Fibrous and apertured, three-dimensional macroscopically expanded plastic web

Abstract

A fluid pervious web suitable for use as a topsheet on an absorbent article is disclosed. The topsheet includes a fibrous and apertured, three-dimensional, macroscopically expanded, plastic web. The fibrous and apertured, three-dimensional, macroscopically expanded, plastic web permits bodily fluids to penetrate while providing an improved, less plastic-like feel and visual aesthetics.

What is claimed: 
     
       1. A process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web having a fibrous wearer-contacting surface, said process comprising the steps of: (a) extruding a polymeric resin onto a forming structure to form a semi-molten film web, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place opposed surfaces of said forming structure in fluid communication with one another;   (b) providing a web of nonwoven fabric;   (c) disposing said web of nonwoven fabric onto said semi-molten film web while said semi-molten film web is supported by said forming structure so as to join said webs to form a composite web; and   (d) applying a pneumatic pressure to said composite web to cause said composite web to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces. said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface, said pneumatic pressure causing said fibers to be pulled against said first surface of said formed web and into said capillaries of said formed web along said sidewall portions, said fibers being secured to said first surface and said sidewall portions of said formed web such that said capillaries are substantially free of fibers spanning across said capillaries between opposing sidewall portions forming said fibrous wearer-contacting surface of said fibrous and apertured, three-dimensional, macroscopically expanded web.