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.

In accordance with an embodiment of the disclosure, an article includes a first web and second web underlying the first web. The article further includes a bonding pattern. The bonding pattern includes a plurality of discrete bonding points and a sized spacing between each adjacent bonding point sufficient to have inscribed therein a circle having a diameter of about 1 mm to about 12 mm. The bonding pattern is located solely in one of the front end region or the back end region.

An absorbent article having a longitudinal axis extending in a longitudinal direction and a transversal axis extending in a transversal direction perpendicular to the longitudinal direction. The absorbent article comprises a fluid-permeable topsheet, a lotion on the topsheet having a lotion pattern covering a lotion pattern area, a fluid-impermeable backsheet, and an absorbent core between the topsheet and the backsheet. The core wrap defines a core footprint in a plane parallel to the longitudinal direction and transversal direction. The article comprises an intermediate layer between the topsheet and the absorbent core, the intermediate layer comprising at least one longitudinally-extending channel, preferably at least a pair of longitudinally-extending channels disposed symmetrically on each side of the longitudinal axis. The topsheet is depressed in the channel(s). The lotion-to-channel overlap ratio ranges from 0% to 20% of the area of the channel(s). The lotion-to-channel overlap ratio is the percentage of the channel(s) of the intermediate layer overlapping with the lotion pattern.

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.

In accordance with an embodiment of the disclosure, an article includes a first web and second web underlying the first web. The article further includes a bonding pattern. The bonding pattern includes a plurality of discrete bonding points and a sized spacing between each adjacent bonding point sufficient to have inscribed therein a circle having a diameter of about 1 mm to about 12 mm. The bonding pattern is located solely in one of the front end region or the back end region.

A liquid permeable substrate for an absorbent article is disclosed. The substrate includes a first layer including a hydrophobic material and a second layer including a hydrophilic material. The first layer is joined to the second layer. The substrate includes a plurality of recesses, a plurality of projections, and a plurality of land areas. The land areas surround at least a majority of the plurality of projections and a plurality of the recesses. The plurality of recesses, the plurality of projections, and the plurality of land areas together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate. The substrate has an overall z-directional height in the range of about 1000 ?m to about 6000 ?m according to the Overall Substrate Height Test.

Three-dimensional laminates and methods for making the same are provided. The three-dimensional laminates may be apertured and may have welds between various substrates. The three-dimensional laminates may be used in absorbent articles, such as diapers and pants, for example, as topsheets, as topsheets and acquisition layers, or as outer cover materials, for example. The three-dimensional laminates may be produced on an absorbent article manufacturing line.

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.

An activated composite web includes a nonwoven layer, and a formed film layer attached to the nonwoven layer. The formed film layer includes a plurality of first apertured protuberances having a mesh count of at least 35, and a plurality of second apertured protuberances. Each of the second apertured protuberances has a cross-sectional area larger than each of the first apertured protuberances. A plurality of first lanes are aligned in a first direction and have a first width extending in a second direction substantially perpendicular to the first direction. The first apertured protuberances are located in the first lanes. A plurality of second lanes are aligned in the first direction and have a second width, less than the first width, extending in the second direction. The first lanes and the second lanes alternate with each other in the second direction. The second apertured protuberances are located in the second lanes.

A method and an apparatus for making a non-woven fabric article are provided. The method includes providing a screen mold, disposing a formable material thereover, and evacuating air from the screen mold. The screen mold is made of a non-pliable material, and has an annular surrounding wall that defines an internal space, and multiple screen holes that extend through the annular surrounding wall and communicate with the internal space. The formable material is disposed over the annular surrounding wall and the screen holes of the screen mold, and then air is evacuated from the internal space via a suction device to form the fabric article.