A process for manufacturing multi-ply disintegratable absorbent sheets is provided. Each said sheet includes at least five plies including two exterior plies and at least three interior plies. Each of at least three of the plies in the sheet is in at least one group of plies and each of the at least three plies is joined to another ply by mechanical deformation.

An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO.sub.2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

A method of making a face mask is disclosed. The method includes providing an elastic nonwoven web continuous in a machine direction, the elastic nonwoven web having a central lane extending in the machine direction; bonding a filtering web to the central lane of the elastic nonwoven web to provide a layered web, the filtering web being continuous in the machine direction and having a cross-web width that is substantially the same as the cross-web width of the central lane; and stamping a face mask into the layered web. A face mask and a continuous layered web having a plurality of face masks disposed thereon are also disclosed.

The embossing-laminating device comprises a first embossing roller provided with embossing protrusions defining a first embossing pattern and comprising first embossing protrusions and second embossing protrusions, of a height greater than the first embossing protrusions. The device further comprises a first pressure roller defining, with the first embossing roller, a first embossing nip; wherein a first path for a first ply extends through the first embossing nip. A second embossing roller, provided with embossing protrusions defining a second embossing pattern, coacts with a second pressure roller defining, with the second embossing roller, a second embossing nip. The second embossing pattern of the second embossing roller comprises third embossing protrusions and fourth embossing protrusions, of a height greater than the third embossing protrusions.