WO2002056810A1

WO2002056810A1 - Heterogeneous apertured film for absorbent articles

Info

Publication number: WO2002056810A1
Application number: PCT/US2001/001498
Authority: WO
Inventors: Carol Gell; Bruce Johnson; Judith Roller
Original assignee: Mcneil-Ppc, Inc.
Priority date: 2001-01-18
Filing date: 2001-01-18
Publication date: 2002-07-25
Also published as: BR0104303A; MXPA01009414A; CA2402067A1

Abstract

A heterogeneous apertured film wrapping element for an absorbent article is disclosed. The fluid-impervious plastic material that forms the apertured film has a continuous phase of a thermoplastic polymeric component and an immiscible, dispersed phase of a thermoplastic polymeric component having a lower melting point. The wrapping element is useful in applications involving heat sealing and similar thermal processes in absorbent articles, such as sanitary napkins, diapers, bandages, tampons, and the like.

Description

HETEROGENEOUS APERTURED FILM FOR^' ABSORBENT ARTICLES

Cross Reference to Related Applications This invention is related to the following copending applications: US Ser. No. 09/343,759, filed June 30, 1999, entitled "Continuous Method of Providing Individual Sheets from a Continuous Web" (Attorney Docket, PPC-668) ; US Ser. No. 09/345,088, filed June 30, 1999, entitled "Tampon with Cover and Nonionic

Surfactant" (Attorney Docket, PPC-708) ; US Ser. No. 09/345,090, filed June 30, 1999, entitled "Multilayered Apertured Film Wrapping Element for Absorbent Articles" (Attorney Docket, PPC-691) ; US Ser. No. 09/343,760, filed June 30, 1999, entitled "Domed Tampon with

Surfactant-Treated Cover" (Attorney Docket, J&J-1810) ; US Ser. No. 60/141,688, filed June 30, 1999, entitled "Sealing Roller and Sealing Roller Element, Particularly for Producing a Tampon for Feminine Hygiene and Method Therefore" (Attorney Docket, J&J-1819) ; and US Ser. No. 60/141,690, filed June 30, 1999, entitled "Tampon for Feminine Hygiene and Process and Apparatus for its Production" (Attorney Docket, J&J-1820) .

Background, of the Invention

The present invention relates to a heterogeneous apertured film wrapping element for an absorbent article. The fluid-impervious plastic material that makes up the apertured film has a continuous phase of a thermoplastic polymeric component and an immiscible, dispersed phase of a thermoplastic polymeric component having a lower melting point. The wrapping element is useful in applications involving heat sealing and similar thermal processes in absorbent articles, such as sanitary napkins, diapers, bandages, tampons, and the like .

There are several types of wrapping elements, including covers, that have been or are currently in use for absorbent articles: woven fabrics, nonwoven fabrics, apertured films, reticulated films, polymer nets, and the like. There has been a progression from woven fabrics to nonwoven fabrics and apertured films in these covers. These covers are often adhesively attached to other components in the absorbent article. An adhesive may be applied as a separate component between the cover and another component, or adhesion may result from "heat sealing" or heating one of the components to cause it to become adhesive.

Nonwoven fabrics may incorporate multicomponent fibers having at least two different melting points. Then these fabrics may be adhered to an absorbent article, such as a tampon, as described in Friese, U.S. Patent Nos . 4,816,100; 4,836,450; and 4,859,273. This is one example of heat sealing a wrapping element or cover . It may also be desirable to heat seal an apertured film. While it may be possible to heat seal an apertured film that is formed of only one component, this is generally only in areas where it is acceptable or even desirable that the apertures in the film become closed. However, heat sealing an apertured film to an underlying fibrous structure in a manner that maintains open apertures in the heat sealing area is more complex, and it generally requires the use of a film material having at least two different components having at least two different melting point temperatures. An example of this is described in Thompson et al . , U.S. Patent No. 5,342,334. In this example, the apertured film is formed from a co-extruded film having a higher melting point polymeric material on a first, non-bonded surface, and a lower melting point polymeric material on a second, heat-bondable surface. Unfortunately, this arrangement provides a large surface area of bondable material on the second surface, and it may allow unwanted or overly aggressive adhesion in the manufacturing process or final product . The film may adhere to process equipment, such as the apertured film forming surfaces and heat sealing elements. In addition, both layers of the film are exposed to process equipment.

Therefore, what is needed is an apertured film that is heat sealable in a controlled manner, that maintains open apertures, and that allows improved balance of film properties over a single component film.

Summary of the Invention The present invention relates to a heterogeneous wrapping element useful in absorbent articles. The wrapping element is formed of a fluid-impervious plastic material in the form of a resilient three-dimensional web exhibiting a fiber-like appearance and tactile impression. The fluid-impervious plastic material is formed of a film having a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature. Therefore, when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond. The web has first and second surfaces. The first surface is defined at least in part by either of the first and second layers, and it has a multiplicity of apertures therein. The apertures are defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface. Each of the fiber-like elements exhibits a cross-section having a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion. The sidewall portions extend generally in the direction of the second surface of the web, and the intersecting sidewall portions are interconnected to one another intermediate the first and the second surfaces of the web. The interconnected sidewall portions terminate substantially concurrently with one another in the plane of the second surface. In another aspect, the invention relates to a tampon having an absorbent structure substantially enclosed by the wrapping element .

The invention also relates to a method of forming a heterogeneous wrapping element useful in absorbent articles . The method includes the steps of forming a film having a blend of at least two thermoplastic polymeric components, as described above, applying fluid at a temperature greater than ambient temperature to the film while it is supported on a three-dimensional surface to form a resilient three-dimensional web, and separating the web into individual pieces of material of a size appropriate for a wrapping element.

Again, the web has first and second surfaces, and the first surface is defined at least in part by the either of the first and second layers and having a multiplicity of apertures therein. Each of the apertures is defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, and each of the fiber-like elements exhibits a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion. The sidewall portions extend generally in the direction of the second surface of the web, and the intersecting sidewall portions are interconnected to one another intermediate the first and the second surfaces of the web. The interconnected sidewall portions terminate substantially concurrently with one another in the plane of the second surface.

Finally, the invention also relates to a method of making a tampon. In the method, a cover is separated from a supply of an apertured film, which film is a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature. In addition, the absorbent structure is substantially enclosed with the cover, and thermal energy is applied to the cover to heat it to a temperature between the first melting point temperature and the second melting point temperature of the first layer to form an adhesive bond. Brief Description of the Drawing

Fig. 1 is a tampon having an apertured film cover according to the present invention.

Fig. 2 is an enlarged cross-section of an apertured film according to the present invention.

Detailed Description of the Preferred Embodiment

As used herein, the term "absorbent article" refers to devices that absorb and contain body exudates and that are worn on or inside the body. These devices preferably absorb and contain blood, urine, and/or vaginal discharges, such as bandages, dental and nasal tampons, diapers, sanitary napkins, incontinence guards or pads, interlabial sanitary protection devices, and internal sanitary protection devices such as tampons .

As used herein, the term "apertured film" refers to a fluid-impervious plastic material in the form of a resilient three-dimensional web having first and second surfaces and exhibiting a fiber-like appearance and tactile impression. The first surface of the three- dimensional web has a multiplicity of apertures therein.

Preferably, each of the apertures is defined by a multiplicity of intersecting, fiber-like elements interconnected to one another substantially in the plane of the first surface. Each of the fiber-like elements exhibits a cross-section, preferably having a base portion in the plane of the first surface and a sidewall joined to each edge of the base portion. The sidewall portions extend generally in the direction of the second surface of the three-dimensional web. Further, the intersecting sidewall portions are interconnected to one another intermediate the first and second surfaces of the web. The interconnected sidewall portions preferably terminate substantially concurrently with one another in the plane of the second surface.

As used herein, the term "wrapping element" refers to an element of an absorbent article that, alone or in conjunction with one or more additional element (s), substantially encloses an absorbent structure. As used herein, the term "cover" refers to a wrapping element located on the outer surface of an absorbent article. The absorbent articles of the present invention, e.g., a tampon 10, comprise an apertured film wrapping element, e.g., a cover 12, and an absorbent structure 14. The wrapping element at least partially encloses the absorbent structure that is generally designed and constructed to absorb and contain bodily exudates As indicated above, the presence of the sidewalls

16 between the first surface 18 and second surface 20 of the web imparts a generally three-dimensional quality to the wrapping element. This three-dimensional quality is distinct from the generally two-dimensional quality of a reticulated film, such as that described in U.S. Patent No. 4,710,186, the disclosure of which is hereby incorporated by reference. Two-dimensional reticulated films more readily allow portions of the absorbent materials of the absorbent structure to protrude through to the surface of the absorbent article, such as a tampon.

The three-dimensional quality provided by the sidewalls 16 helps to separate the absorbent materials of the absorbent structure 14 from the surface of the absorbent article, often defined by the first surface 18 of the wrapping element 12. The longer the sidewalls 16, the greater the separation of the absorbent structure materials from the article surface and the less likely it is that any absorbent structure materials will protrude through the openings 22 in the apertured film 12 to contact the user's body tissues during use.

Some types of absorbent materials may protrude more easily through the openings 22 in the apertured film 12, and thus, longer sidewalls 16 may be needed to prevent protrusion. It will be recognized by those familiar in the art that tampons 10 are often compressed during the manufacturing process . Such compression may cause the sidewalls 16 of the apertured film 12 to fold over.

Such folding, however, does not appear to detract from the ability of the sidewalls 16 to prevent protrusion of the absorbent materials through the openings 22 in the apertured film 12. Fig. 2 is an enlarged cross-section of a wrapping element, e.g., cover 12, according to the present invention. The wrapping element is a web having first surface 18 and second surface 20. The web is formed by aperturing a base film comprising polymeric material . This material is a blend of at least two thermoplastic polymeric components. The first thermoplastic polymeric component forms a continuous phase that exhibits a first melting point temperature. In order to form the continuous phase, it is preferred that the first thermoplastic polymeric component be present at about 45 to about 95 wt-% of the layer, more preferably about 60 to about 80 wt-% of the layer. A dispersed phase comprises a second thermoplastic polymeric component that exhibits a second melting point temperature. It is preferred that the second thermoplastic polymeric component is present at about 55 to about 5 wt-% of the layer, more preferably about 40 to about 20 wt-% of the layer. In addition, the second melting point temperature is sufficiently less than the first melting point temperature to allow the film to be heated to a temperature between the first and second melting point temperatures, rendering the second thermoplastic polymeric component capable of forming an adhesive bond. This bond may be formed between different portions of the wrapping element, or it may be between the wrapping element and another element of the absorbent article. Preferably, the difference between the first melting point temperature and the second melting point temperature is greater than about 20° C, and more preferably, the difference between the first melting point temperature is greater than about 30° C. Most preferably, the difference is greater than about 40° C.

The continuous phase provides the "backbone" of the layer and contributes most of the layer's mechanical properties, such as tensile strength, stiffness, elongation at break, coefficient of friction, modulus, and the like. The first thermoplastic polymeric component substantially provides these properties. Therefore, the first thermoplastic polymeric component of the first layer will be chosen for its desirable properties. A representative, non-limiting list of suitable polymers for the first thermoplastic polymeric component includes polyolefins, such as polypropylene and polyethylene; polyolefin copolymers, such as ethylene-vinyl acetate ("EVA"), et ylene-propylene, ethylene-acrylates, and ethylene-acrylic acid and salts thereof; halogenated polymers; polyesters and polyester copolymers; polyamides and polyamide copolymers; polyurethanes and polyurethane copolymers ; polystyrenes and polystyrene copolymers; and the like. Preferred first thermoplastic polymeric components include polyolefins, especially polypropylene.

The dispersed phase provides localized areas for thermal bonding to adjacent elements. The second thermoplastic polymeric component provides these properties, and it may also contribute to some of the mechanical properties, including coefficient of friction. A representative, non-limiting list of suitable polymers for the second thermoplastic polymeric component includes polyolefins, such as polypropylene and polyethylene; polyolefin copolymers, such as ethylene-vinyl acetate ("EVA"), ethylene-propylene, ethylene-acrylates, and ethylene-acrylic acid and salts thereof; halogenated polymers; polyesters and polyester copolymers; polyamides and polyamide copolymers; polyurethanes and polyurethane copolymers; polystyrenes and polystyrene copolymers; and the like. Preferred second thermoplastic polymeric components include polyethylene and its copolymers, especially linear low density polyethylene (LLDPE) , low density polyethylene (LDPE) and EVA.

The first and second thermoplastic polymeric components should be selected to allow the desired properties of each material to be apparent. For example, a combination of polypropylene (continuous phase) and polyethylene (dispersed phase) employs thermoplastic polymeric components that have a viable melting point differential to allow for heat sealing and that are compatible, e.g., they can be extruded from the same extrusion head without charring, etc. In contrast, a combination of LLDPE (continuous phase) and LDPE (dispersed phase) would be less desirable, because there is insufficient melting point differential to provide for acceptable heat sealing. Additionally, a combination of nylon-6 (continuous phase) and EVA (dispersed phase) would also be less desirable as the dispersed phase is likely to be degraded in a film extrusion process.

In addition, other components and further additives can be added in an amount that will not hinder obtaining the object of the present invention, including, without limitation, antioxidants, UV absorbers, lubricants, antiblock and slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and inorganic or organic fillers. The absorbent structure may be any absorbent means that is capable of absorbing and/or retaining liquids (e.g., menses and/or urine). The absorbent structure can be manufactured in a wide variety of sizes and shapes and from a wide variety of liquid-absorbing materials. A representative, non-limiting list of useful materials includes cellulosic materials, such as rayon, cotton, wood pulp, creped cellulose wadding, tissue wraps and laminates, peat moss, and chemically stiffened, modified, or cross-linked cellulosic fibers; synthetic materials, such as polyester fibers, polyolefin fibers, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials; formed fibers, such as capillary channel fibers and multilimbed fibers; combinations of materials, such as synthetic fibers and wood pulp including coformed fibrous structures (e.g., those materials described in Anderson et al . , U.S. Patent No. 4,100,324); or any equivalent material or combinations of materials, or mixtures of these.

The wrapping element of the present invention can be manufactured by standard processes known to those of ordinary skill in the art. For example, the base film that is to be apertured can be extruded, cast, blown, or it may be formed in other processes that will be recognized by those of ordinary skill in the art. The base film can then be apertured by any of the known processes. Several examples include hot air aperturing, and water jet aperturing. Examples of these process are disclosed in Curro, US Pat. No. 4,695,422; Turi, US Pat. No. 5,567,376; and Mullane, US Pat. No. 4,741,877. The resulting apertured film can be coated, for example as described in commonly assigned, co-pending application US Ser. No. 09/345,088, filed June 30, 1999, entitled "Tampon with Cover and Nonionic Surfactant" (Attorney Dockey PPC-708) , and/or slit to a desired width for use in manufacturing an absorbent A preferred embodiment of the present invention is a tampon 10 having an apertured film cover 12 substantially enclosing an absorbent structure 14. The cover 12 is useful to contain the absorbent structure materials to reduce, preferably prevent, the likelihood that any significant portion of the absorbent structure 14 will escape from the tampon 10 and remain after the tampon 10 has been removed, e.g., by pulling on the withdrawal string 30. The cover 12 can also protect the tissue in contact with the tampon 10 from excessive friction or other irritation during insertion, use, and removal of the tampon 10. Further, the cover 12 can add aesthetic qualities to the tampon 10. Therefore, it is desirable that the cover 12 have the following properties low coefficient of friction, smooth surface, high opacity, clear apertures, and unmelted appearance.

In addition, because the cover 12 contains the absorbent structure 14, and because it is often desirable that the cover 12 and absorbent structure 14 be secured to each other, the cover 12 should be capable of thermally bonding at least to itself in a manner that secures the absorbent structure 14 within it . Preferably, the cover 12 is also capable of thermally bonding to the outer portions of the absorbent structure 14, itself. These thermal bonding processes include, without limitation, heat, heat & pressure, ultrasonics, and hot air.

One method of applying the apertured film cover material to an absorbent structure in the manufacture of a tampon is the use of a cut-and-place unit to cut the material from the slit roll and to place it on the absorbent structure. Another method is generally described in Friese, U.S. Patent No. 4,816,100. While this describes the use of a nonwoven cover to a tampon, improvements are necessary to employ this general method using apertured films. Such improvements are disclosed in the commonly-assigned, copending applications: US Ser. No. 60/141,688, filed June 30, 1999, entitled "Sealing Roller and Sealing Roller Element, Particularly for Producing a Tampon for Feminine Hygiene and Method Therefore" (Attorney Docket, J&J-1819) ; and US Ser. No. 09/343,759, filed June 30, 1999, entitled "Continuous

Method of Providing Individual Sheets from a Continuous Web" (Attorney Docket PPC-668) . The latter copending application discloses a method to achieve the total separation of a section of material comprises the following steps : severing a supply material in a plurality of discrete regions along a transverse axis, scoring the material residing between the severed regions along the same transverse axis, and then applying a force sufficient to fracture the scored regions, thereby separating the section of material from its supply.

The disclosures of all US patents and patent applications, as well as any corresponding published foreign patent applications, mentioned throughout this patent application are hereby incorporated by reference herein.

The specification and embodiments above are presented to aid in the complete and non-limiting understanding of the invention disclosed herein. Since many variations and embodiments of the invention can be made without departing from its spirit and scope, the invention resides in the claims hereinafter appended.

Claims

WHAT IS CLAIMED IS;

1. A wrapping element useful in absorbent articles comprising fluid-impervious plastic material in the form of a resilient three-dimensional web exhibiting a fiber- like appearance and tactile impression, the fluid- impervious plastic material comprises a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond; the web has first and second surfaces, the first surface having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface.

2. The wrapping element of claim 1 wherein the first thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.

3. The wrapping element of claim 2 wherein the first thermoplastic polymeric component comprises a polyolefin.

4. The wrapping element of claim 1 wherein the second thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.

5. The wrapping element of claim 4 wherein the second thermoplastic polymeric component comprises a polyolefin.

6. The wrapping element of claim 1 wherein the difference between the first melting point temperature and the second melting point temperature is greater than about 20° C.

7. The wrapping element of claim 1 which comprises about 45 to about 95 wt-% of the first thermoplastic polymeric component and about 55 to about 5 wt-% of the second thermoplastic polymeric component.

8. The wrapping element of claim 7 which comprises about 60 to about 80 wt-% of the first thermoplastic polymeric component and about 40 to about 20 wt-% of the second thermoplastic polymeric component .

9. The wrapping element of claim 1 which further comprises one or more components selected from the group comprising antioxidants, UN absorbers, lubricants, antiblock agents, slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and fillers.

10. A tampon comprising an absorbent structure substantially enclosed by a cover wherein (1) the cover comprises fluid-impervious plastic material in the form of a resilient three-dimensional web exhibiting a fiber- like appearance and tactile impression, (2) the fluid- impervious plastic material comprises a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond; (3) the web has first and second surfaces, the first surface having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface.

11. The tampon of claim 10 wherein the first thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof .

12. The tampon of claim 11 wherein the first thermoplastic polymeric component comprises a polyolefin.

13. The tampon of claim 10 wherein the second thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof .

14. The tampon of claim 13 wherein the second thermoplastic polymeric component comprises a polyolefin.

15. The tampon of claim 10 wherein the difference between the first melting point temperature and the second melting point temperature is greater than about 20° C.

16. The tampon of claim 10 which comprises about 45 to about 95 wt-% of the first thermoplastic polymeric component and about 55 to about 5 wt-% of the second thermoplastic polymeric component.

17. The tampon of claim 10 which further comprises one or more components selected from the group comprising antioxidants, UV absorbers, lubricants, antiblock agents, slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and fillers.

18. The tampon of claim 10 wherein the cover is adhered to the absorbent structure .

19. A method of forming a wrapping element useful in absorbent articles, comprising the steps of: a) forming a film comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond; b) applying fluid at a temperature greater than ambient temperature to the film while it is supported on a three-dimensional surface to form a resilient three-dimensional web exhibiting a fiberlike appearance and tactile impression, wherein the web has first and second surfaces, the first surface having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface . -dimensional web exhibiting a fiber-like appearance and tactile impression; and c) separating the web into individual pieces of material of a size appropriate for a wrapping element .

20. The method of claim 19 wherein the step of forming the film comprises extruding thermoplastic polymeric components through an extruder.

21. A method of making a tampon comprising the steps of: a) separating a cover from a supply of a resilient three-dimensional web exhibiting a fiberlike appearance and tactile impression, the web comprising fluid-impervious plastic material which comprises a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond; the web has first and second surfaces, the first surface having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface; b) substantially enclosing an absorbent structure with the cover; and c) applying thermal energy to the cover to heat it to a temperature between the first melting point temperature and the second melting point temperature of the first layer to form an adhesive bond .

22. The method of claim 21 wherein the adhesive bond is between the cover and the absorbent structure.

23. The method of claim 22 wherein the adhesive bond is between overlapped portions of the cover.