Method For Making An Apertured Web

Abstract

The present invention relates to a method for making an aperture web. The method includes the steps of: moving a micro-textured web through a first member having male elements and a second member having discontinuous female elements, wherein the male elements are arranged in a staggered pattern.

What is claimed is: 
     
         1 . A method for making an apertured web, the method comprising the steps of:
 a) providing a precursor web having a first surface and a second surface opposite to the first surface, the precursor web comprising a plurality of discrete extended elements on the first surface, the discrete extended elements comprising open proximal ends, open or closed distal ends, and sidewalls;   b) providing a forming apparatus for macro apertures comprising a first member and a second member, wherein the first member comprises a first plurality of male elements on its surface and the second member comprises a first plurality of discontinuous female elements on its surface;   c) moving the precursor web through the first and second members so that macro apertures are formed in the precursor web as the first plurality of male elements and the first plurality of discontinuous female elements are engaged;   wherein the first plurality of male elements comprise teeth having a shape to form the macro apertures on the precursor web, and being arranged in a staggered pattern; and   wherein each of the teeth comprise a proximal part joined to the surface of the first member and a distal part directly adjacent to the proximal part, the distal part tapering to a tip, and wherein the proximal part and the distal part have a different degree of taper, wherein the teeth have a tooth-to-tooth spacing between two adjacent teeth located along a line that is not parallel either to the cross-sectional length dimension or to the cross-sectional width dimension not greater than about 1.9 mm.   
     
     
         2 . The method according to  claim 1 , wherein each of the teeth further comprises a middle part between the proximal part and the distal part, the middle part having a degree of taper different from the proximal part. 
     
     
         3 . The method according to  claim 1 , wherein the each of the teeth has a base having a polygonal shape. 
     
     
         4 . The method according to  claim 3 , wherein the each of the teeth has a base having a shape selected from the group consisting of a quadrilateral shape, a hexagonal shape, an octagonal shape and combinations thereof. 
     
     
         5 . The method according to  claim 1 , wherein the precursor web comprises the discrete extended elements selected from discrete extended elements having a diameter of less than about 500 microns, discrete extended elements having an aspect ratio of at least about 0.2, at least about 95 discrete extended elements per square centimeter, and mixtures thereof. 
     
     
         6 . The method according to  claim 1 , wherein the teeth have a base having a ratio of a cross-sectional length to a cross-sectional width not greater than about 3.3. 
     
     
         7 . The method according to  claim 1 , wherein the first member comprises male elements with a male element density of from about 5 to about 60 male elements/cm 2 . 
     
     
         8 . The method according to  claim 1 , wherein at least one of the first and the second members is a generally cylindrical roll. 
     
     
         9 . The method according to  claim 1 , wherein the teeth are arranged so that the cross-sectional length dimension is parallel to a machine direction or a cross direction. 
     
     
         10 . The method according to  claim 1 , wherein the teeth are arranged so that the cross-sectional length dimension is not parallel either to a machine direction or to a cross direction. 
     
     
         11 . The method according to  claim 1 , wherein the precursor web is a polymeric film or a laminate having a polymeric film layer. 
     
     
         12 . The method according to  claim 1 , wherein at least one of the first member and the second member is heated. 
     
     
         13 . The method according to  claim 12 , wherein the first member and the second member have a clearance between a top surface of the second member and a bottom surface of the first member when the first member and the second member are in maximum engagement so that the discrete extended elements are substantially intact from heat-induced damages after the step c). 
     
     
         14 . The method according to  claim 13 , wherein the clearance is no less than about 1.5 mm. 
     
     
         15 . The method according to  claim 1 , wherein the discrete extended elements are formed by a vacuum formation process. 
     
     
         16 . The method according to  claim 1 , wherein the discrete extended elements are formed by a hydroforming process. 
     
     
         17 . The method of  claim 1 , wherein the first member further comprises a second plurality of discontinuous female elements on its surface and the second member comprises a second plurality of male elements on its surface, and wherein when the precursor web is moved through the first and second members, the second plurality of male elements and the second plurality of discontinuous female elements are engaged to form discontinuities in the precursor web.