Perforated Film vs. Nonwoven Top Sheet: Which Offers Better Fluid Acquisition?

In the design of diapers and sanitary napkins, the top sheet is the first layer of defense—it must allow liquid to pass through quickly while keeping the surface dry and comfortable against the skin. Two material types dominate this application: perforated film and nonwoven top sheet. Each has distinct performance characteristics that make it suitable for different product tiers and usage scenarios.

Perforated Film: Precision Engineering for Speed

Perforated film is a thin polymer film (typically PE or PP) that has been mechanically or thermally apertured to create thousands of tiny holes per square centimeter. These holes serve as rapid liquid channels, drawing fluid directly into the absorbent core.

• Liquid strike-through speed: Excellent. The high pore density (typically 10–40 pores/cm²) creates a low-resistance path for liquid, allowing it to pass through in under 15 seconds.

• Rewet resistance: Excellent. The film's non-absorbent nature prevents liquid from holding on the surface. Once fluid passes through the apertures, the film itself does not retain moisture, minimizing rewet under pressure.

• Skin feel: Smooth, initially cool to the touch. The film does not trap heat, providing a fresh, clean sensation. However, some users find it less comfortable than soft nonwoven options.