Method for making a composite material

A method for manufacturing a composite material, the method comprising:

• forming a composite precursor material comprising a nonwoven layer comprising a plurality of fibers and a polymer film layer, comprising a solid polymeric web, laminated to the nonwoven layer;
• loading the composite precursor material onto a forming structure comprising a plurality of apertures such that the polymer film layer is disposed against the forming structure and the nonwoven layer is separated from the forming structure by the polymer film layer;
• forming a plurality of apertured extended cells by applying a fluid to the composite precursor material on a side with the nonwoven layer while the composite precursor material is disposed against the forming structure, thereby creating a composite material,
• wherein the plurality of apertured extended cells extend away from lands, in the polymer film layer, and
• wherein each of the apertured extended cells comprises
• a first aperture, with a first area, proximal to the nonwoven layer,
• a second aperture, with a second area smaller than the first area, distal from the nonwoven layer, and
• a continuous sidewall extending from the first aperture and terminating at the second aperture at a distal end thereof;
• while forming the plurality of apertured extended cells, pushing, with the fluid, a portion of at least one of the fibers into at least one of the apertured extended cells, so that the portion of the at least one of the fibers extends into the at least one of the apertured extended cells and through the second aperture at the distal end thereof;
• and
• aperturing the composite material to form a plurality of macro extended cells in addition to the plurality of apertured extended cells;
• wherein the polymer film layer comprises a first surface separated from a second surface by a thickness of the polymer film layer,
• wherein the first surface is disposed adjacent to the nonwoven layer, the second surface is separated from the nonwoven layer by the thickness, and the continuous sidewall extends away from the nonwoven layer, from the first aperture to the second aperture,
• wherein a height of the plurality of apertured extended cells is greater than the thickness, and
• wherein, during aperturing, macro extended cells are formed by passing the composite material through a nip between a pin roll having a pattern of pins protruding from a surface thereof and a counter roll having a matching pattern of cavities recessed in a surface thereof while the pin roll and the counter roll rotate in opposite directions.