Apertured hydrophilic polymer film topsheet with improved absorbency and comfort properties

Abstract

An improved topsheet for use in absorbent articles such as sanitary pads. The topsheet comprises a three-dimensional hydrophilic formed film having a plurality of openings leading from a surface of the topsheet to an absorbent core. The topsheet presents a more comfortable and dryer surface which contacts the wearer and a clean, dry appearance to the wearer. The clean, dry appearance is obtained by employing an opacifying agent in the film. The openings comprise tapered capillaries having a base in the surface plane of the topsheet and an apex remote from the surface plane of the topsheet. Each apex is in intimate contact with the absorbent core. In a preferred arrangement, the hydrophilic polymer film topsheet comprises Nylon 6, Nylon 6 and polyetheramide, or other resins having chemistries similar to nylon.

What is claimed is: 
     
       1. A topsheet for an absorbent article, said topsheet comprising a three-dimensional hydrophilic polymer film having a plurality of openings for fluid passage, said openings being tapered capillaries each having a base in a surface plane of said topsheet and an apex remote from said surface plane, said capillaries having an angle of taper such that said tapered capillaries are of decreasing cross-section in the direction from said capillary base to said capillary apex, said film having inherent and permanent hydrophilic properties whereby said film has hydrophilic properties without the necessity of a surface active agent. 
     
     
       2. The topsheet of claim 1 wherein said film is a copolymer of nylon 6 and polyetheramide. 
     
     
       3. The topsheet of claim 2 wherein the copolymer is up to 23% by weight polyetheramide. 
     
     
       4. The topsheet of claim 1 wherein said film further includes an opacifying agent for providing said topsheet with a clean, dry and white appearance. 
     
     
       5. The topsheet of claim 4 wherein said opacifying agent is titanium dioxide, wherein said titanium dioxide comprises at least 2% of said film by weight. 
     
     
       6. The topsheet of claim 1 wherein said tapered capillaries have an angle of taper from about 10° to about 60°, said base has an opening dimension from about 0.006 inches (0.152 mm) to about 0.250 inches (6.35 mm), and said apex has an opening dimension from about 0.004 inches (0.102 mm) to about 0.100 inches (2.54 mm). 
     
     
       7. The topsheet of claim 1 wherein said tapered capillaries are positioned substantially perpendicular to said topsheet surface plane. 
     
     
       8. An absorbent article, comprising a topsheet and an absorbent core, wherein said topsheet is a three dimensional hydrophilic polymer film having inherent and permanent hydrophilic properties and being devoid of any surface active agent, said film further having a plurality of openings comprising tapered capillaries each having a base in a surface plane of said topsheet and an apex remote from said surface plane, said capillaries having an angle of taper such that said tapered capillaries are of decreasing cross-section in the direction from said capillary base to said capillary apex. 
     
     
       9. The absorbent article of claim 8 wherein said film is a block copolymer of nylon 6 and polyetheramide. 
     
     
       10. The absorbent article of claim 9 wherein the polyetheramide component of said block copolymer is about 0% to about 23% by weight of said copolymer. 
     
     
       11. The absorbent article of claim 8 further includes a fluid-impervious backsheet. 
     
     
       12. The absorbent article of claim 11 wherein said article is a sanitary pad. 
     
     
       13. The absorbent article of claim 11 wherein said article is a diaper. 
     
     
       14. The absorbent article of claim 11 wherein said article is an incontinence pad. 
     
     
       15. The absorbent article of claim 8 wherein said tapered capillaries have an angle of taper from about 10° to about 60°, said base having an opening dimension from about 0.006 inches (0.152 mm) to about 0.250 inches (6.35 mm), and said apex having an opening dimension from about 0.004 inches (0.102 mm) to about 0.100 inches (2.54 mm). 
     
     
       16. The absorbent article of claim 8 wherein said tapered capillaries are positioned substantially perpendicular to said topsheet surface plane. 
     
     
       17. An absorbent article, comprising: an absorbent core having a body facing side and a garment facing side;   a fluid-impervious backsheet overlaying at least a portion of said garment facing side of said core; and   a three-dimensional hydrophilic polymer film topsheet having inherent and permanent hydrophilic properties and a surface plane, said topsheet overlaying at least a portion of said body facing side of said core, said topsheet having a plurality of openings for fluid passage, said topsheet being formed of a copolymer of nylon 6 and polyetheramide, the copolymer being about 15% polyetheramide by weight;   said openings comprising tapered capillaries in the form of a frustrum of a cone, each having a base in a surface plane of said topsheet, and an apex remote from said surface plane, said capillaries having an angle of taper such that said tapered capillaries are of decreasing cross-section in the direction from said capillary base to said capillary apex, said angle of taper ranging from about 10° to about 60°, said base having an opening dimension from about 0.006 inches (0.152 mm) to about 0.250 inches (6.35 mm), and said apex having an opening dimension from about 0.004 inches (0.102 mm) to about 0.100 inches (2.54 mm); and   wherein said absorbent core is located adjacent the apexes of said capillaries in use.   
     
     
       18. The absorbent article of claim 17 wherein said absorbent article is a sanitary pad. 
     
     
       19. The absorbent article of claim 16 wherein said absorbent article is a diaper. 
     
     
       20. The absorbent article of claim 16 wherein said article is an incontinence pad.