Disclosed is a wearable article comprising front and back elastic belt regions and a crotch region between the front and back elastic belt regions; the front and back elastic belt regions each comprising a laminate, an elastic bonding continuously bonding an elastic member in the direction of stretch, and a vertical bonding applied to at least one of inner and outer sheets to intermittently bond the elastic member to at least one of the inner and outer sheets, the vertical bonding having a transverse dimension VG2 and spaced apart from each other with a transverse pitch VG1, wherein the outer sheet comprises a repeating pattern of apertures, the repeating pattern of apertures spaced apart from each other with a longitudinal pitch DF2, and spaced apart from each other with a transverse pitch DF1, wherein VG1 is greater than DF1, and wherein the repeating pattern of apertures have a Longitudinal Orientation.

Disclosed is a wearable article continuous in longitudinal and transverse directions comprising a front elastic belt, a back elastic belt, and a crotch region; the crotch region extending longitudinally between the front elastic belt and the back elastic belt; the front elastic belt and back elastic belt being discontinuous with each other in the crotch region, wherein certain of the front/back elastic belt is a non-elastic region; the front and back non-elastic regions have a First Belt Pattern FBP and the crotch region has a First Crotch Pattern FCP; wherein the First Belt Pattern FBP as well as First Crotch Pattern FCP is a Geometric Pattern, wherein 1) both the First Belt Pattern FBP and the First Crotch Pattern FCP have a Longitudinal Orientation, or 2) both the First Belt Pattern FBP and the First Crotch Pattern FCP form a High Order Pattern HOP and have a Non-directional Orientation.

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.

Deformed web materials are disclosed. The web materials have discrete deformations formed therein. The deformations may be features in the form of portions of a web with apertures therein, protrusions, depressed areas, and combinations thereof. These features may extend out from the surface on one side of the web, or from both of the surfaces of the web. Different features may be intermixed with one another.

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 acquisition layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The acquisition layer has a first and second surface. The topsheet and acquisition 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 acquisition layer and simultaneously mechanically deformed which combines the topsheet 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.

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.

As absorbent article for absorbing urine includes a topsheet which is a nonwoven fabric that has a skin-side surface having projections formed thereon. The content by percentage of fibers oriented in the thickness direction in each projection of the nonwoven fabric is greater than the content by percentage of fibers oriented in the thickness direction in sections of the nonwoven fabric other than the projections. The thickness of the nonwoven fabric when wet is greater than or equal to 85% the thickness of the nonwoven fabric when dry. The nonwoven fabric includes a first fiber layer and a second fiber layer. The first fiber layer is constituted by durable hydrophilic fibers, and the second fiber layer is constituted by durable hydrophilic fibers and non-durable hydrophilic fibers.

Deformed web materials are disclosed. The web materials have discrete deformations formed therein. The deformations may be features in the form of portions of a web with apertures therein, protrusions, depressed areas, and combinations thereof. These features may extend out from the surface on one side of the web, or from both of the surfaces of the web. Different features may be intermixed with one another.

A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.

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.