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 intermediate layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The intermediate layer has a first and second surface. The topsheet and intermediate 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 intermediate layer and simultaneously mechanically deformed which combines the topsheet with the intermediate layer. The topsheet web and intermediate 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 intermediate layer to provide a topsheet/intermediate layer laminate web having three-dimensional protrusions.

Nonwoven webs/nonwoven laminates for use in absorbent articles are disclosed. The nonwoven laminate includes a first nonwoven web with continuous spunbond crimped fibers and a second web joined to the first nonwoven web. A plurality of apertures extend through at least one of the first nonwoven web or the second web. The nonwoven web includes a plurality of continuous spunbond crimped fibers wherein a plurality of apertures extend through the nonwoven web.

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 disposable absorbent article having a crimped fiber spunbond nonwoven web is described herein. The disposable absorbent article has a topsheet, a backsheet attached to the topsheet, and an absorbent core disposed between the topsheet and the backsheet. The crimped fiber spunbond nonwoven web is either at least a portion of the topsheet or the backsheet or at least a portion of the topsheet and the backsheet. The crimped fiber spunbond nonwoven web includes a plurality of apertures extending therethrough.

Nonwoven webs/nonwoven laminates for use in absorbent articles are disclosed. The nonwoven webs/nonwoven laminates are useful in leg cuffs of absorbent articles.

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 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 shaped non-woven fabric for an absorbent has a first surface and a second surface and is usable with the second surface facing a constituent member of an absorbent article. The shaped non-woven fabric is includes a thermoplastic resin fiber. The non-woven fabric includes a plurality of first recesses which have openings in the first surface and are recessed toward the second surface, and a plurality of through-holes which penetrate from the first surface to the second surface. Each of the plurality of first recesses has a peripheral wall section which extends in the thickness direction from the end edges of the openings toward the second surface, and a bottom section connected to the end edge of the peripheral wall section. At least a portion of the plurality of first recesses includes a hole section which penetrates from the first surface to the second surface.

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.

A shaped non-woven fabric for an absorbent has a first surface and a second surface and is usable with the second surface facing a constituent member of an absorbent article. The shaped non-woven fabric is includes a thermoplastic resin fiber. The non-woven fabric includes a plurality of first recesses which have openings in the first surface and are recessed toward the second surface, and a plurality of through-holes which penetrate from the first surface to the second surface. Each of the plurality of first recesses has a peripheral wall section which extends in the thickness direction from the end edges of the openings toward the second surface, and a bottom section connected to the end edge of the peripheral wall section. At least a portion of the plurality of first recesses includes a hole section which penetrates from the first surface to the second surface.