Methods and tooling for forming performance zones in substrates are provided. The methods and tooling for forming performance zones in substrates may be for use on an absorbent article manufacturing line.

Methods and tooling for making three-dimensional substrates and/or apertured substrates are provided. The three-dimensional substrates and/or apertured substrates may be used in absorbent articles, such as diapers and pants, for example. The methods and tooling may be used on an absorbent article manufacturing line.

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.

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.

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 web for use in disposable absorbent articles is disclosed herein. The web has a first surface and an opposing second surface. A plurality of discrete extended elements and a plurality of macro apertures arranged in a staggered pattern are provided. A plurality of web regions between adjacent macro apertures has a top plane having a length less than or equal to about 0.9 mm between the two adjacent macro apertures.

Provided are a perforated non-woven fabric and a production method thereof. The perforated non-woven fabric is formed by overlapping three-dimensional funnel-shaped openings of two perforated non-woven fabric layers. The first perforated non-woven fabric layer has a protruding portion and a recessed portion. The protruding portion has an internal space. An upper side of the second perforated non-woven fabric layer is adhered to a lower side of the recessed portion of the first perforated non-woven fabric layer. The overlapped three-dimensional funnel-shaped openings pass through the first perforated non-woven fabric layer and the second perforated non-woven fabric layer. An air flow passage is formed between continuous internal spaces of the protruding portions of the first perforated non-woven fabric layer and the second perforated non-woven fabric layer, thereby facilitating penetration of liquid and soft feces, reducing residues, enabling internal and external air flow circulation, and reducing discomfort from wetness.

The present invention relates to a web comprising: discrete extended elements having open proximal ends, open or closed dismal ends and side walls; macro apertures arranged in a staggered pattern; first regions comprising a first top plane; and second regions comprising a second top plane having a length less than or equal to about 0.9 mm, wherein each of the first regions is surrounded by four distinctive second regions, the four distinctive second regions being connected by two adjacent macro apertures in the first direction and another two adjacent macro apertures in the second direction which is orthogonal to the first direction, and wherein each of the second regions is surrounded by two adjacent first regions and two adjacent macro apertures located in a third direction or a fourth direction not parallel either to the first direction or to the second direction.

A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend through at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

A breathable structural web includes a layered structure having at least a layer of a non-woven material. The layered structure includes a base layer portion that has opposite first and second sides, a plurality of hollow protrusions that are disposed at the first side and that protrude and that are tapered from the base layer portion in a first direction, and a plurality of indented portions that are disposed at the second side, that extend from the base layer portion in a second direction opposite to the first direction, and that respectively define a plurality of recesses which open in the first direction. The hollow protrusions are scattered among the indented portions.