An apparatus for making a multilayer absorbent element apt to be incorporated in a sanitary article is provided. The apparatus has an embossing roller bearing a plurality of protruding elements, a pierced roller bearing a plurality of protruding elements and cavities, and a unit of cohesion and drilling. The configuration of the apparatus is such that, after a first layer of sheet material is deformed by the embossing roll and the perforated roller continues to slide on the pierced roller, a second layer of sheet material is superimposed. The first and second layer of sheet material are then carried to the joining and piercing unit in which, at the intermediate zones of the first layer, it forms a plurality of holes passing through the first and second layer and joins them near or at the plurality of holes.

A film for use in an absorbent article includes a first side and a second side opposite the first side, and a plurality of apertured protuberances arranged in a pattern having 60 to 120 protuberances per linear inch in at least one direction. Each of the protuberances includes a continuous sidewall extending from the first side. The second side has a plurality of apertures aligned with the plurality of apertured protuberances and land areas in between the apertures. The film has a melt index of at least about 8 g/10 min, and an air permeability of at least about 80 m.sup.3/m.sup.2/min.

A fluid distribution material for an absorbent article includes a formed film that includes a first side and a second side opposite the first side. The first side includes a plurality of elongated ridges extending from a first land area, a plurality of valleys defined by adjacent elongated ridges and the first land area, and a plurality of primary apertures located at bottoms of the valleys. The second side includes a plurality of apertured protuberances extending from a second land area. Each of the protuberances includes a continuous sidewall extending from the second land area to a distal end that includes a secondary aperture substantially aligned with a primary aperture. The formed film has a thickness greater than about 0.9 mm under a pressure of 0.071 psi, and a thickness greater than about 0.3 mm under a pressure of 0.6 psi.

A patterned apertured web includes a plurality of first arrays forming a first zone in the patterned apertured web. At least some of the first arrays include a first plurality of land areas and a first plurality of apertures. At least some of the first plurality of land areas surround at least some of the first plurality of apertures. The first plurality of apertures of the first zone have a plurality of Interaperture Distances, according to the Aperture Test. The Interaperture Distances of the first zone have a first distribution having a first mean and a first median. The first mean is greater than the first median by at least 4%.

Methods for deforming a multilayer web are disclosed. Steps of the method include: supplying a first layer of a precursor web; supplying a second layer of the precursor web onto at least the first area of the first layer; forming a plurality of first features and a plurality of second features in the precursor web. The plurality of first features are apertures formed in a first area of the precursor web, and the plurality of second features are formed in a second area of the precursor web in a positive and/or negative Z-direction. The plurality of first features and the plurality of second features are formed simultaneously.

A laminate web having a polymer film layer and a nonwoven layer is disclosed. The polymer film layer makes up a first side of the laminate web and the nonwoven layer makes up a second side of the laminate web. The laminate web has a plurality of first elements extending from the polymer film. The web also has a plurality of second elements formed outwardly from the first side of the laminate web.

A disposable absorbent article having a topsheet, a backsheet, and an absorbent core disposed therebetween is described. The topsheet has an array of apertures forming apertured indicia. The array of apertures includes a first plurality of apertures having a first aspect ratio; a second plurality of apertures having a second aspect ratio and a first Absolute Feret Angle; and a third plurality of apertures having a third aspect ratio and a second Absolute Feret Angle, wherein the first Absolute Feret Angle and the second Absolute Feret Angle are different, and wherein the first aspect ratio is less than the second and third aspect ratios.

Methods for making an apertured composite web are disclosed. These webs may be utilized as a topsheet in an absorbent article and can provide fluid handling and softness benefits.

A laminate web having a polymer film layer and a nonwoven layer is disclosed. The polymer film layer makes up a first side of the laminate web and the nonwoven layer makes up a second side of the laminate web. The laminate web has a plurality of first elements extending from the polymer film. The web also has a plurality of second elements such as recesses, protrusions, apertures, embossing and combinations thereof.

An apertured extrusion coated nonwoven web for use as a topsheet in an absorbent article includes a nonwoven material having a user-facing side and a garment-facing side opposite the user-facing side. The nonwoven material includes a plurality of fibers. The apertured extrusion coated nonwoven web also includes a polymer coating on the garment-facing side of the nonwoven material, the polymer coating having a basis weight of about 2 gsm to about 6 gsm, and a plurality of three-dimensional apertures that extend through the nonwoven material and the polymer coating. Each of the plurality of three-dimensional apertures includes a continuous sidewall extending from a garment-facing side of the polymer coating. The apertured extrusion coated nonwoven web has an open area of greater than 5% when subjected to a pressure of 0.6 psi.