A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property.

A composite web including a first continuous web having a first face and a second face; the first web includes a molded portion having at least one protrusion, at least partly delimited by a base portion, on the first face; the composite web includes a segment of a second continuous web joined to the second face of the first web at least at the base portion.

An absorbent body in which a larger amount of a granular absorbent substance penetrates into the inside of a fiber sheet is produced. A fiber sheet having napped one main surface is supplied to a conveying device and conveyed while the other main surface of the fiber sheet is being sucked through a conveyance surface. A granular absorbent substance is sprayed onto the napped one main surface of the fiber sheet to cause the substance to penetrate into the inside of the fiber sheet in a suction section. A pressure difference increasing device is provided that faces the one main surface of the fiber sheet sprayed with the absorbent substance and being conveyed in the suction section, and that suppresses air from flowing through the fiber sheet inward from the conveyance surface to increase the pressure difference between the conveyance surface side and the opposite side of the fiber sheet.

A system having a first polymer source and a spin beam in fluid communication with the first polymer source is provided. The spin beam includes a spinneret assembly having filament nozzles configured and arranged to extrude a plurality of filaments of a first polymer. A gas distribution plate is disposed downstream of the spinneret assembly, and includes a plurality of gas distribution slots that are configured and arranged to receive two or more corresponding filament nozzles of the spinneret assembly therein. A stream of gas is introduced into the plurality of slots to draw and attenuate the filaments extruded by the plurality of filament nozzles. The drawn and attenuated filaments are collected on a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric. A solid additive, such as pulp fibers may be blended with the filaments prior to collecting the filaments on the collection surface.

Extensible nonwoven fabrics having improved elongation, extensibility, abrasion resistance and toughness. In particular, embodiments of the invention are directed to extensible spunbond fabrics comprising a polymeric blend of a metallocene catalyzed polypropylene, polyethylene, and a third polymer component.

A process for forming a composite absorbent structure by advancing a nonwoven web including from 20% to 100% by weight of superabsorbent fibers. Superabsorbent particles may be distributed to the nonwoven web and at least some of the superabsorbent particles may be drawn into void spaces of the nonwoven web to form the composite absorbent structure. The composite absorbent structure may include a nonwoven web comprising from 20% to 100% by weight of superabsorbent fibers, and the superabsorbent particles may be distributed heterogeneously into void spaces within the nonwoven web. The composite absorbent structure may be used in an absorbent article.

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Disposable absorbent articles are disclosed herein having a first and second fold line. The disposable absorbent articles have a topsheet, a backsheet, and an absorbent system disposed therebetween. The absorbent system has a first absorbent core and a second absorbent core which may be configured in an offset manner. And, the absorbent system and/or the first and second fold lines may be configured with respect to the absorbent article to effect a caliper change in the folded article.

A method for making an absorbent article comprising an absorbent core comprising one or more channels, the method comprising the steps of: i. providing a first endless moving surface comprising a plurality of molds typically in the form of pockets, each mold comprising an insert therein, wherein the molds are in fluid communication with an under-pressure source except for said insert such that a suction zone is formed in areas neighboring said insert; ii. feeding a first nonwoven web to said first endless moving surface and over one or more said molds; iii. depositing an absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of said nonwoven web; iv. optionally further selectively removing said absorbent material from areas of the nonwoven web corresponding to said insert; v. applying a second nonwoven web directly or indirectly over the absorbent material, or folding said first nonwoven web, such to sandwich said absorbent material between upper and lower layers of said nonwoven web(s); vi. joining said upper and lower layers together at least in the areas of the nonwoven web(s) corresponding to the insert to form an absorbent core having one or more channels substantially free of absorbent material; vii. optionally joining an acquisition distribution layer to said absorbent core, typically a skin facing surface of said upper layer; viii. optionally laminating said absorbent core and acquisition distribution layer between a liquid pervious topsheet and a liquid impervious backsheet; wherein at least a portion of said insert is porous and is in fluid communication with a positive pressure source such that air is blown out of said insert to form an air cushion or air film around at least an uppermost surface of said insert and in that said absorbent material is thereby forced away from areas of the nonwoven web corresponding to said insert.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.