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| An improved manufacturing process for forming three-dimensional, macroscopically-expanded fluid-pervious webs is presented. Such webs possess an improved, functional textured surface, which makes them particularly suitable for use in disposable absorbent articles, such as diapers, sanitary napkins, panty liners, and incontinence pads. The surface of these webs is comprised of a sheet of polymeric material having a first surface and a second surface. According to the method, a plurality of discrete deposits of a water-resistant, resinous material having a pre-determined curing ("open") time are first deposited on the surface of the first sheet surface. The deposits of resinous material are then drawn upwardly from the first surface of the sheet to form corresponding fibrils during the open time. After the resinous material has cured, the sheet is then fed onto a forming structure having opposed surfaces, such that each sheet is in contact with the forming structure. The forming structure exhibits a multiplicity of apertures, which place the opposed surfaces of the forming structure in fluid communication with one another. A fluid pressure differential is applied across the thickness of the sheet that is sufficiently great as to cause the sheet to rupture in those areas coinciding with the apertures in the forming structure and to conform with the forming structure, while substantially maintaining the orientation of the fibrils. The printing and drawing steps are preferably accomplished via a screen printing roll, and the fluid pressure differential preferably comprises a high-pressure jet or liquid. |
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