Apertured Polymeric Film Webs And Absorbent Articles Using Such Webs

Abstract

An apertured polymeric film web and a composite structure web are disclosed. These webs may be utilized as a topsheet in an absorbent article and can provide fluid handling and softness benefits.

What is claimed is: 
     
         1 . A polymeric film comprising a first surface and an opposing second surface, the polymeric film further comprising:
 a plurality of apertures extending through the polymeric film, each of the plurality of apertures comprising aperture sidewalls which extend in a first direction away from the first or second surface and each of the plurality of apertures comprising a first size;   contiguous land areas between adjacent apertures, wherein the contiguous land areas comprise a plurality of three dimensional structures each of which comprise a sidewall and an open distal end, each of the plurality of three dimensional structures having a second size, wherein the first size is greater than the second size, wherein each sidewall extends from the first surface or second surface in a second direction opposite the first direction, and wherein each of the three-dimensional structures has an open area of at least 1000 square micrometers.   
     
     
         2 . The polymeric film of  claim 1 , wherein the plurality of three-dimensional structures provide an average open area of greater than 2600 square micrometers. 
     
     
         3 . The polymeric film of  claim 1 , wherein the polymeric film is hydrophobic. 
     
     
         4 . The polymeric film of  claim 1 , wherein the polymeric film is hydrophilic. 
     
     
         5 . The polymeric film of  claim 1  further comprising titanium dioxide in an amount of about 1 to 15 weight percent. 
     
     
         6 . The polymeric film of  claim 1 , further comprising a basis weight of about 5 to 30 gsm. 
     
     
         7 . The polymeric film of  claim 1 , wherein the plurality of apertures comprise a first diameter in a range of 0.4 mm to 1.5 mm. 
     
     
         8 . The polymeric film of  claim 1 , wherein at least 50 percent of the plurality of three dimensional structures comprise an open area of greater than 2000 square micrometers. 
     
     
         9 . The polymeric film of  claim 1 , wherein at least 30 percent of the plurality of three dimensional structures comprise an open area of greater than 3000 square micrometers. 
     
     
         10 . The polymeric film of  claim 1 , wherein at least 25 percent of the plurality of three dimensional structures comprise an open area of greater than 4000 square micrometers. 
     
     
         11 . The polymeric film of  claim 1 , wherein at least 20 percent of the plurality of three dimensional structures comprise an open area of greater than 6000 square micrometers. 
     
     
         12 . A composite structure comprising a first surface and an opposing second surface, the composite structure further comprising:
 a plurality of apertures comprising aperture sidewalls which extend in a first direction away from the first or second surface and each of the plurality of apertures comprising a first size;   contiguous land areas between adjacent apertures, wherein the land areas comprise a plurality of three dimensional structures each of which comprise a sidewall and an open distal end, each of the plurality of three dimensional structures having a second size, wherein the first size is greater than the second size, wherein each sidewall extends from the first surface or second surface, and wherein each of the three-dimensional structures has an open area of at least 1000 square micrometers.   
     
     
         13 . The composite structure of  claim 12 , further comprising a polymeric film layer and a carrier layer, wherein the polymeric film layer has a basis weight of from between 5 to 30 gsm, and wherein the carrier layer has a basis weight of from between 7 to 40 gsm. 
     
     
         14 . The composite structure of  claim 12 , wherein the plurality of three-dimensional structures provide an average open area of greater than 2600 square micrometers. 
     
     
         15 . The composite structure of  claim 13 , wherein the polymeric film layer is hydrophobic. 
     
     
         16 . The composite structure of  claim 13 , wherein the polymeric film layer is hydrophilic. 
     
     
         17 . The composite structure of  claim 12 , wherein each of the plurality of apertures has a first diameter in a range of 0.4 mm to 1.5 mm. 
     
     
         18 . The composite structure of  claim 13 , wherein the polymeric film layer and the carrier web have different air permeability. 
     
     
         19 . The composite structure of  claim 13 , wherein the polymeric film layer has a thickness of less than 25 microns. 
     
     
         20 . The composite structure of  claim 13 , wherein the carrier layer comprises a nonwoven layer, and wherein the nonwoven layer. 
     
     
         21 . The composite structure of  claim 20 , wherein the nonwoven layer comprises a plurality of fibers having a denier of between 3 to 15. 
     
     
         22 . The composite structure of  claim 12 , wherein the composite structure has a wearer-facing surface and an opposing garment-facing surface, and wherein a surface energy gradient exists between the wearer-facing surface and the garment-facing surface of the composite structure. 
     
     
         23 . The composite structure of  claim 12 , wherein the plurality of three dimensional structures are present in an amount of at least 1300 per square cm. 
     
     
         24 . The composite structure web of  claim 13 , wherein the composite structure comprises a tie layer disposed between the polymeric film web and a carrier web layer. 
     
     
         25 . The method of  claim 24 , wherein the tie layer is hydrophilic. 
     
     
         26 . The polymeric film of  claim 12 , wherein at least 50 percent of the plurality of three dimensional structures comprise an open area of greater than 2000 square micrometers. 
     
     
         27 . The polymeric film of  claim 12 , wherein at least 30 percent of the plurality of three dimensional structures comprise an open area of greater than 3000 square micrometers. 
     
     
         28 . The polymeric film of  claim 12 , wherein at least 25 percent of the plurality of three dimensional structures comprise an open area of greater than 4000 square micrometers. 
     
     
         29 . The polymeric film of  claim 12 , wherein at least 20 percent of the plurality of three dimensional structures comprise an open area of greater than 6000 square micrometers. 
     
     
         30 . A disposable absorbent article comprising:
 a topsheet comprising a polymeric film having a plurality of apertures extending through the polymeric film, each of the plurality of apertures comprising aperture sidewalls which extend in a first direction away from a first or an opposing second surface and each of the plurality of apertures comprising a first size and contiguous land areas between adjacent apertures, wherein the contiguous land areas comprise a plurality of three dimensional structures each of which comprise a sidewall and an open distal end, each of the plurality of three dimensional structures having a second size, wherein the first size is greater than the second size, wherein each sidewall extends from the first surface or second surface, and wherein each of the three-dimensional structures has an open area of at least 1000 square micrometers;   a backsheet; and   an absorbent core disposed between the topsheet and the backsheet.   
     
     
         31 . The absorbent article of  claim 30 , wherein the polymeric film is hydrophobic. 
     
     
         32 . The absorbent article of  claim 30 , wherein the polymeric film is hydrophilic. 
     
     
         33 . The absorbent article of  claim 30 , wherein the polymeric film comprises a basis weight of about 5 to 30 gsm. 
     
     
         34 . The absorbent article of  claim 30 , wherein the topsheet further comprises a carrier layer joined to the polymeric film. 
     
     
         35 . The absorbent article of  claim 34 , wherein the carrier layer comprises a nonwoven layer. 
     
     
         36 . The absorbent article of  claim 35 , wherein the polymeric film is extrusion coated onto the nonwoven layer. 
     
     
         37 . The absorbent article of  claim 35 , wherein the polymeric film forms a portion of a garment-facing surface of the topsheet. 
     
     
         38 . The absorbent article of  claim 35 , wherein the polymeric film forms a portion of a wearer-facing surface of the absorbent article. 
     
     
         39 . The absorbent article of  claim 35 , wherein the polymeric film and the carrier layer have different air permeability. 
     
     
         40 . The method of  claim 35 , wherein the polymeric film has a basis weight of from between 5 to 30 gsm, and wherein the nonwoven layer has a basis weight of from between 7 to 40 gsm. 
     
     
         41 . The absorbent article of  claim 30 , wherein the topsheet further comprises a tie layer disposed between the polymeric film and a carrier layer. 
     
     
         42 . The absorbent article of  claim 41 , wherein the tie layer is hydrophilic. 
     
     
         43 . The absorbent article of  claim 41 , wherein the carrier layer is a nonwoven. 
     
     
         44 . The absorbent article of  claim 30 , wherein the polymer film web has a thickness of less than  25  microns. 
     
     
         45 . The polymeric film of  claim 30 , wherein at least 50 percent of the plurality of three dimensional structures comprise an open area of greater than 2000 square micrometers. 
     
     
         46 . The polymeric film of  claim 30 , wherein at least 30 percent of the plurality of three dimensional structures comprise an open area of greater than 3000 square micrometers. 
     
     
         47 . The polymeric film of  claim 30 , wherein at least 25 percent of the plurality of three dimensional structures comprise an open area of greater than 4000 square micrometers. 
     
     
         48 . The polymeric film of  claim 30 , wherein at least 20 percent of the plurality of three dimensional structures comprise an open area of greater than 6000 square micrometers. 
     
     
         49 . A polymeric film comprising a first surface and an opposing second surface, the polymeric film further comprising:
 a plurality of apertures extending through the polymeric film, each of the plurality of apertures comprising aperture sidewalls which extend in a first direction away from the first or second surface and each of the plurality of apertures comprising a first size;   contiguous land areas between adjacent apertures, wherein the contiguous land areas comprise a plurality of three dimensional structures each of which comprise a sidewall and an open distal end, each of the plurality of three dimensional structures having a second size, wherein the first size is greater than the second size, wherein each sidewall extends from the first surface or second surface in a second direction opposite the first direction, and wherein at least 50 percent of the plurality of three dimensional structures comprise an open area of greater than 2000 square micrometers.   
     
     
         50 . The polymeric film of  claim 49 , wherein at least 30 percent of the plurality of three dimensional structures comprise an open area of greater than 3000 square micrometers. 
     
     
         51 . The polymeric film of  claim 49 , wherein at least 25 percent of the plurality of three dimensional structures comprise an open area of greater than 4000 square micrometers. 
     
     
         52 . The polymeric film of  claim 49 , wherein at least 20 percent of the plurality of three dimensional structures comprise an open area of greater than 6000 square micrometers.