Method for forming a nonwoven web exhibiting surface energy gradients

Abstract

The present invention pertains, in a preferred embodiment, to a method for forming a nonwoven web exhibiting a plurality of surface energy gradients. The method includes the steps of: providing a nonwoven web of fibers exhibiting a surface energy, the nonwoven web having a first surface, a second surface, a caliper, and a plurality of fluid passageways placing the first and second surfaces in fluid communication with one another; applying a surface treatment to the first surface of the nonwoven web, the surface treatment having a surface energy less than the surface energy of the fibers of the nonwoven web creating a plurality of surface energy gradients defined by discontinuous, spaced regions which are adapted to exert a force on a fluid contacting the first surface, such that the fluid will be directed toward the fluid passageways for transportation away from the first surface and in the direction of the second surface; and increasing the caliper of the nonwoven web by feeding the nonwoven web between a first pressure applicator and a second pressure applicator each having three-dimensional surfaces which at least to a degree are complementary to one another. The nonwoven web is particularly well suited for use as a topsheet on a disposable absorbent article.