A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

The present disclosure is directed to a three-dimensional substrate comprising a pattern comprising a repeat unit, wherein the repeat unit comprises a non-apertured area and a plurality of apertures defining the non-apertured area, wherein the non-apertured area comprises a protrusion, the non-apertured area having an area no less than 100 mm.sup.2 as measured according to Area of Non-apertured Area; a three-dimensional substrate comprising a pattern comprising a repeat unit, wherein the repeat unit comprises at least one three-dimensional element such as protrusion and at least one land, wherein the three-dimensional element comprises at least one concave portion; and an absorbent article comprising the three-dimensional substrate disclosed herein.

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 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 process of making an absorbent article is disclosed. A liquid permeable topsheet web extending substantially continuously in a machine direction a backsheet web, and an intermediate layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The intermediate layer has a first and second surface. The topsheet and intermediate layer are aligned in a face to face relationship such that the second surface of the topsheet in in contact with the first surface of the intermediate layer and simultaneously mechanically deformed which combines the topsheet with the intermediate layer. The topsheet web and intermediate 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 intermediate layer to provide a topsheet/intermediate layer laminate web having three-dimensional protrusions.

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.

A sheet is used for a disposable wearable article. The sheet is such that a plurality of projections are formed on a single nonwoven fabric. A hole is formed in the apex of the projection. The projection includes a holding portion, in a periphery of the hole and at a position adjacent to the hole, for holding the projection and holding an open state of the hole.

A disposable absorbent article is described herein. The disposable absorbent article includes a topsheet, a backsheet, and an absorbent system disposed between the topsheet and the backsheet. At least a portion of the has a plurality of conforming features such that the absorbent article has a blot residual value of less than 30 mg and a bending stiffness of less than 12.

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.