Three dimensional nonwoven materials and methods of manufacturing such materials are disclosed. In one embodiment, a nonwoven material may comprise a plurality of fibers, a first surface, and an apertured zone comprising: a plurality of nodes extending away from a base plane on the first surface, a plurality of connecting ligaments interconnecting the plurality of nodes, wherein a majority of the plurality of nodes include at least three connecting ligaments connecting to adjacent nodes, and a plurality of openings. The apertured zone may further comprise a lane of nodes which extends substantially in the longitudinal direction, and wherein the lane of nodes extending substantially in the longitudinal direction is formed of longitudinally adjacent nodes which are aligned such that lines drawn between centers of longitudinally adjacent nodes within the lane of nodes each form an angle with respect to the longitudinal direction of less than about 20 degrees.

Three dimensional nonwoven materials and methods of manufacturing such materials are disclosed. In one embodiment, a nonwoven material may comprise a plurality of fibers and may further comprise an opposing first surface and a second surface, an apertured zone comprising a plurality of nodes extending away from a base plane on the first surface, a plurality of connecting ligaments interconnecting the plurality of nodes, and a plurality of openings providing a percent open area for the apertured zone that is greater than about 15%, as determined by the Material Sample Analysis Test Method. The material may further comprise a first and second side zones with the nonwoven material having a material width and the first and second side zones having first and second side zone widths, and wherein each of the first and second side zone widths are between about 5% and about 25% of the nonwoven material width.

Three dimensional nonwoven materials and absorbent articles comprising such materials are disclosed. In one embodiment, an absorbent article may comprise an outer cover, a bodyside liner, an absorbent body, and a nonwoven material coupled to the bodyside liner. The nonwoven material may comprise an apertured zone providing a percent open area for the apertured zone that is greater than about 15%. The nonwoven material may be coupled to liner by a front waist bond forming a front waist bonding region which extends through the apertured zone and a rear waist bond forming a rear waist bonding region, wherein the rear waist bonding region has a length that is between about 2% and about 10% of the material length and the front waist bonding region has a length that is between about 20% and about 50% of the material length.

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.

An absorbent article is disclosed, including a three-dimensional material formed of a liquid permeable topsheet and an acquisition material. The acquisition material is positioned beneath the topsheet, and both may be formed of nonwoven material. The three dimensional material may have two surfaces and a plurality of protrusions extending in a z-direction from one of the surfaces, each protrusion having side walls defining an opening in the other of the surfaces. One of the topsheet and the acquisition material may include fibers spun of polymer resin pigmented with a first color that differs from a second color of fibers of the other of the topsheet and the acquisition material, and the differing colors are visible when viewing a wearer-facing surface of the absorbent article.

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 μm to about 6000 μm according to the Overall Substrate Height Test.

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.

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.

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.

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.