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.

The present invention relates to a method for making an aperture web. The method includes the steps of: moving a micro-textured web through a first member having male elements and a second member having discontinuous female elements, wherein the male elements are arranged in a staggered pattern.

A material web having a film layer and a nonwoven layer, along with methods of making the material web, are described. The material web has a plurality of micro-deformations and a plurality of macro-deformations, each of the macro-deformations having a distal end, wherein a first portion of macro-deformations has an open or partially open distal end and wherein a second portion of macro-deformations has distal ends which are configured differently than the distal ends of the first portion, and wherein the material web forms a portion of the topsheet.

The present invention relates absorbent article having a wearer facing surface and a garment facing surface, the absorbent article comprising: a topsheet, a backsheet, and a layer of absorbent material disposed between the topsheet and the backsheet, wherein the topsheet comprises a first layer comprising cellulose-based fibers, the first layer comprising a first surface, an opposite second surface, and a plurality of apertures having side walls, wherein the first surface of the first layer forms at least part of the wearer facing surface; wherein the first surface of the first layer comprises at least one non-aperture area having a first non-aperture area contact angle as measured by Contact Angle Test; and wherein each of majority of the apertures has a side wall having an aperture contact angle as measured by Contact Angle Test, the aperture contact angle being higher than the first non-aperture area contact angle.

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 disposable absorbent article has a topsheet; a backsheet; an absorbent core disposed between the topsheet and the backsheet; and a first plurality of conforming features in at least the absorbent core or a combination of the absorbent core and the topsheet. At least a portion of the are depressions, wherein the depressions have a depression centerline bisecting a length and/or width of the depression. A first strut forms a first sidewall of the depression opposite a second sidewall of the depression formed by a second strut, wherein neither of the first strut nor the second strut extend longitudinally and/or laterally beyond the depression centerline by more than 0.75 mm.

A material web having a film layer and a nonwoven layer, along with methods of making the material web, are described. The material web has a plurality of micro-deformations and a plurality of macro-deformations, each of the macro-deformations having a distal end, wherein a first portion of macro-deformations has an open or partially open distal end and wherein a second portion of macro-deformations has distal ends which are configured differently than the distal ends of the first portion, and wherein the material web forms a portion of the topsheet.

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 disposable absorbent article has a topsheet; a backsheet; an absorbent core disposed between the topsheet and the backsheet; and a first plurality of conforming features in at least the absorbent core or a combination of the absorbent core and the topsheet. At least a portion of the are depressions, wherein the depressions have a depression centerline bisecting a length and/or width of the depression. A first strut forms a first sidewall of the depression opposite a second sidewall of the depression formed by a second strut, wherein neither of the first strut nor the second strut extend longitudinally and/or laterally beyond the depression centerline by more than 0.75 mm.

The present invention relates to a method for making an aperture web, comprising moving a micro-textured web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web. The present invention also relates to a method for making an aperture web, comprising forming microtextures on a web, and continuously moving the web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web.