Method of perforating a nonwoven web and use of the web as a cover for a feminine pad

Claim 1

A method of perforating a nonwoven web of fibrous fabric comprising the steps of: (a) directing said web through a nip defined by first and second movable members; and (b) penetrating said web with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said fabric to separate and enter into said apertures to form openings through said web, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.

Claim 2

A method of perforating a nonwoven web of fibrous fabric comprising the steps of: (a) directing said web through a nip defined by first and second movable members; and (b) penetrating said web with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said fabric to separate and enter into said apertures to form openings through said web, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.

Claim 5

A method of forming a perforated liquid permeable nonwoven cover material for a feminine pad, said pad including a fluid absorbent partly covered by said cover material and partly surrounded by a baffle which in turn is bonded to said cover material, said method comprising the steps of: (a) directing said cover material through a nip defined by first and second movable members; and (b) penetrating said cover material with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said cover material to separate and enter into said apertures to form openings through said cover material, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said cover material between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said cover material.

Claim 6

A method of forming a perforated liquid permeable nonwoven cover material for a feminine pad, said pad including a fluid absorbent partly covered by said cover material and partly surrounded by a baffle which in turn is bonded to said cover material, said method comprising the steps of: (a) directing said cover material through a nip defined by first and second movable members; and (b) penetrating said cover material with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said cover material to separate and enter into said apertures to form openings through said cover material, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said cover material between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said cover material.

Claim 7

A method of perforating a nonwoven web of fabric including fusible polymeric filaments, said method comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures arranged and sized to receive said pins each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters (b) heating both said first and second rolls to a predetermined temperature; (c) directing said web between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said web and enter into said apertures, said penetration causing fibers of said fabric to separate and be drawn into said apertures to form openings in said web which are surrounded by consolidated rings formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings, said rings imparting a three dimensional profile to said web which facilitates passage of fluid through said openings.

Claim 8

A method of perforating a nonwoven web of fabric including fusible polymeric filaments, said method comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures arranged and sized to receive said pins each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters (b) heating both said first and second rolls to a predetermined temperature; (c) directing said web between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said web and enter into said apertures, said penetration causing fibers of said fabric to separate and be drawn into said apertures to form openings in said web which are surrounded by consolidated rings formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings, said rings imparting a three dimensional profile to said web which facilitates passage of fluid through said openings.

Claim 13

A method of perforating a nonwoven web of fibrous fabric comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures arranged and sized to receive said pins each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters; (b) heating both said first and second rolls to a predetermined temperature; (c) directing said web between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said web and enter into said apertures, said penetration causing fibers of said fabric to separate and be drawn into said apertures to form openings in said web which are surrounded by consolidated rings formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.

Claim 14

A method of perforating a nonwoven web of fibrous fabric comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures arranged and sized to receive said pins each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters; (b) heating both said first and second rolls to a predetermined temperature; (c) directing said web between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said web and enter into said apertures, said penetration causing fibers of said fabric to separate and be drawn into said apertures to form openings in said web which are surrounded by consolidated rings formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.

Claim 19

A method of forming a perforated nonwoven cover material for a feminine pad, said pad including a fluid absorbent having a first surface facing the body of a user which is covered by said cover material and a liquid impermeable baffle surrounding the remaining portion of said absorbent and which is bonded to said cover material, said method comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures, arranged and sized to receive said pins, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters; (b) heating both said first and second rolls to a predetermined temperature; (c) directing said cover material between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said cover material and enter into said apertures, said penetration causing fibers of said cover material to separate and be drawn into said apertures to form openings therein which are surrounded by consolidated rings formed by pressing said cover material between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings, exhibiting a greater hydrophilic property than the non-perforated surface of said cover material.

Claim 20

A method of forming a perforated nonwoven cover material for a feminine pad, said pad including a fluid absorbent having a first surface facing the body of a user which is covered by said cover material and a liquid impermeable baffle surrounding the remaining portion of said absorbent and which is bonded to said cover material, said method comprising the steps of: (a) positioning a first roll relative to a second roll to obtain a preselected nip opening therebetween, said first roll containing a plurality of radially extending pins each having a shoulder which surrounds a penetrating point, and said second roll containing a plurality of circular apertures, arranged and sized to receive said pins, each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters; (b) heating both said first and second rolls to a predetermined temperature; (c) directing said cover material between said nip; and (d) rotating said first and second rolls to cause said pins to penetrate said cover material and enter into said apertures, said penetration causing fibers of said cover material to separate and be drawn into said apertures to form openings therein which are surrounded by consolidated rings formed by pressing said cover material between one of said heated pins and a corresponding aperture and between one of said shoulders and said second roll, a combination of said openings and said consolidated rings, exhibiting a greater hydrophilic property than the non-perforated surface of said cover material.

Claim 21

A method of perforating a nonwoven web of fabric comprising the steps of: (a) directing said web through a nip defined by first and second movable members; and (b) penetrating said web with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said fabric to separate and enter into said apertures and form openings through said web which occupy approximately 20 to 55% of the available surface area of said web each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.

Claim 22

A method of perforating a nonwoven web of fabric comprising the steps of: (a) directing said web through a nip defined by first and second movable members; and (b) penetrating said web with a plurality of heated pins each having a shoulder which surrounds a penetrating point, said pins projecting outward from said first member and entering heated apertures formed in said second member causing fibers of said fabric to separate and enter into said apertures and form openings through said web which occupy approximately 20 to 55% of the available surface area of said web each of said shoulders having a diameter larger than the diameter of a corresponding aperture into which said point enters, each of said openings being surrounded by a consolidated ring formed by pressing said web between one of said heated pins and a corresponding aperture and between one of said shoulders and said second member, a combination of said openings and said consolidated rings exhibiting greater hydrophilic properties than the non-perforated surface of said web.