Composite sheet material for use as acquisition distribution layer in an absorbent article
AssigneeFitesa Film Products LLC
InventorsPhillip Mellor, Andrew D. Maschino
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Abstract
A composite sheet material having improved fluid management properties is provided. The composite sheet material includes a nonwoven substrate comprising a carded nonwoven having a basis weight greater than about 16 gsm, or a high loft spunbond nonwoven and a film layer having a plurality of apertured protuberances extending outwardly from a face of the film. The composite sheet material is particularly useful in the preparation of absorbent articles.
Claims21
A composite sheet material comprising
- a nonwoven substrate selected from the group consisting of a carded nonwoven and a high loft spunbond nonwoven, wherein the carded nonwoven comprises a plurality of staple fibers bonded to each other to form a coherent web, and has a basis weight from about 16 to 80 gsm, and the high loft spunbond nonwoven has a density of less than 0.080 g/cm3;
- and
- a microperforated polymeric film layer overlying and bonded to the nonwoven substrate, wherein the film comprises a plurality of apertured protuberances extending outwardly from a face of the film, the apertures including a first opening disposed opposite the nonwoven substrate, a second opening at a vertex of the aperture, and a continuous sidewall extending between the first and second openings.
A method of preparing a composite sheet material, the method comprising the steps of
- providing a nonwoven substrate, the nonwoven substrate selected from the group consisting of a carded nonwoven fabric and a high loft spunbond nonwoven;
- extruding a polymer film onto a cylinder having a forming surface thereon while the polymer film is in a molten or semi-molten state.
- forming a plurality of apertured protuberances in the film to form a formed film layer, wherein each apertured protuberance including a proximal end, a distal end, and a continuous sidewall extending therebetween;
- contacting a surface of the nonwoven substrate to a surface of the formed film layer;
- and
- bonding the nonwoven substrate to the formed film to form a composite sheet material.
A method of preparing a composite sheet material, the method comprising the steps of
- providing a nonwoven substrate, the nonwoven substrate selected from the group consisting of a carded nonwoven fabric and a high loft spunbond nonwoven;
- providing a polymer film comprising plurality of apertured protuberances in the film, wherein each apertured protuberance including a proximal end, a distal end, and a continuous sidewall extending therebetween;
- depositing a layer of adhesive on one or more of a surface of the nonwoven substrate or a surface of the polymer film such that the adhesive layer is disposed between the nonwoven substrate and the polymer film;
- and
- contacting a surface of the nonwoven substrate to a surface of the formed film layer;
- and adhesively bonding the nonwoven substrate to the formed film to form a composite sheet material.
Dependencies are inferred from the claim text.