A process of making an absorbent article is disclosed. A liquid permeable topsheet web extending substantially continuously in a machine direction a backsheet web, and an acquisition layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The acquisition layer has a first and second surface. The topsheet and acquisition layer are aligned in a face to face relationship such that the second surface of the topsheet in in contact with the first surface of the acquisition layer and simultaneously mechanically deformed which combines the topsheet with the acquisition layer. The topsheet web and acquisition layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet web coincide with and fit together with a majority of the three-dimensional protrusions formed in the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions.

A topsheet for use with an absorbent article is provided and comprises a first layer and a second layer. The first layer is a spunlace nonwoven and comprises at least 15% by weight of natural fibers by total weight of the first layer. The first layer comprises a plurality of protrusions and a plurality of apertures. The first layer and the second layer are in contact with each other between the plurality of the protrusions. The second layer has a plurality of apertures at least partially aligned with the apertures of the first layer. The first layer has a minimum CD strength of at least 3N/(5 cm), according to the Tensile Strength Test Method.

The present disclosure relates to a nonwoven substrate having a top surface and an opposite bottom surface comprising: an upper layer forming the top surface of the nonwoven substrate, the upper layer comprising hydrophobic fibers, and a lower layer forming the bottom surface of the nonwoven substrate, the lower layer comprising hydrophilic fibers, wherein the top surface of the nonwoven substrate has a first contact angle of no lower than about 90 degrees as measured according to Contact Angle Test, wherein the bottom surface of the nonwoven substrate has a second contact angle of lower than about 90 degrees as measured according to Contact Angle Test, wherein the nonwoven has a unitary structure, and wherein the upper layer has a thickness no greater than about 1400 ?m as measured according to the Thickness Test.

A process of making an absorbent article is disclosed. A liquid permeable topsheet web extending substantially continuously in a machine direction a backsheet web, and an acquisition layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The acquisition layer has a first and second surface. The topsheet and acquisition layer are aligned in a face to face relationship such that the second surface of the topsheet in in contact with the first surface of the acquisition layer and simultaneously mechanically deformed which combines the topsheet with the acquisition layer. The topsheet web and acquisition layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet web coincide with and fit together with a majority of the three-dimensional protrusions formed in the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions.

A topsheet for use with an absorbent article is provided and comprises a first layer and a second layer. The first layer may be a spunlace nonwoven and may comprise at least 15% by weight of natural fibers by total weight of the first layer. The first layer may comprise a plurality of protrusions and a plurality of apertures. The first layer and the second layer may be in contact with each other between the majority of the protrusions. The second layer may have a plurality of apertures at least partially aligned with the apertures of the first layer. The first layer may have a minimum CD strength of at least 3N/(5 cm), according to the Tensile Strength Test Method.

A process of making an absorbent article comprising providing a liquid permeable topsheet web extending substantially continuously in a machine direction. The topsheet web having a first and second surface and a backsheet web extending substantially continuously in the machine direction and an acquisition layer having a first and second surface. The process comprises aligning the topsheet web and the acquisition layer in a face to face relationship such that the second surface of the topsheet in in contact with the first surface of the acquisition layer and simultaneously mechanically deforming and combining the topsheet web together with the acquisition layer. The topsheet web and acquisition layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet web coincide with and fit together with a majority of the three-dimensional protrusions formed in the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions.

A composite sheet that includes a first sheet and a second sheet is disclosed. The first and second sheets are bonded to each other at a number of spaced apart discrete inter-sheet bond locations. The first sheet is a nonwoven material that has discrete three-dimensional deformations therein forming protrusions that extend outward from the first surface of the first sheet to their distal ends and wide base openings adjacent to the second surface of the first sheet. The second sheet is a generally planar sheet that contacts the distal ends of the protrusions on the first sheet. The second sheet is bonded to the first sheet at spaced apart inter-sheet bond locations where the first region of the first sheet contacts the second sheet.

A nonwoven fabric for an outer sheet of an absorbent article has a liquid-impermeable sheet having moisture vapor permeability, the nonwoven fabric having a thickness direction and a planar direction, and a first surface and a second surface, the nonwoven fabric including thermoplastic resin fibers, and cellulosic fibers that are cellulosic fibers of which at least a portion form a plurality of fiber masses, the nonwoven fabric comprising a plurality of gaps that are adjacent to first regions of each of the plurality of fiber masses that are facing the first surface, wherein each of the plurality of fiber masses are not joined with the thermoplastic resin fibers.

A nonwoven substrate for an absorbent article including a layer of fibers is provided. The nonwoven substrate has a low surface tension fluid strikethrough time to basis weight ratio in the range of about 0.37 s/gsm to about 5 s/gsm. A plurality of the fibers each include fibrils extending outwardly from a surface of the fibers. The plurality of the fibers are made from a composition including a polyolefin and about 11% to about 35% of glycerol tristearate by weight of the composition. The nonwoven substrate has a specific surface area in the range of about 1 m.sup.2/g to about 4 m.sup.2/g.

Nonwoven materials having a first region and a plurality of discrete integral second regions that are in the form of three-dimensional deformations forming protrusions that extend outward from the first surface of the nonwoven material and wide base openings adjacent to the second surface of the nonwoven material are disclosed. The nonwoven materials include at least two layers that are each formed of a plurality of fibers. The first region has a first light transmission value and the second regions have a second light transmission value.