A disposable absorbent having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, is described herein. The topsheet has first and second webs where the second web forms a body-contacting surface of the disposable absorbent article and the first web is disposed between the second web and the absorbent core. The second web is hydrophobic compared to the first web. And, the second web is a nonwoven with a plurality of fibers having a diameter less than about 10 microns.

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 topsheet for use with an absorbent article is provided and comprises a first layer and a second layer. The first layer may be a spunlace nonwoven and may comprise at least 15% by weight of natural fibers by total weight of the first layer. The first layer may comprise a plurality of protrusions and a plurality of apertures. The first layer and the second layer may be in contact with each other between the majority of the protrusions. The second layer may have a plurality of apertures at least partially aligned with the apertures of the first layer. The first layer may have a minimum CD strength of at least 3N/(5 cm), according to the Tensile Strength Test Method.

The present disclosure is directed to substrates or topsheets having repeating patterns of apertures for absorbent articles. Each of the repeat units comprises at least three apertures.

A topsheet for use with an absorbent article is provided and comprises a first layer and a second layer. The first layer is a spunlace nonwoven and comprises at least 15% by weight of natural fibers by total weight of the first layer. The first layer comprises a plurality of protrusions and a plurality of apertures. The first layer and the second layer are in contact with each other between the plurality of the protrusions. The second layer has a plurality of apertures at least partially aligned with the apertures of the first layer. The first layer has a minimum CD strength of at least 3N/(5 cm), according to the Tensile Strength Test Method.

An apertured nonwoven web is provided. The apertured nonwoven web comprises carded fibers, a first side, and a second side. The apertured nonwoven web defines a plurality of apertures therein. The apertures may each have a first side aperture size and a second side aperture size, and a ratio of the first side aperture size to the second side aperture size may be between about 1.15:1 to about 1:1.15. The plurality of apertures may have an aperture size regularity of about 1% to about 15%. The plurality of apertures may have an aperture shape regularity between about 1% to about 12%.

A three-dimensional sheet material can be provided with a pattern of various material treatments. The material treatments can include a pattern of embossments and a pattern of apertures. The three-dimensional sheet material can be utilized in a personal care absorbent article including, but not limited to, diapers, training pants, incontinence products, feminine hygiene products such as sanitary napkins and panty liners, as well as other absorbent article such as bandages and wound dressings.

An apparatus for manufacturing a formed film includes a first forming station configured to receive a polymer web and a second forming station configured to receive the polymer web from the first forming station after the polymer web has been apertured. The first forming station has a first forming structure with a plurality of first openings configured to form a plurality of apertures in the polymer web. The second forming station includes a second forming structure with a plurality of second openings and an overlying pattern configured to form raised areas in the polymer web to create a three-dimensional formed film.

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.

The present disclosure is directed to substrates or topsheets having repeating patterns of apertures for absorbent articles. Each of the repeat units comprises at least three apertures.