Apertured nonwoven materials and methods for forming the same
The present disclosure is generally directed, in part, to a selectively apertured nonwoven material forming a portion of a disposable absorbent article. The nonwoven material comprises a layer of bicomponent fibers, and a plurality of apertures formed in the layer of bicomponent fibers. Each aperture has a major axis and a minor axis. Each major axis is larger than each minor axis. Each major axis has a length of greater than about 1.5 mm and less than about 10 mm and each minor axis has a length of greater than about 0.4 mm and less than about 1.25 mm. The nonwoven material has a basis weight of less than 25 gsm, but greater than 10 gsm. The layer of bicomponent fibers has an effective open area greater than about 3% but less than about 30%. The apertures have an aperture area greater than about 0.5 mm 2 and less than about 10 mm 2 .
1. A selectively apertured nonwoven material forming a portion of a disposable absorbent article, the nonwoven material, comprising:
a layer of bicomponent fibers; and
a plurality of apertures formed in the layer of bicomponent fibers, wherein each aperture has a major axis and a minor axis, wherein each major axis is larger than each minor axis, wherein each major axis has a length of greater than about 1.5 mm and less than about 10 mm, and wherein each minor axis has a length of greater than about 0.4 mm and less than about 1.25 mm;
the nonwoven material having a basis weight of less than 25 gsm, but greater than 10 gsm;
wherein at least a portion of the layer of bicomponent fibers comprising the plurality of the apertures is treated to be hydrophilic;
wherein the layer of bicomponent fibers has an effective open area greater than about 4% but less than about 10.4%; and
wherein the apertures have an aperture area greater than about 0.5 mm 2 and less than about 10 mm 2 .
2. The selectively apertured nonwoven material of claim 1 , wherein each major axis has a length of greater than about 1.5 mm and less than about 5 mm, and wherein each minor axis has a length of greater than about 0.5 mm and less than about 1 mm.
3. The selectively apertured nonwoven material of claim 1 , wherein the aperture area is greater than about 0.5 mm 2 and less than about 2.14 mm 2 .
4. The selectively apertured nonwoven material of claim 1 , wherein the nonwoven material has a longitudinal axis and a lateral axis.
5. The selectively apertured nonwoven material of claim 4 , wherein the major axis of at least some of the apertures extends generally parallel to the longitudinal axis.
6. The selectively apertured nonwoven material of claim 4 , wherein the major axis of at least some of the apertures extends generally transverse to the longitudinal axis.
7. The selectively apertured nonwoven material of claim 4 , wherein the major axis of at least some of the apertures extends in a first transverse direction relative to the longitudinal axis, and wherein the major axis of at least some of the apertures extends in a second transverse direction relative to the longitudinal axis.
8. The selectively apertured nonwoven material of claim 1 , wherein the bicomponent fibers comprise spunbond bicomponent fibers.
9. The selectively apertured nonwoven material of claim 8 , wherein the bicomponent fibers comprise a polypropylene core and polyethylene sheath.
10. The selectively apertured nonwoven material of claim 1 , comprising a layer of meltblown fibers, wherein the basis weight of the nonwoven material is less than 20 gsm.
11. The selectively apertured nonwoven material of claim 1 , wherein at least some of the apertures form an ellipse-like shape.
12. The selectively apertured nonwoven material of claim 1 , wherein the material forms a topsheet of the disposable absorbent article.
13. The selectively apertured nonwoven material of claim 1 , wherein the length of each major axis is at least three times as long as the length of each minor axis.
14. The selectively apertured nonwoven material of claim 1 , wherein the apertures have an aperture area greater than about 0.84 mm 2 and less than about 2.14 mm 2 .
15. The selectively apertured nonwoven material of claim 1 , wherein the effective open area is greater than about 4.4%.
16. A disposable absorbent article, comprising:
a liquid pervious layer;
a liquid impervious layer;
an absorbent core disposed at least partially between the liquid pervious layer and the liquid impervious layer;
wherein the liquid pervious layer comprises:
a selectively apertured nonwoven material having a plurality of apertures formed therein, wherein the selectively apertured nonwoven material comprises bicomponent fibers;
wherein at least a portion of the layer of bicomponent fibers comprising the plurality of the apertures is treated to be hydrophilic;
wherein each aperture has a major axis and a minor axis, wherein each major axis has a length of greater than about 1.5 mm and less than about 10 mm, and wherein each minor axis has a length of greater than about 0.4 mm and less than about 1.25 mm;
wherein the liquid pervious layer has a basis weight of less than about 25 gsm but greater than 10 gsm;
wherein the selectively apertured nonwoven material has an effective open area in the range of about 4.4% to about 10.4%; and
wherein the apertures have an aperture area greater than about 0.84 mm 2 and less than about 2.14 mm 2 .
17. The disposable absorbent article of claim 16 , wherein said bicomponent fibers are spunbonded bicomponent fibers.
18. The disposable absorbent article of claim 16 , comprising a patterned adhesive, wherein the patterned adhesive is printed on the liquid pervious layer or the absorbent core.
19. The disposable absorbent article of claim 16 , wherein the absorbent core comprises a channel, and wherein the channel is arcuate.
20. A disposable absorbent article, comprising:
a liquid pervious layer;
a liquid impervious layer;
an absorbent core disposed at least partially between the liquid pervious layer and the liquid impervious layer;
wherein the liquid pervious layer comprises:
a selectively apertured nonwoven material having a plurality of apertures formed therein, wherein the selectively apertured nonwoven material comprises bicomponent fibers;
wherein at least a portion of the layer of bicomponent fibers comprising the plurality of the apertures is treated to be hydrophilic;
wherein each aperture has a major axis and a minor axis, wherein each major axis has a length of greater than about 1.5 mm and less than about 10 mm, and wherein each minor axis has a length of greater than about 0.4 mm and less than about 1.25 mm;
wherein the liquid pervious layer has a basis weight of less than about 25 gsm but greater than 10 gsm;
wherein the selectively apertured nonwoven material has an effective open area in the range of about 4.0% to about 10.4%; and
wherein the apertures have an aperture area greater than about 0.5 mm 2 and less than about 2.14 mm 2 .