A forming apparatus for forming a plurality of apertures in a nonwoven substrate is provided. The apparatus includes intermeshing members having a first and second member. The first member includes a body portion and a plurality of conical-shaped pins. The plurality of conical-shaped pins each have a first section having a first wall extending from a base portion to a distal portion, at least a portion of the first wall disposed at a first angle greater than 17.5 degrees relative to a central axis. The plurality of conical-shaped pins each have a second section having a second wall extending from a base portion, the base portion extending from the first member body portion, at least a portion of the second wall disposed at a second angle relative to the central axis of each conical-shaped pin, the second angle being different than the first angle and less than 20 degrees.

A method for making an extrusion coated perforated nonwoven web. The method comprises the steps of extruding a molten polyethylene coating onto a nonwoven web, and aperturing the molten polyethylene coating through heat and pneumatic pressure differential to create microperforations therein at a density of between about 35 and about 120 perforations per linear inch. The resulting microperforated nonwoven web is then thermomechanically perforated by feeding it through perforating rolls, at least one of which has raised protuberances to create macroperforations that extend though at least the polyethylene coating. The macroperforations have a density of between about 6 and about 35 perforations per linear inch. The perforated nonwoven web is useful as a topsheet for absorbent articles.

A formed film includes a first surface generally located in a first plane, a second surface generally located in a second plane parallel to and spaced from the first plane, and a third surface generally located in a third plane parallel to and spaced from the first plane and the second plane, in between the first plane and the second plane. A porous structure extends between the second surface and the third surface. A plurality of raised areas have sidewalls that extend between the first surface and the third surface, and top portions that define the first surface. The plurality of sidewalls, the porous structure, and the first plane define a plurality of gathering volumes.

A formed web comprising discrete three-dimensional elements formed therein, wherein at least some of the discrete three-dimensional elements comprise chads with corresponding apertures, wherein the aperture has a perimeter, wherein the chad has a length, wherein the chads are attached along a portion of the aperture perimeter which forms a connection segment, wherein the connection segment is less than about 50% of the entire aperture perimeter, and wherein the web comprises a film.

A perforated non-woven fabric having at least one fiber layer that has a plurality of through holes. The total area of the through holes accounts for 10˜80% of the total area of the perforated non-woven fabric; the opening of the through holes is flat with the surface of the perforated non-woven fabric; and the density of through holes on the perforated non-woven fabric is 3/cm.sup.2˜100/cm.sup.2. The fiber density at the edge of each through hole is similar to or the same as the fiber density in other areas of the perforated non-woven fabric. The fiber surrounds the through hole, and only the surface of the fiber is bonded to each other.

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.

The present disclosure is directed to multi-component topsheets having three-dimensional materials. The present disclosure is directed to absorbent articles having multi-component topsheets having three-dimensional materials. The three-dimensional materials may have apertures. The topsheets may have a first material, a second material, and a third material. The first and second materials may be the same and the third material may be different from the first and second materials. The first and second materials may have a lower basis weight than the third material.

Absorbent articles having three-dimensional, apertured, liquid permeable topsheets, acquisition materials, liquid permeable backsheets, and absorbent cores are disclosed. The absorbent articles provide improved topsheet dryness, reduced collagen rewet, and improved modified fluid acquisition.

Three dimensional nonwoven materials and methods of manufacturing such materials are disclosed. In one embodiment, a method can include providing a precursor web that includes a plurality of fibers and transferring the precursor web to a forming surface having a plurality of forming holes. The method can also include directing a plurality of pressurized fluid streams of entangling fluid in a direction towards the precursor web on the forming surface to move at least some of the fibers into the plurality of forming holes to create a fluid entangled web. The method can further include removing the fluid entangled web from the forming surface such that the at least some of the fibers moved into the plurality of forming holes provide a plurality of nodes. The plurality of nodes can have an anisotropy value greater than 1.0 as determined by the Node Analysis Test Method.

The present invention relates to a three-dimensional nonwoven comprising a first side, a second side, a protruded first area comprising an upper portion formed in the first side and a lower portion formed in the second side, and a second area comprising a plurality of deformations, wherein the upper portion has a shape memory index higher than a shape memory index of the lower portion, an absorbent article comprising the three-dimensional nonwoven, and a process for producing the three-dimensional nonwoven.