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.

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.

The present disclosure is directed to an absorbent article comprising a liquid pervious topsheet, a backsheet, an absorbent core disposed between the topsheet and the backsheet, and an outer cover forming at least part of a garment-facing surface of the absorbent article, the outer cover comprising a three-dimensional substrate, wherein the three-dimensional substrate comprises a first layer and a second layer, and a plurality of protrusions where the first layer is unbonded to the second layer, and wherein the absorbent article has a Qmax-wet of 1300 W/m.sup.2 or less as measured according to Qmax Test.

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

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 apparatus for making a multilayer absorbent element apt to be incorporated in a sanitary article is provided. The apparatus has an embossing roller bearing a plurality of protruding elements, a pierced roller bearing a plurality of protruding elements and cavities, and a unit of cohesion and drilling. The configuration of the apparatus is such that, after a first layer of sheet material is deformed by the embossing roll and the perforated roller continues to slide on the pierced roller, a second layer of sheet material is superimposed. The first and second layer of sheet material are then carried to the joining and piercing unit in which, at the intermediate zones of the first layer, it forms a plurality of holes passing through the first and second layer and joins them near or at the plurality of holes.

A patterned apertured web includes a plurality of first arrays forming a first zone in the patterned apertured web. At least some of the first arrays include a first plurality of land areas and a first plurality of apertures. At least some of the first plurality of land areas surround at least some of the first plurality of apertures. The first plurality of apertures of the first zone have a plurality of Interaperture Distances, according to the Aperture Test. The Interaperture Distances of the first zone have a first distribution having a first mean and a first median. The first mean is greater than the first median by at least 4%.

An absorbent article comprises a three-dimensional liquid permeable topsheet. The topsheet comprises a first layer comprising a hydrophobic material and a second layer comprising a hydrophilic material. The first layer is joined to the second layer. The topsheet comprises 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 absorbent article comprises a liquid impermeable backsheet, an acquisition material, an absorbent core disposed at least partially intermediate the acquisition material and the liquid impermeable backsheet, and an indicia. The indicia is on the acquisition material or the liquid permeable topsheet. The indicia is visible from a wearer-facing side of the absorbent article. The indicia is different color than the acquisition material or the liquid permeable topsheet.

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.