Apertured polymeric film webs and absorbent articles using such webs

Abstract

The present invention pertains to an apertured polymeric film web material provided with a multiplicity of substantially three dimensional surface structures and provided with a multiplicity of fluid transport apertures. In one embodiment, the fluid transport apertures are formed using a process that substantially preserves the integrity of the surface structures. Methods of producing webs are also disclosed. The present invention also includes multi-ply composite structures formed using apertured polymeric film web materials and a sub-ply. The present invention also pertains to absorbent articles which preferably include a topsheet in accordance with the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.

What is claimed is:  
     
         1 . An apertured polymeric film web having multiple surfaces and exhibiting a soft and silky tactile impression on at least one of said surfaces, wherein: 
 said polymeric film web is provided with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces of said polymeric film web;    said polymeric film web is provided with a multiplicity of fluid transport apertures that place at least two of said surfaces in fluid communication with one another; and    said polymeric film web has a softness index greater than 35.    
     
     
         2 . An apertured polymeric film web having multiple surfaces and exhibiting a soft and silky tactile impression on at least one of said surfaces, wherein: 
 said polymeric film web is provided with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces of said polymeric film web;    said polymeric film web is provided with a multiplicity of fluid transport apertures that place at least two of said surfaces in fluid communication with one another; and    said polymeric film web has a compressibility index greater than 25 percent.    
     
     
         3 . The polymeric film web of  claim 1 , wherein said three dimensional surface structures are substantially unaltered relative to their as-made state.  
     
     
         4 . The polymeric film web of  claim 2 , wherein said three dimensional surface structures are substantially unaltered relative to their as-made state.  
     
     
         5 . The polymeric film web of  claim 1 , said web further comprises a top surface and a bottom surface, wherein: 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.    
     
     
         6 . The polymeric film web of  claim 2 , said web further comprises a top surface and a bottom surface, wherein: 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.    
     
     
         7 . The polymeric film web of  claim 1 , said polymeric film web further comprising a thermoplastic formed film ply comprising at least a first layer and a second layer, wherein: 
 said first layer is less hydrophilic than said second layer; and    said second layer is permanently hydrophilic.    
     
     
         8 . The polymeric film web of  claim 2 , said polymeric film web further comprising a thermoplastic formed film ply comprising at least a first layer and a second layer, wherein: 
 said first layer is less hydrophilic than said second layer; and    said second layer is permanently hydrophilic.    
     
     
         9 . A method of making an apertured polymeric film web having a softness index greater than 35, the method comprising the steps of: 
 a) providing at least one thermoplastic material;    b) melting each of said thermoplastic materials;    c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;    d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures; and    e) providing said film with a multiplicity of fluid transport apertures.    
     
     
         10 . The method of making an apertured polymeric film web of  claim 9 , wherein step e is completed prior to step d.  
     
     
         11 . A method of making an apertured polymeric film web having a compressibility index greater than 25 percent, the method comprising the steps of: 
 a) providing at least one thermoplastic material;    b) melting each of said thermoplastic materials;    c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;    d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures; and    e) providing said film with a multiplicity of fluid transport apertures.    
     
     
         12 . The method of making an apertured polymeric film web of  claim 11 , wherein step e is completed prior to step d.  
     
     
         13 . A method of making an apertured polymeric film web, the method comprising the steps of: 
 a) providing at least one thermoplastic material;    b) melting each of said thermoplastic materials;    c) passing said melted thermoplastic materials through extrusion die orifices to form individual layers of thermoplastic film;    d) providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures using a process selected from the group consisting of vacuum forming, hydroforming, solid needle punching, hollow needle punching, ultrasonics, and hydrosonics; and    e) providing said film with a multiplicity of fluid transport apertures using a process selected from the group consisting of mechanical embossing, stretch rupturing, vacuum forming, solid needle punching, hollow needle punching, ultrasonics, hydrosonics, slitting, ring-rolling, forming structural elastic like film, and sintering.    
     
     
         14 . The method of making an apertured polymeric film web in  claim 13 , wherein: 
 said process for providing at least one surface of said film with a multiplicity of substantially three dimensional surface structures is selected from the group consisting of vacuum forming, solid needle punching, hollow needle punching, ultrasonics, and hydrosonics; and    said process for providing said film with a multiplicity of fluid transport apertures is hydroforming.    
     
     
         15 . The method of making an apertured polymeric film web of  claim 13 , wherein step e is completed prior to step d.  
     
     
         16 . The method of making an apertured polymeric film web of  claim 14 , wherein step e is completed prior to step d.  
     
     
         17 . A multi-ply composite structure comprised of a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply, wherein: 
 said thermoplastic formed film ply is comprised of the apertured polymeric film web in  claim 1;  and    said fluid permeable sub-ply is adjacent to said garment facing surface of said thermoplastic formed film ply.    
     
     
         18 . A multi-ply composite structure comprised of a fluid permeable thermoplastic formed film ply having a body facing surface and a garment facing surface and a fluid permeable sub-ply, wherein: 
 said thermoplastic formed film ply is comprised of the apertured polymeric film web in  claim 2;  and    said fluid permeable sub-ply is adjacent to said garment facing surface of said thermoplastic formed film ply.    
     
     
         19 . The multi-ply composite structure of  claim 17 , said thermoplastic formed film ply further comprises: 
 at least a top surface and a bottom surface, wherein    said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.    
     
     
         20 . The multi-ply composite structure of  claim 18 , said thermoplastic formed film ply further comprises: 
 at least a top surface and a bottom surface, wherein 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.  
   
     
     
         21 . A multi-ply composite structure comprised of a thermoplastic formed film ply having a body facing surface and a garment facing surface and a sub-ply, wherein: 
 said body facing surface has a multiplicity of substantially three dimensional surface structures disposed thereon;    said thermoplastic formed film ply is provided with fluid transport apertures to form an apertured thermoplastic formed film ply;    said sub-ply is provided with fluid transport apertures and is adjacent to said garment facing surface of said apertured thermoplastic formed film ply; and    said fluid transport apertures form fluid pathways common to both of said ply.    
     
     
         22 . The multi-ply composite structure of  claim 21 , wherein said sub-ply is comprised of a fluid permeable material.  
     
     
         23 . The multi-ply composite structure of  claim 21 , said apertured thermoplastic formed film ply further comprising: 
 at least a top surface and a bottom surface, wherein 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.  
   
     
     
         24 . A method of making a multi-ply composite, the method comprising the steps of: 
 a) providing a fluid permeable thermoplastic formed film ply having multiple surfaces with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces;    b) providing a sub-ply having multiple surfaces; and    c) feeding said fluid permeable thermoplastic formed film ply and said sub-ply simultaneously through an aperturing process to form an apertured multi-ply composite structure having fluid transport pathways common to both of said ply.    
     
     
         25 . The method of making a multi-ply composite structure in  claim 24 , wherein said sub-ply is comprised of a fluid permeable material.  
     
     
         26 . The method of making a multi-ply composite structure in  claim 24 , wherein the aperturing process leaves said three dimensional surface structures substantially unaltered relative to their as-made state.  
     
     
         27 . The method of making a multi-ply composite structure in  claim 24 , said thermoplastic formed film ply further comprising: 
 at least a top surface and a bottom surface, wherein 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.  
   
     
     
         28 . The method of making a multi-ply composite structure in  claim 24 , said thermoplastic formed film ply further comprising: 
 at least a first layer and a second layer, wherein 
 said first layer is less hydrophilic than said second layer; and  
 said second layer is permanently hydrophilic.  
   
     
     
         29 . A method of making a multi-ply composite, the method comprising the steps of: 
 a) providing a fluid permeable thermoplastic formed film ply having multiple surfaces with a multiplicity of substantially three dimensional surface structures on at least one of said surfaces;    b) providing a fluid permeable sub-ply having multiple surfaces; and    c) laying one surface of said thermoplastic formed film ply adjacent to one surface of said sub-ply to form a multi-ply composite structure.    
     
     
         30 . The method of making a multi-ply composite structure in  claim 29 , said thermoplastic formed film ply further comprising: 
 at least a top surface and a bottom surface, wherein 
 said top surface and said bottom surface are comprised of materials that provide a surface energy gradient between the surfaces.  
   
     
     
         31 . The method of making a multi-ply composite structure in  claim 29 , said thermoplastic formed film ply further comprising: 
 at least a first layer and a second layer, wherein 
 said first layer is less hydrophilic than said second layer; and  
 said second layer is permanently hydrophilic.  
   
     
     
         32 . The apertured polymeric film web of  claim 1 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is disposable.  
     
     
         33 . The apertured polymeric film web of  claim 1 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a sanitary napkin or a pantiliner.  
     
     
         34 . The apertured polymeric film web of  claim 1 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a disposable diaper.  
     
     
         35 . The apertured polymeric film web of  claim 1 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a tampon.  
     
     
         36 . The apertured polymeric film web of  claim 2 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is disposable.  
     
     
         37 . The apertured polymeric film web of  claim 2 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a sanitary napkin or a pantiliner.  
     
     
         38 . The apertured polymeric film web of  claim 2 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a disposable diaper.  
     
     
         39 . The apertured polymeric film web of  claim 2 , wherein said web is suitable for use as a topsheet on an absorbent article and said article is a tampon.  
     
     
         40 . The multi-ply composite structure of  claim 17 , wherein said structure is suitable for use in an absorbent article and said article is disposable.  
     
     
         41 . The multi-ply composite structure of  claim 17 , wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.  
     
     
         42 . The multi-ply composite structure of  claim 17 , wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.  
     
     
         43 . The multi-ply composite structure of  claim 17 , wherein said structure is suitable for use in an absorbent article and said article is a tampon.  
     
     
         44 . The multi-ply composite structure of  claim 18 , wherein said structure is suitable for use in an absorbent article and said article is disposable.  
     
     
         45 . The multi-ply composite structure of  claim 18 , wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.  
     
     
         46 . The multi-ply composite structure of  claim 18 , wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.  
     
     
         47 . The multi-ply composite structure of  claim 18 , wherein said structure is suitable for use in an absorbent article and said article is a tampon.  
     
     
         48 . The multi-ply composite structure of  claim 21 , wherein said structure is suitable for use in an absorbent article and said article is disposable.  
     
     
         49 . The multi-ply composite structure of  claim 21 , wherein said structure is suitable for use in an absorbent article and said article is a sanitary napkin or a pantiliner.  
     
     
         50 . The multi-ply composite structure of  claim 21 , wherein said structure is suitable for use in an absorbent article and said article is a disposable diaper.  
     
     
         51 . The multi-ply composite structure of  claim 21 , wherein said structure is suitable for use in an absorbent article and said article is a tampon.