NONWOVEN AND FILM CORRUGATED LAMINATES

摘要

The present invention is directed to corrugated laminates with density differentials created in at least one of the layers of the laminate. The laminates (10) include a first layer (12) bonded to a second layer (14) to form a composite which has a plurality of corrugations forming a series of peaks separated by a series of valleys. At least the second layer is formed from a compressible material such as a fibrous nonwoven web which has formed therein areas of different density due to the formation process used to form the laminate. In one process the first and second layers are bonded to one another along a series of generally parallel bond lines (16) while at least one of the materials is in a tensioned state. Once bonding is completed, the tension is released and the laminate forms a series of corrugations. In the valley areas (18) immediately adjacent the bond lines the laminate and in particular the second layer has an increased density due to the bonding process. In the peak areas (20), which are between the valley areas, the laminate and in particuar the second layer has a lower density. As a result, fluids entering the laminate through the first layer tend to be drawn toward the more dense areas adjacent the bond lines. This couples with the reduced surface contact area of the first layer due to the corrugations, tend to make the material particularly well-suited for use as a body side liner for personal care absorbent articles.