Method of making a hydroformed composite material

1. A method for hydroforming a composite precursor material, the method comprising:

forming a composite precursor material comprising an original spun bonded nonwoven web having an original loft and an original air permeability, and a polymer film layer; and

applying a plurality of pressurized liquid jets onto an outer surface of the original spun bonded nonwoven web while the composite precursor material passes over a forming structure comprising a pattern of apertures and a vacuum slot area located beneath the forming structure to push and reorient a plurality of spun bonded fibers in the original spun bonded nonwoven web from a closely packed substantially horizontal orientation to a more loosely packed orientation with greater vertical spacing between the fibers to produce a hydroformed composite material comprising an expanded spun bonded nonwoven layer having a loft of at least about 1.3 times greater than the original loft of the original spun bonded nonwoven web, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web,

wherein the polymer film layer is in contact with the forming structure as the plurality of pressurized liquid jets are applied onto the outer surface of the original spun bonded nonwoven web,

wherein the plurality of pressurized liquid jets provide a liquid jet pressure sufficient to form a pattern of extended cells in the polymer film layer corresponding to the pattern of apertures of the forming structure, and

wherein the extended cells contain continuous fibers and/or fibrils of the expanded spun bonded nonwoven layer.

2. The method according to claim 1 , wherein the liquid jet pressure is sufficient to form apertures in the extended cells and cause a plurality of the fibrils to extend outwardly from the polymer film layer, beyond a plane containing apexes of the extended cells of the polymer film layer.

3. The method according to claim 1 , wherein said forming the composite precursor material comprises passing the original spun bonded nonwoven web through low pressure nip rolls while a layer of molten polymer film is simultaneously extruded into the nip to form the polymer film layer on the original spun bonded nonwoven web, before applying the plurality of pressurized liquid jets to the outer surface of the original spun bonded nonwoven web.

4. The method according to claim 1 , wherein said forming the composite precursor material comprises passing the original spun bonded nonwoven web over a second forming structure in synchronized speed while passing through a second vacuum slot area while a layer of molten polymer film is simultaneously extruded on top of the original spun bonded nonwoven web in the second vacuum slot area, before applying the plurality of pressurized liquid jets to the outer surface of the original spun bonded nonwoven web.

5. The method according to claim 1 , further comprising applying the plurality of pressurized liquid jets onto an outer surface of the hydroformed composite material while the hydroformed composite material passes over a second forming structure comprising apertures and a second vacuum slot area located beneath the second forming structure to produce a pattern of macro extended cells, the macro extended cells having a mesh count of less than 40 cells per linear inch.

6. The method according to claim 5 , wherein the macro extended cells have sidewalls comprising a continually thinning portion of the hydroformed composite material extending away from an original plane of the hydroformed composite material.

7. The method according to claim 5 , wherein the hydroformed composite material is introduced to the second forming structure with the expanded spun bonded nonwoven layer oriented upward and the polymer film layer on the second forming structure.

8. The method according to claim 5 , wherein the hydroformed composite material is introduced to the second forming structure with the polymer film layer oriented upward and the expanded spun bonded nonwoven layer on the second forming structure.

9. The method according to claim 1 , further comprising passing the hydroformed 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 to form macro extended cells in the hydroformed composite material.

10. The method according to claim 9 , wherein the hydroformed composite material is introduced to the nip with the expanded spun bonded nonwoven layer oriented upward against the pin roll and the polymer film layer oriented downward against the counter roll.

11. The method according to claim 9 , wherein the hydroformed composite material is introduced to the nip with polymer film layer oriented upward against the pin roll and the expanded spun bonded nonwoven layer oriented downward against the counter roll.

12. The method according to claim 1 , further comprising passing the hydroformed composite material through a nip between an embossing roll having a three-dimensional pattern on an outer surface thereof and a counter roll while the embossing roll and the counter roll rotate in opposite directions to form the three-dimensional pattern in the hydroformed composite material.

13. A method for hydroforming a composite precursor material, the method comprising:

feeding a nonwoven and polymer film composite precursor material comprising an original spun bonded nonwoven web having an original loft and an original air permeability, and a polymer film layer into a hydroforming apparatus; and

applying a plurality of pressurized liquid jets onto an outer surface of the original spun bonded nonwoven web while the composite precursor material passes over a forming structure comprising apertures and a vacuum slot area located beneath the forming structure to push and reorient a plurality of fibers in the original spun bonded nonwoven web from a closely packed substantially horizontal orientation to a more loosely packed orientation with greater vertical spacing between the fibers to produce a hydroformed composite material comprising an expanded spun bonded nonwoven layer having a loft of at least about 1.3 times greater than the original loft of the original spun bonded nonwoven web, and an air permeability of at least about 1.2 times greater than the original air permeability of the original spun bonded nonwoven web,

wherein a plurality of extended cells are formed in the polymer film layer as the composite precursor material passes over the forming structure, and

wherein the extended cells contain continuous fibers and/or fibrils of the expanded spun bonded nonwoven layer.