MXPA04008404A

MXPA04008404A - Two layer structure for absorbent articles

Info

Publication number: MXPA04008404A
Application number: MXPA/A/2004/008404A
Authority: MX
Inventors: William A James; Archie Jones; William Gf Kelly
Original assignee: William A James; Archie Jones; William Gf Kelly
Priority date: 2003-08-29
Filing date: 2004-08-30
Publication date: 2008-09-26

Abstract

A two layer structure comprising a fluid permeable, first layer in fluid communication with a fluid permeable second layer is provided. The two layers contact one another through a plurality of disconnected macrofeatures that project either from the first layer or the second layer. The structure has particular utility as a cover/transfer layer for use in absorbent articles.

Description

STRUCTURE WITH TWO LAYERS FOR ABSORBING ITEMS CROSS REFERENCE TO THE RELATED APPLICATION The present application is a continuation in part of the U.S. Patent Application. Serial No. 10 / 366,051, filed on February 13, 2003.

FIELD OF THE INVENTION This present invention relates to a two-layer structure for use in absorbent articles, and more particularly, to a two-layer structure including a fluid-permeable first layer in fluid communication with a second fluid-permeable layer, the second layer includes a plurality of separate macro features. The structure is particularly useful as a cover / transfer layer for use in absorbent articles.

BACKGROUND OF THE INVENTION The transfer layers are commonly used in absorbent articles, to aid in the transport of fluid away from a body-facing layer or cover, towards the absorbent core. The layers conventional transfer are often made of non-woven materials. They typically operate by pumping or wicking the fluid away from the body facing layer, directly down to the underlying absorbent core. Combinations of cover / transfer layers are also known. See, for example, Patents of the U.S.A. Nos. 5,665,082; 5,797,894 and 5,466,232. Applicants have discovered that a two-layered structure comprising a fluid-permeable first layer in fluid communication with a second fluid-permeable layer, said layers in contact with each other at least in a plurality of separate macro features, functions of efficiently, among other things, as a body-oriented layer or a cover / transfer layer. After the supply of a liquid in the first layer of this structure, the structure moves and / or transfers the fluid through and through the structure, thereby allowing the fluid to be transported more rapidly through the structure. the structure in the z direction, that is, through the first and second layers towards the absorbent core.

BRIEF DESCRIPTION OF THE INVENTION According to one aspect of the invention, the invention provides a structure with two layers for use in absorbent articles, comprising a first fluid-permeable layer in fluid communication with a second fluid-permeable layer, wherein the layers are in contact with each other substantially only in the plurality of remote separated macro features that project from the second layer. According to another aspect of the invention, the invention provides a two-layered structure that includes a fluid-permeable first layer in fluid communication with a second fluid-permeable layer, the second layer having a plurality of spaced apart macro features in where the first and second layers are in contact with one another in the macro features and in selected areas located between the macro features. According to yet another aspect of the invention, the invention provides a structure with two layers for use in absorbent articles, comprising a first fluid-permeable layer comprising a three-dimensional perforated film in fluid communication with a second fluid-permeable layer. . The three-dimensional film of the first layer comprises a plurality of apertures and a plurality of perforated macro features that project in the direction of the second layer, each perforated macro feature is separated from the other perforated macro features, and wherein the first and second layers are contact with each other substantially only through the perforated macro features.

According to yet another aspect of the invention, the invention provides a structure with two layers for use in absorbent articles., comprising a first fluid-permeable layer comprising a three-dimensional perforated film in fluid communication with a second fluid-permeable layer. The three-dimensional film of the first layer comprises a plurality of openings and a plurality of remote perforated macro features which project in the direction of the second layer, each perforated macro feature is separated from other perforated macro features, and wherein the first and second layers are in contact with each other in the perforated macro features and in selected areas located between the perforated macro features. According to another aspect of the invention, the invention further provides a structure with two layers for use in absorbent articles, comprising a fluid-permeable layer, in contact with the body, in fluid communication with a second layer permeable to a fluid. The second layer comprises a plurality of macro features that project in the direction of the layer that comes into contact with the body, and the macro features are separated from one another. In addition, the layer that comes in contact with the body and the second layer are in contact with each other substantially only through the macro features. According to yet another aspect of the invention, the invention further provides a structure with two layers for use in articles absorbents, comprising a fluid-permeable layer, which comes into contact with the body, in fluid communication with a second fluid-permeable layer. The second layer comprises a plurality of remote macro features that project in the direction of the layer i that comes in contact with the body, the macro features are separated from one another. The layer that comes in contact with the body and the second layer are in contact with each other through the macro features, and in selected areas located between the macro features. Finally, the invention relates to absorbent articles comprising such structures with two layers.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a photomicrograph of one embodiment of the three-dimensional film of the present invention. Figure 1A is an illustration of a cross section of the film of Figure 1, along line A-A. Figure 2 is a photomicrograph of another embodiment of the three-dimensional film of the present invention. Figure 2A is an illustration of a cross section of the film of Figure 2, along line A-A.

Figure 2B is an illustration of a cross section of the film of Figure 2, along line B-B. Figure 3 is a photomicrograph of yet another embodiment of the three-dimensional film of the present invention. Figure 3A is an illustration of a cross section of the film of Figure 3, along line A-A. Figure 4 is a photomicrograph of another embodiment of the three-dimensional film of the present invention. Figure 5 is a schematic illustration of a type of three-dimensional topographic support member useful for making a film of the present invention. Figure 6 is a schematic illustration of an apparatus for laser sculpting a workpiece to form the three-dimensional topographic support member useful for making a film of the present invention. Figure 7 is a schematic illustration of a computer control system for the apparatus of Figure 6. Figure 8 is a graphical amplification of an example of a data series of a pattern for perforating a weft in a workpiece for producing a support member for the perforated film. Figure 9 is a photomicrograph of a workpiece after it has been perforated with a weft using the data series of Figure 8.

Figure 10 is a graphical representation of a data series for laser sculpting a workpiece to produce the film of Figure 2. Figure 11 is a graphic representation of a data series for laser sculpting a workpiece for producing a three-dimensional topographic support member useful for making a film of this invention. Figure 12 is a photomicrograph of a workpiece that has been sculpted with a laser using the data series of Figure 11. Figure 12A is a photomicrograph of a cross section of the laser-sculpted workpiece of Figure 12. Figure 13 is a photomicrograph of a perforated film produced using the laser-sculpted support member of Figure 12. Figure 13A is another photomicrograph of a perforated film produced using laser-sculptured support member of Figure 12. Figure 14 is an example of a series of data that can be used to produce a support member by laser modulation. Figure 14A is a graphical representation of a series of repetitions of the data series of Figure 14. Figure 15 is an amplified view of portion B of the data series of Figure 14.

Figure 16 is a graphical enlargement of a pattern data series, used to create the C portion of Figure 14. Figure 17 is a photomicrograph of a support member produced by laser modulation using the data series of the Figure 14. Figure 18 is a photomicrograph of a portion of the support member of Figure 17. Figure 19 is a photomicrograph of a film produced using the support member of Figure 17. Figure 20 is a photomicrograph of a portion of the film of Figure 19. Figure 21 is a view of a support member used to make a film according to the invention, in place on an apparatus to form the film. Figure 22 is a schematic view of an apparatus for producing a perforated film according to the present invention. Figure 23 is a schematic view of the portion enclosed in a circle of Figure 22. Figure 24 is a photomicrograph of a perforated film of the prior art. Figure 25 is a photomicrograph of another example of a perforated film of the prior art.

Figure 26 is a photomicrograph of another example of a perforated film of the present invention. Figure 27 describes a cross section of a structure with two layers according to the invention. Figure 28 describes a cross-section of an absorbent article comprising a two-layer structure according to the invention. Figure 29 is a photomicrograph of a portion of a perforated film, produced according to the invention. Figure 30 is an enlarged perspective view showing a portion of a two-layer structure according to the invention, with the upper layer thereof partially parted, to show the upper surface of the lower layer. Figure 31 is a cross-sectional view of an absorbent article including the two-layered structure shown in Figure 30, taken along line 31-31. Figure 32 is a simplified cross-sectional schematic illustration of a method for producing the two-layer structure shown in Figure 30.

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to two-layer structures, particularly useful in personal care products. These structures can be used as oriented layers or that come in contact with the body, or cover, as layers for the transfer or handling of fluids, or as other components of personal care products. It has been found that the structures of the invention exhibit improved fluid handling properties, when used in disposable absorbent articles, such as, for example, feminine sanitary protection products. The first layer, which, in one embodiment is a layer that comes in contact with the body, can be made of any of a variety of fluid-permeable materials. As a layer that comes in contact with the body, the first layer is preferably pleasant, with a soft touch and non-irritating to the wearer's skin. The first layer must also exhibit good penetration and a reduced tendency to re-wet, allowing body discharges to quickly penetrate into it, and flow to subsequent underlying layers, while not allowing such discharges to flow back through the layer that it comes in contact with the body towards the user's skin. The first layer can be made from a wide range of materials including, but not limited to, woven or woven fabrics by point, non-woven materials, perforated films, hydroformed films, porous foams, cross-linked foams, cross-linked thermoplastic films and thermoplastic films. In addition, the first layer may be constructed from a combination of one or more of the above materials, such as a layer composed of a non-woven material and a perforated film. Likewise, the second layer can also be formed from a variety of fluid-permeable materials, including, but not limited to, knitted or knitted fabrics, non-woven materials, perforated films, hydroformed films, porous foams, cross-linked foams, crosslinked thermoplastic films, thermoplastic films and combinations thereof. Non-woven materials and perforated films are preferred for use as the first layer and the second layer. Suitable nonwoven materials can be made of any of a variety of fibers, as is known in the art. The fibers can vary in length, from 0.635 centimeters (one quarter of an inch) or less, to 3.81 centimeters (one and a half inches) or more. It is preferred that when using shorter fibers (including wood pulp fiber), the short fibers are mixed with longer fibers. The fibers may be any of the well-known artificial, natural or synthetic fibers such as cotton, rayon, nylon, polyester, polyolefin or the like. The nonwoven materials can be formed by any of the various techniques known in the field, such as like carded, placing with air, placing in humid, blowing in the molten state, glued spinning and the like. The perforated films are typically made of a starting film such as a thin, continuous, uninterrupted film of a thermoplastic polymeric material. This film may be vapor permeable or vapor impermeable; it may be recorded or not recorded; it may be treated by corona discharge on one or both of its principal surfaces or may be free of such treatment with corona discharge; it can be treated with an agent with active surface after the film is formed, by coating, spraying or printing the agent with active surface on the film, or the agent with active surface can be incorporated as a mixture in the thermoplastic polymer material before the film is formed. The film may comprise any thermoplastic polymeric material including, but not limited to, polyolefins, such as high density polyethylene, linear low density polyethylene, low density polyethylene, polypropylene; copolymers of olefins and vinyl monomers, such as copolymers of ethylene and vinyl acetate or vinyl chloride; polyamides; polyesters; polyvinyl alcohol and copolymers of olefins and acrylate monomers, such as copolymers of ethylene and ethyl acrylate and ethylene methacrylate. Films comprising mixtures of two or more such polymeric materials can also be used. The elongation in the direction of the machine (MD) and the direction through the machine (CD) of the start film to be perforated, must be at least 100%, as determined in accordance with Test No. D-882 of the ASTM, performed on an Instron test apparatus, with a jaw speed of 50 inches / minute (127 cm / minute). The thickness of the starting film is preferably uniform and may vary from about 0.0127 (0.5) to about 0.127 millimeters (5 mils) or from about 0.0005 inches (0.0013 cm) to about 0.005 inches (0.076 cm). Co-extruded films can be used, such as coated films that have been modified, for example, by treatment with an active surface agent. The start film can be made by any known technique, such as molding, extrusion or blowing. The methods of drilling are known in the art. Typically, a start film is placed on the surface of a carved support member. The film is subjected to a high pressure differential of a fluid while it is in the support member. The differential pressure of the fluid, which can be liquid or gaseous, causes the film to adopt the pattern of the surface of the carved support member. The portions of the film superposed to the openings in the support member are broken by the fluid pressure differential to create a perforated film. A method for creating a perforated fibrous film is described in detail in the U.S. Patent. commonly owned 5,827,597, by James et al., incorporated herein by reference. According to one aspect of the invention, the first layer and the second layer are in contact with each other, substantially only at through a plurality of separate, remote macro features. This means that the layers are joined with each other substantially only in the macro features. The macro features can be located in the first layer or in the second layer. When the macro features are located in the first layer, they are projected in the direction of the second layer. When the macro features are located in the second layer, they are projected in the direction of the first layer. According to another aspect of the invention, the first layer and the second layer are in contact with one another in the plurality of remote separated macro features and in selected areas located between the remote separated macro features. As used here, the term "macro features", means a superficial projection visible to the normal human eye, without assistance, at a perpendicular distance of approximately 300 mm between the eye and the surface. Preferably, the macro features each have a maximum dimension of at least about 0.15 mm. More preferably, the macro features each have a maximum dimension of at least about 0.305 mm. More preferably, the macro features each have a maximum dimension of at least about 0.50 mm. The macro features are discrete and are separated from each other. That is, if an imaginary plane, that is, a foreground, were to be lowered onto the first surface of the three-dimensional layer, it would touch the layer at the top of the macro features. in multiple discrete areas separated from each other. It is not necessary that each and every one of the macro features touch the imaginary plane; instead, the foreground is defined by the uppermost portions of the macro features, that is, those parts of the macro features that are projected farthest from the second surface of the layer. Where the macro feature layer comprises a perforated film, the film has a first surface, a second surface and a thickness defined by a first plane and a second plane. The film comprises a plurality of separate macro features and a plurality of openings. The openings are defined by side walls that originate in the first surface of the film and extend generally in the second surface direction of the film, to end in the second plane. The first surface of the film matches the foreground in the separate macro features. Where the macro feature layer comprises a nonwoven material, the nonwoven material has a first surface, a second surface and a thickness defined by a first plane and a second plane. The nonwoven material further comprises a plurality of separate macro features, wherein the first surface of the nonwoven material matches the first plane in the separate macro features. In one modality, the macro features are arranged in a regular pattern with respect to each other. Also, if the macro features are projected from a layer that is a film perforated, the macro features and the openings are arranged in a regular configuration with respect to each other in the layer. The openings and the macro features are repeated at fixed or uniform intervals, one with respect to the other. The spatial relationship between apertures and macro features defines a geometric pattern that is consistently repeated across the surface area of the film. The openings and macro features are arranged in a regular, defined pattern, repeated evenly throughout the film. Openings and macro features can be arranged so that there are more openings than macro features, although the relative arrangement of openings and macro features is regular. The exact sizes and shapes of openings and macro features are not critical, provided that the macro features are large enough to be visible to the normal human eye, unaided, at a distance of approximately 300 mm, and as long as the macro features are discrete and separate one of the others. According to one embodiment of the invention, the first layer and the second layer are in contact with each other substantially only through the macro features. That is, the macro features function as separators to keep the first layer away from the surface of the second layer, except where they are in contact with each other in the macro features.

According to another embodiment of the invention, the first layer and the second layer are in contact with one another in the macro features and in selected areas located between the remote macro features. Within the areas defined by the contacting portions of the macro feature, the first layer is disposed above the second layer, so that it is separated therefrom. In yet another embodiment of the invention, the first layer comprises a nonwoven material, while the second layer comprises a nonwoven material or a perforated film. The macro features can be located in the first layer or the second layer. In yet another embodiment, the first layer comprises a perforated film, while the second layer comprises a non-woven material or a perforated film. In this mode, the macro features can also be located in the first layer or the second layer. Nevertheless, when the macro features are present in the first layer, the macro features in the first layer, preferably, contain apertures, ie, perforated macro features and are separated from all other macro features perforated in the first layer. Each perforated macro feature is a discrete physical element. Figure 13 shows a film of this mode, a perforated film with perforated macro features.

In still another embodiment of the invention, shown in Figure 27, the macro features are projected from the second layer, which is a three-dimensional perforated film, as described in the commonly assigned EUA Application, No. Series (dossier of proxy No. CHI-868). Such a second layer 501 may be used in combination with a first layer 500 which is a non-woven material or a perforated film. Preferably, it is used in combination with a first layer which is a non-woven material. The three-dimensional perforated film has a first surface and a second surface. The film also has a thickness defined by a first plane and a second plane. The film has a plurality of openings defined by side walls that originate in the first surface and extend generally in the direction of the second surface, to end in the second plane. The film also comprises a plurality of separate macro features 14. The first surface of the film matches the first plane in these macro features. Figure 1 is a photomicrograph of a modality of such a three-dimensional perforated film. The three-dimensional perforated film 10 of Figure 1 has openings 12 and macro features 14. The openings are defined by side walls 15. The macro features are discrete extensions in the film and can be seen projecting above the lower regions 16 of the first surface. If an imaginary plane, that is, a close-up, is brought down on the first The surface of the three-dimensional perforated film would touch the film on top of the macro features in multiple discrete areas separated from one another. It is not necessary that each and every one of the macro features touch the imaginary plane; instead, the foreground is thus defined, by the uppermost portions of the macro features, that is, those parts of the macro features that project farther from the second surface of the film. In the embodiment of Figure 1, the openings alternate with the macro features in both the x and y directions and the ratio of openings to macro features is one. Figure 1A is an illustration of a cross section of the film 10 of Figure 1, along line AA of Figure 1. As shown in Figure 1A, the macro features 14 are separated from one another in the first plane. 17 and are separated from each other by lower regions 16 of the first surface of the film and by the openings 12. The openings 12 are defined by side walls 15, which originate from the first surface and extend generally in the direction of the second surface, to finish in the second plane 19. It is not necessary that all the openings end in the second plane 19; instead, the second plane is defined by the side walls 15 that extend further down. In one embodiment of the invention, at least a portion of the openings have side walls that have a first portion that is originates in the first plane of the film and a second portion that originates in a plane located between the first and second planes of the film, that is, an intermediate plane to the first and second planes. In a preferred embodiment, in addition to having openings with side walls having first portions that originate in the first plane and second portions originating in an intermediate plane, the film comprises openings whose side walls originate completely in an intermediate plane. That is, the film contains openings that originate in a plane different from the plane defined by the uppermost surface of the macro features. In a particularly preferred embodiment of the present invention, the three-dimensional perforated film comprises a combination of several different types of apertures. The film comprises openings whose side walls originate in the first plane of the film. The film also comprises openings having side walls, a portion of which originates in the first plane and a portion of which originates in an intermediate plane. Finally, the film also comprises openings whose side walls originate completely in an intermediate plane. In Figure 2, the openings 12 are defined by side walls 15. The macro features are projected above the lower regions 16 of the first surface of the film 20. The macro features and apertures are formed differently from the macro features and the openings in the film of Figure 1. In the Figure 2, the macro features are separated from one another by the openings in the x direction and in the y direction. However, some of the openings are separated from one another by the lower regions 16 of the first surface both in the x direction and in the y direction. In the film 20 of Figure 2, the ratio of the openings to the macro features is 2.0. In addition, each opening in the film 20 of Figure 2 has a portion of its side wall that originates in the first plane 17, that is, at an edge 18 of a macro feature, and a portion of its side wall originates in a lower region 16 of the first surface. Figure 2A shows a cross section of the film 20 of Figure 2 along the line A-A. The macro features 14 are separated from one another in the first plane 17 by the openings 12, which are defined by the side walls 15 that originate in the first surface of the film and extend generally in the direction of the second surface, to finish in the second plane 19. It can be seen in Figure 2A that the portions of the side walls 15 shown in the cross section originate in the first plane 17 at the edges 18 of the macro features 14. Figure 2B shows a section of the film 20 of Figure 2 taken along the line BB. In this particular cross section, the macro features are not visible and the openings 12 are separated from one another by the lower regions 16 of the first surface of the film. The lower regions 16 of the film are disposed between the first plane 17 and the second plane 19, the planes define the thickness of the three-dimensional perforated film shown. The side walls 15 end in the second plane 19. Figure 3 shows a photomicrograph of a further embodiment of a three-dimensional perforated film with yet another arrangement of the openings and the macro features. The film 30 of Figure 3 has openings 12 arranged with the macro features 14, and the openings 22 arranged with the macro features 24. All the openings 12, 22 and the macro features 14, 24 are arranged together, so that their relative positions one with the other. with respect to the others they are regular. Figure 3A is a cross section of the film 30 of Figure 3 taken along line AA of Figure 3. This particular cross section shows the macro features 24 and the macro features 14 separated from one another in the first plane. and separated from one another by the openings 12. The openings 12 are defined by the side walls 15 ending in the second plane 19. The portions of the side walls 15 shown in this particular cross section originate in the first plane 17 in edges 18 of macro features 14 and 24. Figure 4 is a photomicrograph of yet another embodiment of a three-dimensional perforated film, in accordance with the present invention. The The film 40 shown in Figure 4 has a regular arrangement of openings 12 and macro features 14. A suitable starting film for making a three-dimensional perforated film is a thin, continuous, uninterrupted film of a thermoplastic polymeric material. This film may be vapor permeable or vapor impermeable; it may be recorded or not recorded; it may be treated by corona discharge on one or both of its main surfaces or may be free of such treatment by corona discharge; it can be treated with an agent with active surface after the film is formed, by coating, spraying or printing the agent with active surface on the film, or the agent with active surface can be incorporated as a mixture in the thermoplastic polymer material before the film is formed. The film can comprise any thermoplastic polymeric material including, but not limited to, polyolefins, such as high density polyethylene, linear low density polyethylene, low density polyethylene, polypropylene; copolymers of olefins and vinyl monomers, such as copolymers of ethylene and vinyl acetate or vinyl chloride; polyamides; polyesters; polyvinyl alcohol and copolymers of olefins and acrylate monomers, such as copolymers of ethylene and ethyl acrylate and ethylene methacrylate. Films comprising mixtures of two or more such polymeric materials can also be used. The elongation in the direction of the machine (MD) and the direction through the machine (CD) of the start film to be perforated, must be at least 100%, as determined in accordance with Test No. D-882 of the ASTM, performed on an Instron test apparatus, with a jaw speed of 50 inches / minute (127 cm / minute). The thickness of the starting film is preferably uniform and may vary from about 0.0127 (0.5) to about 0.127 millimeters (5 mils) or from about 0.0005 inches (0.0013 cm) to about 0.005 inches (0.076 cm). Co-extruded films may be used, such as coated films that have been modified, for example, by treatment with an agent with active surface. The start film can be made by any known technique, such as molding, extrusion or blowing. One method of perforating the film involves placing the film on the surface of a carved support member. The film is subjected to a high pressure differential of a fluid while it is in the support member. The differential pressure of the fluid, which can be liquid or gaseous, causes the film to adopt the pattern of the surface of the carved support member. If the carved support member has openings it can be punctured by the fluid pressure differential to create a perforated film. A method for forming a perforated film is described in detail in the U.S. Patent. commonly owned 5,827,597, by James et al., incorporated herein by reference. Such a three-dimensional perforated film is preferably formed by placing a thermoplastic film through the surface of a perforated support member with a pattern of macro features and openings A stream of hot air is directed against the film to raise its temperature to make it soften. Next, vacuum is applied to the film to make it conform to the shape of the surface of the support member. The portions of the film arranged over the openings in the support member are perforated to create apertures in the film. A perforated support member suitable for making these three-dimensional perforated films is a three-dimensional topographic support member, made by laser-cutting a piece by machine. A schematic illustration of a workpiece that has been sculpted with laser on a three-dimensional topographic support member is shown in Figure 5. The workpiece 102 comprises a thin tubular cylinder 110. The workpiece 102 has non-surface areas. processed 111 and a laser-sculpted central portion 112. A preferred machine part for producing the support member of this invention is a thin-walled, acetal-free tube, which is free of all internal residual stresses. The machine part has a wall thickness of 1-8 mm, more preferably 2.5-6.5 mm. Preferred machine parts for use in the formation of support members are from 0.305 m to 1.83 m (one to six feet) in diameter and have a length ranging from 0.61 m to 4.88 m (two to sixteen feet). However, these measures are a matter of design choice. Other forms can be used and material compositions for the workpiece, such as acrylics, urethanes, polyesters, high molecular weight polyethylene and other polymers that can be processed by a laser beam. Referring now to Figure 6, there is shown a schematic illustration of an apparatus for laser sculpting the support member. A tubular blank coarse piece 102 is mounted on an appropriate chuck or chuck 121, which fixes it in a cylindrical shape and allows rotation about its longitudinal axis in bearings 122. A rotary impeller 123 is provided to rotate the chuck. 121 at a controlled speed. The rotary pulse generator 124 is connected to, and checks the rotation of the mandrel 121, so that its precise radial position is known at all times. Parallel to, and mounted outside the rotation of the mandrel 121 are one or more guides 125 which allow the carriage 126 to traverse the entire length of the mandrel 121, while maintaining a constant separation of the upper surface 103 from the workpiece 102. The driver carriage 133 moves the carriage along the guides 125, while the carriage pulse generator 134 indicates the lateral position of the carriage with respect to the workpiece 102. A focusing platform 127 is mounted on the carriage. The focusing platform 127 is mounted on focusing guides 128. The focusing platform 127 allows movement orthogonal to that of the carriage 126 and provides a means for the focusing lenses 129 relative to the upper surface 103. ST provides a driving force of 132 approach positioning the focusing platform 127 and providing the focus of the lenses 129. Securing the focusing platform 127 are the lenses 129, which are secured in a nozzle 130. The nozzle 130 has means 131 for introducing a pressurized gas into the nozzle 130. for cooling and maintaining lens cleaning 129. A preferred nozzle 130 for this purpose is described in the US Pat. 5,756,962 to James et al., Which is incorporated herein by reference. Also mounted on the carriage 126 is a final refractive mirror 135, which directs the laser beam 136 to the focusing lenses 129. The laser is remotely located 137, with an optional beam refractive mirror 138, for directing the make the final refraction mirror of the beam 135. Although it would be possible to mount the laser 137 directly on the carriage 126 and eliminate the beam refraction mirrors, the space limitations and the connections to the laser services, make remote mounting preferable. When the laser 137 is activated, the beam 136 emitted is reflected by the first refractive mirror of the beam 138, then by the final refractive mirror of the beam 135, which directs it to the lenses 129. The path of the laser beam 136 is configured so that, if the lenses 129 are removed, the beam would pass through the longitudinal center line of the mandrel 121. With the lenses 129 in position, the beam can be focused above, below or near the top surface 103 Although this apparatus could be used with a variety of lasers, the preferred laser is a fast-flowing CO2 laser, capable of producing a nominal beam of up to 2500 watts. However, CO2 lasers of 50 watts nominal fast flow can also be used. Figure 7 is a schematic illustration of the control system of the laser sculpting apparatus of Figure 6. During the operation of the laser sculpting apparatus, the control variables for the focal position, the rotational speed and the transverse speed are send from a host computer 142 through the connection 144 to a control computer 140. The control computer 140 controls the position of the focus through the impeller of the focusing platform 132. The control computer 140 controls the rotational speed of the workpiece 102 through the rotary impeller 123 and the rotary pulse generator 124. The control computer 140 controls the transverse speed of the carriage 126 through the carriage driver 133 and the carriage pulse generator 134. The computer of command 140 also rts the state of the impulse and possible errors to the main computer 142. This system provides a positive control of the in position and in practice, it divides the surface of the workpiece 102 into small areas called pixels, wherein each pixel consists of a fixed number of pulses of the rotary impeller and a fixed number of pulses of the transverse impeller. The main computer 142 also controls the laser 137 through connection 143.

A three-dimensional topographic support member sculpted with laser can be done by several methods. One method of producing such a support member is by a combination of laser drilling and laser milling of the surface of a workpiece. Methods for laser piercing a workpiece include percussion drilling, fly-shot drilling, and screen exploration drilling. A preferred method is perforation by screen scanning. In this procedure, the pattern is reduced to a rectangular at element 141, as described in Figure 8. This ated element contains all the information required to produce the desired pattern. When used as a mosaic, and placed both end-to-end and side-by-side, the result is the largest desired pattern. This ated element is further divided into a grid of smaller rectangular units or "pixels" 142. Although squares are typically, for some purposes, it may be more convenient to employ pixels of unequal proportions. The pixels themselves have no dimensions and the actual dimensions of the image are adjusted during processing, that is, the width 145 of a pixel and the length 146 of a pixel are adjusted only during the actual drilling operation. During drilling, the length of a pixel is adjusted to a dimension corresponding to a selected number of pulses of the carriage pulse generator 134. Similarly, the width of a pixel is adjusted to a dimension corresponding to the number of pulses of the rotary pulse generator 124. Thus, for ease of explanation, the pixels are shown as squares in Figure 8; however, pixels are not required to be square, but only rectangular. Each column of pixels represents a step from the piece to the machine beyond the focal position of the laser. This column is repeated as many times as required to reach completely around the workpiece 102. Each white pixel represents a laser shutdown instruction, that is, the laser is not emitting energy and each black pixel represents an ignition instruction at the laser, that is, the laser is emitting a beam. These results in a simple series of binary data of 1 and 0, where a 1, or white, is an instruction for the laser to turn off and a 0, or black, is an instruction for the laser to turn on. Thus, in Figure 8, areas 147, 148 and 149 correspond to the instructions for the laser to emit full energy and will result in holes in the workpiece 102. Referring again to Figure 7, the contents of a series data for sculpting are sent in a binary form, where 1 in off and 0 is turned on, by the main computer 142 to the laser 137 via the connection 143. By varying the time between each instruction, the duration of the instruction is adjusted so that conform to the size of the pixel. After each column of the data series is completed, that column is processed again, or repeated, until the entire circumference is completed.

While the instructions of a column are carried out, the transverse impeller moves slightly. The crossover speed is adjusted such that upon completion of a circumferential sculpting, the transverse impeller has moved the focusing lenses the width of one column of pixels and the next column of pixels is processed. This continues until the end of the data series is reached, and the data series is repeated in the axial dimension until the desired width is reached. In this method, each pass produces a number of narrow cuts in the material, rather than a large hole. Because these cuts coincide precisely to align side by side and overlap something, the cumulative effect is a hole. Figure 9 is a photomicrograph of a portion of a support member that has been pierced by frame scanning, using the data series of Figure 8. The surface of the support member is an even flat surface 152 with a series of concentric hexagonal holes 153. A highly preferred method for making three-dimensional topographic support members sculpted with laser is through laser modulation. Laser modulation is carried out by gradually varying the energy of the laser on a pixel basis per pixel. In laser modulation, simple on-off or off-screen drill-through instructions are replaced by instructions that adjust, in a gradual scale, the laser energy for each individual pixel. of the data series of laser modulation. In this way, a three-dimensional structure can be imparted to the piece by machine, in a single pass on the piece by machine. Laser modulation has several advantages over other methods to produce a three-dimensional topographic support member. Laser modulation produces a one piece support member, without joints, without the inequalities in the pattern caused by the presence of a joint. With laser modulation, the support member is terminated in a single operation, rather than in multiple operations, thus increasing efficiency and decreasing cost. Laser modulation eliminates problems with pattern matching, which can be a problem in a sequential multi-step operation. Laser modulation also allows the creation of topographic features with complex geometries over a considerable distance. Varying laser instructions, the depth and shape of a feature can be controlled precisely and features can be formed that vary continuously in cross section. The regular positions of the openings and the macro features in relation to each other can be maintained. Referring again to Figure 7, during laser modulation, the host computer 142 can send instructions to the laser 137 in a different format than a simple "on" or "off". For example, the simple binary data series can be replaced with a 8-bit format (byte), which allows a variation in the energy emitted by the laser of 256 possible levels. Using a byte format, instruction "11111111" instructs the laser to shut off, "OOOOOOOO" indicates to the laser that it emits the full power and an instruction such as "10000000" indicates to the laser that emits half the energy of the available laser . A series of data for laser modulation can be created in many ways. One such method is to construct the data series graphically, using a gray scale of a computer image with 256 color levels. In such an image in the gray scale, black can represent complete energy and white can represent without energy, with levels varying from intermediate gray representing intermediate levels of energy. Various computer graphics programs can be used to visualize or create such a data series for laser sculpting. Using such a series of data, the energy emitted by the laser is modulated on a pixel by pixel basis and can therefore directly sculpt a three-dimensional topographic support member. Although an 8-bit byte format is described here, it can be replaced by other levels, such as 4 bits, 16 bits, 24 bits or other formats. A laser suitable for use in a laser modulation system for laser sculpting is a fast-flowing C02 laser with a power output of 2500 watts, although a laser with a lower power output can be used. A main concern is that the laser must be able to switch between energy levels as fast as possible possible. A preferred switching speed is at least 10 kHz and even more preferred is a speed of 20 kHz. The high switching speed of the power is required to be able to process as many pixels per second as possible. Figure 10 shows a graphical representation of a data series for laser modulation, to produce a support member using laser modulation. The support member made with the data series of Figure 10 is used to make the three-dimensional perforated film shown in Figure 2. In Figure 10, the black areas 154 indicate pixels where the laser is instructed to emit the full energy , thereby creating a hole in the support member, which corresponds to the openings 12 in the three-dimensional perforated film 20 illustrated in Figure 2. Similarly, the white areas 155 in Figure 10 indicate the pixels where the laser is instructed to turn off, thereby leaving the surface of the support member intact. These intact areas of the support member correspond to the macro features of the three-dimensional perforated film 20 of Figure 2. The gray area 156 in Figure 10 indicates the pixels where the laser was instructed to emit the partial energy and produce a region bottom of the support member. This lower region in the support member corresponds to the lower region 16 in the three-dimensional perforated film 20 of Figure 2. Figure 11 shows a graphic representation of a data series for laser modulation to produce a support member using laser modulation. As in the data series for laser drilling of Figure 8, each pixel represents a position on the surface of the workpiece. Each row of pixels represents a position in the axial direction of the piece to be sculpted. Each column of pixels represents a position in the circumferential position of the workpiece. Unlike the data series in Figure 8, however, each of the laser instructions represented by the pixels is no longer a binary instruction, but has been replaced by 8-bit or grayscale instructions. That is, each pixel has a value of 8 bits, which translates to a specific level of energy. Figure 11 is a graphical representation of a data series for laser modulation, to produce a support member using laser modulation. The data series shows a series of nine structures similar to a sheet 159, shown in white. The sheets are a series of white pixels and are instructions for the laser to turn off and not emit energy. The sheets of these shapes, therefore, would form the uppermost surface of the support member after the pattern has been sculpted therein. Each leaf structure contains a series of six holes 160, which are defined by the leaf-like structures of the leaves and extend through the thickness of the piece to machine. The holes 160 consist of an area of black pixels, which are instructions for the laser to emit the full energy and therefore pierce the workpiece. The leaves are discrete macro features, say, by themselves they do not form a straight flat structure, since no sheet interconnects with another sheet. The background pattern of this structure consists of a stepped pattern with a tight grouping of hexagonal black areas 161, which are also instructions for the laser to emit the full energy and drill a hole through the machine part. The field 162, which defines the holes 161, is at a laser energy level that is neither completely off nor completely on. This produces a second flat area, which is below the topmost surface of the workpiece, defined by the blanking instructions of the white areas of the sheets. Figure 12 is a photomicrograph of a three-dimensional laser-sculpted topographic support member, produced by laser modulation, using the data series for laser modulation described in Figure 11. Figure 12A is a cross-sectional view of the member. of the support of Figure 12. The regions 159 'of Figure 12 and 159"of Figure 12A correspond to the sheet 159 of Figure 11. The white pixel instructions of the areas 159 of Figure 11 have resulted in the The laser surface does not emit any energy during the processing of these pixels, the upper surface of the leaves 159 'and 159"correspond to the original surface of the workpiece. The holes 160 'in Figure 12 correspond to the areas of the black pixel 160 of Figure 11, and when processing these pixels, the laser emits the entire energy, thereby cutting holes completely through the workpiece. The background film 162 'of Figure 12 and 162"of the Figure 12A corresponds to the area of the pixel 162 of Figure 11. The region 162 'results from the processing of the pixels of Figure 11 with the laser emitting a partial energy. This produces an area in the support member that is lower than the original surface of the workpiece and therefore, is lower than the upper surface of the sheets. Consequently, the individual sheets are discrete macro-features, separated from one another. Figures 13 and 13A are photomicrographs of a three-dimensional perforated film that has been produced in the support member of Figures 12 and 12A. The perforated film has high perforated sheet-shaped micro-features 176 and 176 ', corresponding to the leaves 159' and 159"of the support member of Figures 12 and 12 A. Each of the sheets is discrete and is separated from all the sheets. Other sheets Each sheet contains openings, that is, each sheet is a perforated macro feature The plane defined by the uppermost surfaces of all leaf shaped regions 176 and 176 'is the uppermost surface of a plurality of separate macro features. The perforated regions of the bottom 177 and 177 'define a region that is at a lower depth in the film than the leaf-shaped regions.This gives the visual impression that the sheets are engraved on the film.The support members sculpted with laser of Figures 9, 12 and 12A have simple geometries. That is, the successive cross sections, taken parallel to the uppermost surface of the support member, are essentially the same for a significant depth to through the thickness of the support member. For example, referring to Figure 9, the successive cross sections of this support member, taken parallel to the surface of the support member, are essentially the same for the thickness of the support member. Similarly, the cross sections of the support member of Figures 12 and 12A are essentially the same for the depth of the sheets and are essentially the same from the base of the sheets to the thickness of the support member. Figure 14 is a graphical representation of another data series for laser modulation to produce a laser-carved support member using laser modulation. The data series contains a central floral element 178 and four elements 179, each of which constitutes a quarter of a floral element 178, which are combined when the data series is repeated during laser sculpting. Figure 14A is a graphical representation of 3 repetitions for 3 repetitions of the resulting pattern, when the data series of Figure 14 is repeated. Figure 15 is an amplified view of area B of Figure 14. The gray area represents a region of pixels that indicate to the laser to emit a partial energy. This produces a flat area below the surface of the workpiece. A series of black areas 181 is contained in the gray region 180, which are the pixels that indicate to the laser to emit the full energy and drill a series of hexagonal-shaped holes through the thickness of the workpiece. In the center of Figure 15 is the floral element that corresponds to the floral element 178 of Figure 14. The floral element consists of a central region 183 and six petal-shaped regions 182, which again represent the instructions for the laser to emit the full energy and drill a hole through the thickness of the piece to machine. The region 184 defines the outer edge of the central region 183. The region 184 'defines the outer edge of the petal regions 182. The regions 184 and 184' represent a series of instructions for the laser to modulate the emitted energy. The central black region 183 and its outer edge region 184 are joined in the region 184 'by the region 185, which represents the instructions for the laser to emit the same energy level as in the background area 180. Figure 16 is an amplified graphic representation of the C portion of the region 184 of Figure 15, which forms the outer line of the central region 183 of Figure 15. The C portion contains a single row of white pixels 186, which indicate to the laser that it is turn off This defines part of the uppermost surface of the support member that remains after processing. The rows of pixels 187 and 187 'indicate to the laser to emit a partial energy. The rows 188, 189, 190 and 191 and rows 188 ', 189' 190 'and 191' indicate to the laser to emit energy levels that increase progressively. The rows 192 and 192 'indicate to the laser to emit the energy level also represented by the region 185 of Figure 15. The rows 194, 194' and 194"indicate to the laser to emit the complete energy and to be part of the region 183 of the Figure 15 As each column of Figure 16 is processed, the laser emits the partial energy represented by the rows 192 and 192 '. The rows 191, 190, 189, 188 and 187 indicate to the laser to progressively decrease the energy emitted, until the row 186 is processed and the laser is instructed not to emit energy. The rows 187 ', 188', 189 ', 190' and 191 'then indicate the laser that again progressively increases the emitted energy. The rows 194, 194 'and 194"indicate to the laser that, again, emit the full energy to start drilling through the workpiece, this results in the creation of a separate macro feature, which is tilted from the bottom plane to the surface of the piece to machine and then tilts back to the area of the hole, thus producing a radiated shape, depending on the size of the pixels, as defined during processing, and the variation of the energy of the emitted laser each row, the size and shape of the resulting laser-sculpted feature can be changed, for example, if the variation in the energy level for each row of pixels is small, then a relatively shallow rounded shape is produced; If the variation in the energy level for each row of pixels is greater, then a deep, highly inclined shape with a larger cross section is produced. s triangular.The changes in the pixel size also affects the geometry of the produced characteristics. If the pixel size stays more small that the actual diameter of the focused laser beam emitted, then smooth combined forms will be produced. Figure 17 is a photomicrograph of the laser-sculpted support member resulting from the processing of a data series of Figure 14 by laser modulation. The photomicrograph shows a raised floral element 195, corresponding to the floral element 178 of Figure 14 and the floral element of Figure 15. The photomicrograph also shows portions of additional floral elements 195 '. The raised floral element 195 originates in the flat region 196, which contains holes 197. The floral elements 195 and 195 'are separated from one another and therefore do not form a continuous flat region. Figure 18 is an amplified photomicrograph of a portion of the floral element 195 of Figure 17. The central circular element 198 is the area produced by the instructions for laser modulation contained in the region 184 of Figure 15. The elements 199 are parts of the elements of the petals of the floral element 195 of Figure 17. These elements of the petals are produced by the pixel instructions described in region 184 'of Figure 15. These elements demonstrate an example of a type of complex geometry that can be created by modulation with To be. The central circular element has a semicircular cross section. This is, any of a series of planes of the cross section taken parallel to the original surface of the piece to machine, that is, through the depth, will differ from any other such cross-sectional planes. Figure 19 is a photomicrograph of the upper surface of a film produced in the support member of Figure 17. The film has a perforated planar area 200, which contains the holes 201 corresponding to the planar region 196 of Figure 17. Extending above the flat region are the floral areas 202 and 202 ', corresponding to the floral elements 195 and 195', respectively, of the Figure 17. The floral areas 202 and 202 'give the resulting perforated film an engraved appearance in a single operation. In addition, the floral areas define larger holes 203 and 204 additional, to improve the transmission properties of the fluid. Figure 20 is an amplification of the floral area 202 of the Figure 19. The floral area comprises a hole 204 and the surrounding circular element 205. The element 205 of Figures 19 and 20 has a complex geometry in that it has a semicircular cross section. Again, the successive cross sections, taken parallel to the surface of the film, taken through its depth, are different. Upon completion of laser sculpting of the workpiece, it can be mounted on the structure shown in Figure 21, to be used as a support member. Two terminators 235 are fitted inside the machine part 236 with the area sculpted by laser 237.

These terminators can be adjusted by shrinkage, adjust to pressure joined by mechanical means such as belts 238 and screws 239 as shown, or by other mechanical means. The terminators provide a method for maintaining the circular machine part, for driving the finished assembly and for fixing the finished structure in the perforating apparatus. A preferred apparatus for producing such three-dimensional perforated films is schematically described in Figure 22. As shown here, the support member is a rotating drum 753. In this particular apparatus, the drum rotates in an anti-clockwise direction. A hot air nozzle 759 is positioned outside the drum 753, to provide a curtain of hot air to directly strike the film supported by the laser-carved support member. A means is provided for retracting the hot air nozzle 759 to prevent excessive heating of the film, when stopped or moving at low speed. The bellows 757 and the heater 758 cooperate to supply hot air to the nozzle 759. Placed inside the interior of the drum 753, directly opposite the nozzle 759, is a vacuum head 760. The vacuum head 760 is radially adjustable and is placed to contact the inner surface of the drum 753. A vacuum source 761 is provided to continuously evacuate the vacuum head 760. The cooling zone 762 is provided inside of, and comes into contact with, the surface internal of drum 753. Cooling zone 762 is provided with a vacuum source for cooling 763. In cooling zone 762, the vacuum source for cooling 763 extracts ambient air through openings made in the film, to adjust the pattern created in the perforation zone. The vacuum source 763 also provides a means to hold the film in place in the cooling zone 762 in the drum 753 and provides a means to isolate the film from the effects of tension caused by rolling the film after its drilling. Placed on the upper part of the laser-sculpted support member 753 is a thin, continuous, uninterrupted film 751 of thermoplastic polymer material. In Figure 23, an amplification of the area enclosed in a circle of Figure 22 is shown. As shown in this embodiment, the vacuum head 760 has two vacuum slots 764 and 765 that extend across the width of the film . Nevertheless, for some purposes, it may be preferred to use vacuum sources for each vacuum slot. As shown in Figure 23, the vacuum groove 764 provides a holding area for the starting film as it approaches the air knife 758. The vacuum groove 764 is connected to a vacuum source by a passage 766. This anchors the incoming film 751 securely to the drum 753 and provides insulation from the effects of tension on the incoming film, induced by the unwinding of the film. It also flattens the film 751 on the outer surface of the drum 753. The second vacuum slot 765 defines the vacuum perforation zone. Immediately between the slots 764 and 765 is an intermediate support bar 768. The vacuum head 760 is positioned so that the impact point of the hot air curtain 767 is directly above the intermediate support bar 768. The hot air is provides at a sufficient temperature, at a sufficient angle of incidence to the film and at sufficient distance from the film to cause the film to soften and deform by a force applied thereto. The geometry of the apparatus ensures that the film 751, when it is softened by the hot air curtain 767, is isolated from the effects of the tension by the holding groove 764 and the cooling zone 762 (Figure 22). The vacuum drilling zone 765 is immediately adjacent to the hot air curtain 767, which minimizes the time the film is hot and prevents excessive heat transfer to the support member 753. Referring to Figures 22 and 23 , a flexible thin film 751 is fed from a supply roll 750 onto a free roll 752. The roll 752 can be attached to a load cell or other mechanism for controlling the feed voltage of the incoming film 751. The film 751 then placed in intimate contact with the support member 753. The film and the support member then pass into a vacuum zone 764. In the vacuum zone 764, the differential pressure further forces the film to an intimate contact with the support member 753. Next, the vacuum pressure isolates the film from the supply voltage. The combination of the film and the support member then passes under a hot air curtain 767. The hot air curtain heats the combination of the film and the support member, thereby softening the film. The combination of the heat-softened film and the support member then passes into a vacuum zone 765, where the heated film is deformed by the differential pressure and adopts the topography of the support member. The areas of the heated film that are located over the open areas in the support member are further deformed in the open areas of the support member. If the heat and the deformation force are sufficient, the film on the open areas of the support member is broken to create openings. The still hot combination of the perforated film and the support member then passes to a cooling zone 762. In the cooling zone, a sufficient amount of ambient air is drawn through the now perforated film to cool both the film and the film. to the support member. The cooled film is then removed from the support member around the free roll 754. The free roll 754 may be attached to a load cell or other mechanism for controlling the winding tension. The perforated film then passes to a finishing roll 756, where it is rolled. Figure 24 is a photomicrograph of a perforated film 800 of the prior art, which was produced on a support member that It has been perforated by screening using the data series of Figure 9. The surface of this perforated film is a flat surface 852 with a series of concentric hexagonal holes 853. Figure 25 is a photomicrograph of another perforated film of the art. above, which occurred on another support member that was produced by perforation by raster scanning. The surface of this perforated film is also characterized by a flat surface and a series of concentric hexagonal holes that are larger than those shown in Figure 24. Figure 26 is a photomicrograph of a further embodiment of a three-dimensional perforated film of the present invention. , with an array of openings and macro features. Film 880 of Figure 26 has openings 12 arranged with macro features 14. All openings 12 and macro features 14 are arranged together, so that their relative positions with respect to each other are regular. Although the method for forming a three-dimensional perforated film has been described using a hot air curtain as the mechanism for heating the film, any other suitable method, such as infrared heating, heated rolls or the like, can be employed to produce a perforated film using the three-dimensional topographic support member sculpted with laser of this invention. In another method for producing a perforated film, the delivery system of the incoming film can be replaced with a system of adequate extrusion. In this case, the extrusion system provides an extruded film; which, depending on the temperature of the extrusion, can be cooled to a suitable temperature by various means, such as cold air jets or cooled rolls before coming into contact with the three-dimensional topographic support or coming into direct contact with the topographic support three-dimensional The extruded film and the forming surface are then subjected to the same vacuum forming forces as described above, without the need to heat the film to soften the film to make it deformable. Figure 27 is a cross section of a structure with two layers according to the invention. The structure comprises a layer that comes into contact with the body 500, in this case, a non-woven fabric, superimposed on a second layer 501, also a non-woven fabric. The second layer 501 comprises a plurality of macro features 14 projecting in the direction of the layer coming into contact with the body 500. The second layer 501 can be secured to the layer that comes into contact with the body 500 using a suitable adhesive, known by those with experience and then passing the structure with two layers through a press roller or similar. Figure 29 is a photomicrograph of a portion of a perforated film 300 produced in accordance with the invention. Figure 30 is a partially cut away perspective view of a structure with two layers 400 according to the invention. As shown, structure 400 It includes a layer that comes into contact with the body 301, in this case, a non-woven fabric, superimposed on a second layer 300, in this case, the perforated film 300 shown in Figure 29. The second layer 300 comprises an area substantially flat 303 having a first surface 308, opposite the second surface 310 and a plurality of openings 311 extending from the first surface 308 to the second surface 310. The second layer 300 also includes a plurality of macro features 312 ovals projecting from the first surface 308 of the planar area 303 in the direction of the layer coming into contact with the body 302. The second layer also includes a circular central feature 314. The substantially oval macro features 312 are arranged in an array around the circular macro feature 314, so that the macro features 312 and the macro feature 314 collectively give the visual appearance of a flower. In this way, the macro features 312 and 314 cooperate to define a visual design element. Although a single "flower" is described in Figure 29, it is understood that Figure 29 only shows a portion of the perforated film and the entire perforated film, preferably including a plurality of such "flower" designs, having a plurality of oval macro features 312 and a plurality of circular macro features 314 to give the appearance of a plurality of such "flowers". In the same way, the Figure describes only a portion of a structure with two layers according to the invention and the complete structure with two layers, preferably including a plurality of such flower designs. In addition, although the flower design has been described as the element of visual design, it will be evident that numerous design elements can be created, using the macro features of the type described herein. Figure 31 is a cross-sectional view of an absorbent article 410 that includes the two-layered structure 400 shown in Figure 29, taken along line 31-31. The absorbent article 410 further includes an absorbent core 412 that is in fluid communication with the two-layer structure 400. As best seen in Figure 31, in those areas of the structure with two layers 400 that are located outside the macro features 312. and 314, the second layer 300 is substantially in surface-to-surface contact with the layer that comes into contact with the body 301, as shown. In addition, the second layer 300 comes into contact with the layer that comes into contact with the body 301 in one of the plurality of macro features 312 and 314. In the areas defined within the macro features 312 and 314, ie, within the areas designated 318 and 320 respectively, the layer that comes into contact with the body 301 is arranged in a substantially straight first plane A and the second layer 300 is arranged in a substantially straight second plane B that is separated from the first plane A.

Thus, in those areas defined within the macro features 312 and 314, the layer that comes in contact with the body 301 is arranged in a separate relationship with respect to the second layer 300. The structure with two layers 400 shown in the Figure 30 is preferably formed as a laminate formed under vacuum using the procedure as shown and described substantially in the US Patent. 6,303,208, the subject of which is incorporated here as a reference. The specific technique used to form the structure with two layers 400 will be described with reference to Figure 32. Figure 32 is a simplified schematic illustration showing a method for adhering a fibrous carrier material 900 (e.g., a non-woven material) in a molten or semi-cast film material, having a top surface 904 and a bottom surface 906. The fibrous material 900 is applied through a press roll 911 to form the laminate structure with two layers 600. As shown, the material of Film 902 is distributed from a nozzle of the film 920 to the support member 753. The film material 902 is supplied at an elevated temperature. The film material 902 is formed and perforated by passing the material on the support member 753 and applying a pressure differential by a vacuum head 760. As the film material 901 is extruded from the nozzle 920, the film material enters the film. contact with the surface rotary of the support member 753. The rotating surface of the support member 753 moves continuous portions of the film material through the vacuum head 760, so that the film deforms to assume the topography of the support member 753. The fibrous material 900 has a first surface 940, which is brought into contact with the upper surface of the film 904 of the film 902. The fibrous material 10 has a second surface 942 that is opposite the first surface 904. A distribution means 946 transfers the fibrous material 900 at a shock or lamination point 948, wherein the fibrous material 900 and the film material 902 come into contact with each other to form the laminate 400. In the embodiment shown, the fibrous material 900 enters contact with the film 902 at the impact point 948 before the leading edge 931 of the vacuum head 760. After passing under the impact point 948, the material of film 902 and the fibrous material 900 pass over a vacuum chamber to thereby define the openings and the macro features in the film material 902. The two-layer structures described above can be advantageously used as a cover layer / transferring an absorbent article, such as a sanitary napkin, pantyhose, diaper, incontinence pad or other similar product to absorb exudates from the body, such as menstruation, urine, stool or sweat. Preferably, the absorbent article is a sanitary napkin or a pantiprotector. Such a sanitary napkin or pantyhose can have a shape approximately rectangular, oval, bone or peanut. Depending on the nature of the absorbent article, its size may vary. For example, sanitary napkins typically have a thickness of about 1.4 to about 5 mm, a length of about 8 to about 41 centimeters (cm) and a width of about 2.5 to about 13 cm. Pantiprotectors typically have a thickness of less than about 5 mm, a length of less than about 20 cm and a width of less than about 8 cm. The two-layer structures described above are preferably placed on a suitable absorbent core, which is typically comprised of a loose associated hydrophilic material., such as cellulose fibers, including paper pulp, regenerated cellulose fibers or cotton fibers or other absorbent materials, generally known in the art, including acrylic fibers, polyvinyl alcohol fibers, moss peat and superabsorbent polymers. The absorbent article may further comprise a reinforcing sheet that is substantially or completely impermeable to liquids, the exterior of which forms the surface of the item facing the garment. The reinforcing sheet may comprise any flexible thin material impervious to body fluids, such as a polymeric film, for example, polyethylene, polypropylene or cellophane. Alternatively, the reinforcing sheet may be a material normally permeable to a fluid that has been treated to be waterproof, such as a paper or non-woven fabric impregnated with a fluid repellent or a flexible foam, such as polyurethane or cross-linked polyethylene. The thickness of the reinforcing sheet when formed of a polymeric film is typically about 0.025 mm to 0.051 mm. A variety of materials for use as a reinforcing sheet are known in the art, and any of these can be used. The reinforcing sheet can be breathable, that is, a film that is a barrier to liquids but that allows gases to transpire. Materials for this purpose include microporous films, in which microporosity is created by stretching an oriented film. A single or multiple layers of permeable films, fabrics and combinations thereof, which provide a tortuous path and / or whose surface characteristics provide a liquid surface repellent to liquid penetration can also be used to provide a breathable reinforcing sheet. A cross-sectional view of an absorbent article comprising a two-layer structure according to the invention is shown in Figure 28. The two-layer structure is used as a cover / transfer layer. The absorbent article comprises a reinforcing sheet 503. Superposed to the reinforcing sheet is an absorbent core 502. Superposed to the absorbent core is the two-layer structure 504. The two-layer structure 504 comprises a first non-woven layer or one that enters the contact with the body 500 on a second layer 501 which is a perforated film. The perforated film comprises the separate macro-features 14 and the openings 12. The absorbent article may comprise other known materials, layers and additives, such as adhesives, release paper, foam layers, network-like layers, perfumes, medicaments, humectants and the like. similar, many examples of which are known in the art.

EXAMPLES The structures of the present invention comprising a fluid-permeable first layer in fluid communication with a second fluid-permeable layer, wherein the layers are in contact with each other, substantially only through a plurality of separate macro features. They have favorable properties of fluid handling. In particular, disposable absorbent products with a component layer having a plurality of separate macro features have a low Fluid Penetration time. Additionally, disposable absorbent products that comprise a perforated film, having a plurality of separate macro features, exhibit a Repeated Service Time that increases less than about 40% are six service connections.

The structures according to the present invention comprise a perforated film having a plurality of separate macro features (Examples 1, 2 and 3) and structures containing samples of a conventional perforated film (Prior Art 1 and 2 were compared as transfer layers. using the Fluid Penetration Test and the Repeated Rush Test The test fluid used for the Fluid Penetration Test and the Repeated Rush Test was a synthetic menstrual fluid, which has a viscosity of 30 centipoise to 1 radian per second.The test assemblies were made from Examples 1-3 and the Prior Technique 1 and 2, using the cover layer, the absorbent core and the commercially available sanitary towel barrier, Stayfree Ultrathin, Long Wing, distributed by Personal Products Company Division of McNeil-PPC, Inc. Skillman, NJ. The cover layer is a thermally bonded polypropylene fabric; The absorbent core is a material that contains a superabsorbent polymer and the barrier is a pigmented polyethylene film. Each of the cover and transfer layers were carefully peeled off the product, exposing the absorbent core, which remained adhesively bonded to the barrier film. Next, a piece of the transfer layer material to be tested, of a size of approximately 200 mm in length, was cut by at least the width of the absorbent core and hot melt adhesive, pressure sensitive, was applied. such as the HL-1471xzp, commercially available from HB Fuller Corporation, St. Paul, MN 55110, next to the transfer layer material, oriented adjacent to the exposed surface of the absorbent core. The adhesive was applied to the material to be tested by the transfer of the release paper, which was coated with approximately 1.55 grams per square meter. The material of the transfer layer to be tested was oriented with the adhesive side towards the absorbent core and placed on top of the absorbent core. To complete the test assembly, the cover layer was placed on the material of the transfer layer to be tested. Another structure according to the invention (Example 4) was also tested using the Fluid Penetration Test. This structure comprised a nonwoven layer with a plurality of separate macro features. This structure was made as follows. Both of the layer that comes in contact with the body and the second layer comprised nonwoven materials. The layer that comes in contact with the body comprised a nonwoven material bonded at a point comprising a blend of 40% denier 3 and 60% denier 6 of staple fibers of polypropylene with a basis weight of 34 grams per square meter (gsm) The second layer in this example was made of a 30 gsm nonwoven starting material, comprising a blend of 50% polyester fibers and 50% bicomponent fibers, having a copolyester liner around a polyester core and available from Libeltex nv in Meulebeke, Belgium.

Discrete macro features were formed in the appropriate non-woven layer by heat forming the nonwoven starting material with a metal plate having a regular, repeating pattern of truncated cones. The heat formation of the nonwoven starting material was achieved by placing the nonwoven starting material between the metal plate and a 6.35 mm thick rubber support surface and pressing at a pressure of 30.1 kg force per square centimeter. a temperature of 107 ° C for 15 seconds. The metal plate has a pattern that is repeated of truncated cones in tiered rows in centers of 6.36 mm. Each cone was approximately 3.5 mm in diameter at its base and 1.2 mm in diameter at the top and 2.8 mm in height. The formed with heat created discrete macro features on the surface of the non-woven material. When the layer that comes in contact with the body was placed on the second layer with the macro features that project in the direction of the body-facing layer, the two layers come into contact with each other substantially only through the macro features in the second layer. This two-layered structure was placed on an absorbent core material, comprising wood pulp and a superabsorbent polymer, such as that described in US Pat. 5,916,670 to Tan et al., Which is incorporated herein by reference. The two-layer structure was placed against the absorbent core material, with the second layer oriented towards the absorbent core material. A barrier layer fluid impermeable, it was placed on the opposite surface of the absorbent core material to form an absorbent article to be used for absorbing bodily fluids, such as, for example, menstrual fluid. As a comparison, a structure with two layers comprising the same nonwoven layers, but no layer comprising the macro features (Control Example 4), was also subjected to the Fluid Penetration Test. Table 1 describes the commercial products tested and the absorbent test assemblies, made using the examples of the present invention and the examples representing the prior art.

TABLE 1 It has been found that structures of the present invention comprising three-dimensional perforated films or non-woven materials with a plurality of separate macro features, have improved fluid handling properties. In particular, the structures have a low Fluid Penetration Time when used as a component layer in disposable absorbent products. Additionally, the structures comprising three-dimensional perforated films exhibit a Repeated Service Speed that increases less than about 40% in six connections. The Time of Penetration of the Fluid and the Time of the Rush Repeated are measured according to the following test methods, respectively. The tests were carried out in a room conditioned at 21 degrees centigrade and with 65% relative humidity. Before performing the tests, commercial samples and test assemblies were conditioned for at least 8 hours. The Fluid Penetration Time (FPT) is measured by placing a sample to be tested under an orifice plate for the Fluid Penetration Test. The orifice plate consists of a 7.6 cm X 25.4 cm thick 1.3 cm thick polycarbonate plate with an elliptical hole at its center. The elliptical orifice measures 3.8 cm along its major axis and 1.9 cm along its minor axis. The orifice plate is centered on the sample to be tested. A 10-ce graduated syringe containing 7 ml of test fluid is held on the orifice plate, so that the The syringe outlet is approximately 7.62 cm (3 inches) above the hole. The syringe is held horizontally, parallel to the surface of the test plate, the fluid is then expelled from the syringe at a rate that allows the fluid to flow in a vertical current towards the test plate in the hole and a stopwatch when the fluid first touches the sample to be tested. The stopwatch stops when the surface of the sample becomes visible for the first time inside the hole. The time elapsed in the chronometer is the Fluid Penetration Time. The Average Fluid Penetration Time (FPT) is calculated from the results of testing five samples.

TABLE 2 The Time of the Repeated Service is measured by placing a sample to be tested on an Elastic Cushion, covering the sample with an Orifice Plate for the Repeated Service, then applying the test fluid according to the described plan.

The Elastic Cushion is made as follows: a non-woven fabric of low density (0.03-0.0 g / cm3, measured at 0.24 kPa or 0.035 psi) is used as an elastic material. The non-woven fabric is cut into rectangular sheets (32 x 14 cm) which are placed one on top of the other until a stack with a free height of approximately 5 cm is reached. The non-woven fabric stack is then wrapped with a 0.01 mm thick layer of a polyurethane polymeric film, such as the TUFTANE film (manufactured by Lord Corp., UK), which is sealed on the back with tape transparent double-sided The orifice plate of the Repeated Rush consists of a 7.6 cm X 25.4 cm thick 1.3 cm thick polycarbonate plate with a circular hole in its center. The diameter of the circular hole is 2.0. The orifice plate is centered on the sample to be tested. A 10 cc graduated syringe containing 2 ml of test fluid is held on the orifice plate, so that the exit of the syringe is approximately 2.54 cm above the hole. The syringe is held horizontally, parallel to the surface of the test plate, the fluid is then expelled from the syringe at a rate that allows the fluid to flow in a vertical current towards the test plate in the hole and a stopwatch when the fluid first touches the sample to be tested. The stopwatch stops when the surface of the sample becomes visible for the first time inside the hole. The time elapsed in the chronometer is the first time of penetration of the fluid. After an interval of 5 minutes of elapsed time, 2 ml of a second fluid of The test is expelled from the syringe into the circular orifice of the Orifice Plate for the Repeated Service and is time-tested as previously described to obtain the second time of penetration of the fluid. This sequence is repeated until a total of six fluid connections have been timed, each one separated 5 minutes. The Percentage of Increase in the Time of Penetration of the Fluid after Six Rush is calculated as: 100 times the difference between the first and the sixth times of the rush, divided between the first time of the rush. The Average Increase Percentage in the Fluid Penetration Time is calculated from the results of testing five samples.

Claims

NOVELTY OF THE INVENTION CLAIMS

1. - A structure with two layers for use in absorbent articles, comprising: a first layer permeable to a fluid; a second fluid-permeable layer in fluid communication with the first layer, the second layer having a substantially planar surface and a first plurality of separate macro-features extending from the planar surface; wherein the first layer and the second layer are structured and arranged so that the first layer comes into contact with the second layer in each of the macro features and the first layer comes into contact with the substantially flat surface of the second layer, in selected areas located between the macro features.

2. The structure according to claim 1, further characterized in that in an area defined within each of the plurality of macro features, the first layer is separated from the second layer.

3. The structure according to claim 1, further characterized in that it additionally comprises a second plurality of macro features, the first plurality of macro features and the second plurality of macro features cooperate to produce a plurality of visual design elements.

4. - The structure according to claim 1, further characterized in that the second layer is a perforated film.

5. The structure according to claim 1, further characterized in that the first layer is a non-woven fabric.

6. An absorbent article comprising a structure with two layers superimposed on an absorbent layer, the structure comprising: a first layer permeable to a fluid; a second fluid permeable layer in fluid communication with the first layer, the second layer having a substantially planar surface and a first plurality of separate macro features extending from the planar surface; wherein the first layer and the second layer are structured and arranged so that the first layer comes in contact with the second layer in each of the macro features and the first layer comes into contact with the substantially flat surface of the second layer in areas selected among the macro features.

7. The structure according to claim 6, further characterized in that in an area defined within each of the plurality of macro features, the first layer is separated from the second layer.

8. The structure according to claim 6, further characterized in that it additionally comprises a second plurality of macro features, the first plurality of macro features and the second plurality of macro features cooperate to produce a plurality of visual design elements.

9. The structure according to claim 6, further characterized in that the second layer is a perforated film.

10. The structure according to claim 6, further characterized in that the first layer is a non-woven fabric.