% by weight therebetween. For instance, the nonwoven web formed in accordance with the present disclosure can contain the superabsorbent material in an amount greater than about 15% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight, such as in an amount greater than about 80% by weight, such as in an amount greater than about 90% by weight, such as in an amount greater than about 95% by weight. In one aspect, the nonwoven web contains the superabsorbent particles combined with fibers, such as cellulose fibers and / or polymer synthetic fibers. When combined with fibers, the nonwoven web can contain the superabsorbent particles in an amount less than about 90% by weight, such as in an amount less than about 80% by weight, such as in an amount less than about 70% by weight.

[0092] The nonwoven web containing the superabsorbent material can have a basis weight of from about 100 gsm to about 1,500 gsm, including all increments of 1 gsm therebetween. For instance, the basis weight of the nonwoven web can be greater than about 150 gsm, such as greater than about 200 gsm, such as greater than about 250 gsm, such as greater than about 300 gsm, such as greater than about 350 gsm, and less than about 1 ,000 gsm, such as less than about 800 gsm, such as less than about 600 gsm.

[0093] In one aspect, the nonwoven web contains the superabsorbent material combined with cellulose fibers and / or polymer synthetic fibers.

[0094] The cellulose fibers, for instance, can comprise cellulose pulp fibers and / or synthetic cellulose fibers, such as regenerated cellulose fibers. In addition, other cellulosic fibers that can be used in the present disclosure include nonwoody fibers. As used herein, the term “non-wood fiber” generally refers to cellulosic fibers derived from non-woody monocotyledonous or dicotyledonous plant stems. Non-limiting examples of dicotyledonous plants that may be used to yield non-wood fiber include kenaf, jute, flax, ramie and hemp. Non-limiting examples of monocotyledonous plants that may be used to yield non-wood fiber include cereal straws (wheat, rye, barley, oat, etc.), stalks (corn, cotton, sorghum, Hesperaloe funifera, etc.), canes (bamboo, sisal, bagasse, etc.) and grasses (miscanthus. esparto, lemon, sabai, switchgrass, etc). In still other certain instances non-wood fiber may be derived from aquatic plants such as water hyacinth, microalgae such as Spirulina, and macroalgae seaweeds such as red or brown algae.

[0095] Regenerated cellulose fibers can include synthetic cellulose fiber types formed by spinning, including rayon in all its varieties, and other fibers derived from viscose or chemically-modified cellulose such as, for example, those available under the trade names LYOCELL and TENCEL.

[0096] Crosslinked cellulosic fibers, such as CMC 535, can also be used in forming nonwoven materials described herein. Crosslinked cellulosic fibers can provide increased bulk and resiliency, as well as improved softness.

[0097] In some embodiments, the non-woody and synthetic cellulosic fibers can have fiber length greater than about 0.2 mm including, for example, having an average fiber size between about 0.5 mm and about 50 mm or between about 0.75 and about 30 mm or even between about 1 mm and about 25 mm. Wood pulp fibers can have an average fiber length greater than about 0.2 mm and less than about 3 mm, such as from about 0.35 mm and about 2.5 mm, or between about 0.5 mm to about 2.5 mm or even between about 0.7 mm and about 2.0 mm.

[0098] The nonwoven web containing superabsorbent material can contain cellulose fibers generally in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 25% by weight, such as in an amount greater than about 30% by weight, and in an amount less than about 90% by weight, such as in an amount less than about 70% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 40% by weight.

[0099] The nonwoven webs containing superabsorbent material can also contain synthetic polymer fibers including binder fibers that are combined with the superabsorbent material. In one aspect, the nonwoven web can contain the superabsorbent material, cellulose fibers as described above, and polymer synthetic fibers.

[0100] In still another embodiment, a nonwoven web in accordance with the present disclosure can be bonded to a polymer film using the process illustrated in FIG. 2. In one aspect, the polymer film can comprise an elastic film. The elastic film can be formed from one or more elastomeric polymers that are melt-processable, i.e. thermoplastic. Any of a variety of thermoplastic elastomeric polymers may generally be employed in the present invention, such as elastomeric polyesters, elastomeric polyurethanes, elastomeric polyamides, elastomeric copolymers, elastomeric polyolefins, and so forth.

[0101] In one particular embodiment, elastomeric semi-crystalline polyolefins are employed due to their unique combination of mechanical and elastomeric properties. That is, the mechanical properties of such semi-crystalline polyolefins allows for the formation of films that readily aperture during thermal bonding, but yet retain their elasticity.

[0102] The elastic film of the present invention may be mono- or multi-layered. Multilayer films may be prepared by co-extrusion of the layers, extrusion coating, or by any conventional layering process. Such multilayer films normally contain at least one base layer and at least one skin layer, but may contain any number of layers desired. For example, the multilayer film may be formed from a base layer and one or more skin layers, wherein the base layer is formed from a semi-crystalline polyolefin. In such embodiments, the skin layer(s) may be formed from any film-forming polymer. If desired, the skin layer(s) may contain a softer, lower melting polymer or polymer blend that renders the layer(s) more suitable as heat seal bonding layers for thermally bonding the film to a nonwoven web. For example, the skin layer(s) may be formed from an olefin polymer or blends thereof, such as described above. Additional film-forming polymers that may be suitable for use with the present invention, alone or in combination with other polymers, include ethylene vinyl acetate, ethylene ethyl acrylate, ethylene acrylic acid, ethylene methyl acrylate, ethylene normal butyl acrylate, nylon, ethylene vinyl alcohol, polystyrene, polyurethane, and so forth.

[0103] The thickness of the skin layer(s) is generally selected so as not to substantially impair the elastomeric properties of the film. To this end, each skin layer may separately comprise from about 0.5% to about 15% of the total thickness of the film, and in some embodiments from about 1% to about 10% of the total thickness of the film. For instance, each skin layer may have a thickness of from about 0.1 to about 10 micrometers, in some embodiments from about 0.5 to about 5 micrometers, and in some embodiments, from about 1 to about 2.5 micrometers. Likewise, the base layer may have a thickness of from about 1 to about 40 micrometers, in some embodiments from about 2 to about 25 micrometers, and in some embodiments, from about 5 to about 20 micrometers.

[0104] The properties of the resulting film may generally vary as desired. For instance, prior to stretching, the film typically has a basis weight of about 100 grams per square meter or less, and in some embodiments, from about 50 to about 75 grams per square meter. Upon stretching, the film typically has a basis weight of about 60 grams per square meter or less, and in some embodiments, from about 15 to about 35 grams per square meter. The stretched film may also have a total thickness of from about 1 to about 100 micrometers, in some embodiments, from about 10 to about 80 micrometers, and in some embodiments, from about 20 to about 60 micrometers.

[0105] These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so further described in such appended claims.

Claims

What Is Claimed:

1. A process for aperturing, bonding and texturizing nonwoven materials comprising: feeding a nonwoven web having a first surface and a second and opposite surface into a nip formed between complementary patterned rolls including a first patterned roll positioned opposite a second patterned roll, the nonwoven web comprising unbonded fibers, wherein, within the nip, the nonwoven web is concurrently apertured and textured, the nonwoven web also being subjected to heat and pressure within the nip that causes the unbonded fibers to plasticize and form a pattern of bond sites, and wherein the nonwoven web is texturized in the nip such that a pattern of raised areas are formed on at least one surface of the nonwoven web.

2. A process as defined in claim 1 , wherein the apertures have an average diameter of from about 0.5 mm to about 3.5 mm, such as from about 0.75 mm to about 2.5 mm.

3. A process as defined in any of the preceding claims, wherein the apertures have a density of from about 1 aperture per cm2to about 5 apertures per cm2, such as from about 1 aperture per cm2to about 4 apertures per cm2.

4. A process as defined in any of the preceding claims, wherein the nonwoven web has a surface area and wherein the bond sites comprise from about 1% to about 25% of the surface area of the nonwoven web, such as from about 2% to about 15% of the surface area of the nonwoven web, such as from about 3% to about 10% of the surface area of the nonwoven web.

5. A process as defined in any of the preceding claims, wherein the nonwoven web comprises a spunbond web, a meltblown web, a foam formed web, a wetlaid web, an airlaid web, or a coform web.

6. A process as defined in any of the preceding claims, wherein the raised areas are discrete and have a height of greater than about 0.7 mm, such as greater than about 1 mm.

7. A process as defined in any of the preceding claims, wherein the raised areas are discrete and have a density on a surface of the nonwoven web in an amount of from about 1 raised area per 4 cm2to about 20 raised areas per 4 cm2, such as from about 2 raised areas per 4 cm2to about 15 raised areas per 4 cm2.

8. A process as defined in any of the preceding claims, wherein the bond sites are spaced from and separate from the apertures.

9. A process as defined in any of the preceding claims, wherein the first patterned roll includes a pattern of aperture pins, bonding elements, and discrete depressions for forming the apertures, bond sites, and raised areas, respectively.

10. A process as defined in claim 9, wherein the second patterned roll has a surface pattern that engages and mates with the aperture pins and the discrete depressions.

11. A process as defined in claim 9 or 10, wherein the second patterned roll comprises a flat surface opposite the bonding elements.

12. A process as defined in any of the preceding claims, wherein a pressure of from about 100 pounds per linear inch to about 300 pounds per linear inch, such as from about 125 pounds per linear inch to about 225 pounds per linear inch is applied at the nip.

13. A process as defined in any of the preceding claims, wherein at least one of the patterned rolls is heated to a surface temperature of from about 200°F to about 380°F, such as from about 220°F to about 320°F.

14. A process as defined in any of the preceding claims, wherein at least two superimposed layers are fed into the nip including at least a first layer and a second layer, the nonwoven web comprising the first layer.

15. A process as defined in claim 14, wherein the bond sites bond the first layer and the second layer together.

16. A process as defined in claim 14 or 15, wherein the second layer comprises superabsorbent particles.

17. A process as defined in claim 16, wherein the second layer comprises a foam formed nonwoven web.

18. A process as defined in claim 14 or 15, wherein the second layer comprises a polymer film.

19. A process as defined in claim 14 or 15, wherein the second layer comprises a nonwoven web.

20. A process as defined in any of claims 14-19, wherein the first layer and the second layer are bonded together without using an adhesive.

21. A process as defined in claim 16 or 17, wherein the first layer comprises a meltblown web or a spunbond web.

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