Abstract: A feminine hygiene pad is disclosed. The disclosed pad has a longitudinal axis and a lateral axis, and has a topsheet including a nonwoven web, a backsheet, and an absorbent structure between the topsheet and the backsheet. The nonwoven web includes at least a first arrangement of first apertures having a first average size, and a second arrangement of second apertures having a second average size. The first average size is greater than the second average size. The first arrangement occupies a rectangular central region centered about the longitudinal axis and straddling the lateral axis. The first average size is 0.4 mm2 to 0.6 mm2; and the central region has an Average Percent Open Area of 1 to 12 percent. The second arrangement occupies one or more regions laterally and/or longitudinally outboard of the central region, and the second average size is 0.05 mm2 to 0.2 mm2.

Abstract: A single step method for imparting a pattern of apertures in a fibrous nonwoven web is disclosed. The method may include providing a pinned roller bearing a pattern of aperturing pins thereon; providing an opposing roller; arranging the rollers so as to form a nip therebetween, wherein the nip has effectively zero clearance between top surfaces of the pins and outermost surfaces of the opposing roller; providing heating energy to one or both of rollers; rotating the rollers and conveying the nonwoven web through the nip, whereby material constituting fibers of the nonwoven web is at least partially melted and expressed from regions between the top surfaces of the pins and the opposing roller, and accumulates on the web about perimeter edges of the pin top surfaces. Resulting features of the nonwoven web, and products in which it may be incorporated as a component, are also disclosed.

Abstract: A disposable absorbent article having a topsheet, a backsheet, and an absorbent core structure disposed therebetween. The absorbent core structure includes an upper nonwoven layer comprising polymer fibers, a lower nonwoven layer comprising polymer fibers, and an inner core layer disposed between the upper and lower nonwoven layers. The inner core layer includes from about 50% to about 85% cellulosic fibers, by weight of the inner core layer, and superabsorbent particles. The inner core layer is contained within the nonwoven layers by substantially sealing at least a left side region and a right side region of the upper and lower nonwoven layers. The absorbent article has a CD Dry Bending Stiffness between about 10 to about 30 N·mm2 as measured according to the Wet and Dry CD and MD 3 Point Bend Method and a Total IFF+SFF value of between about 20 and about 200 mg as measuring according to the Acquisition Time and Rewet Method.

Abstract: A disposable absorbent article having a topsheet, a backsheet, and an absorbent core structure disposed between the topsheet and backsheet. The absorbent core structure includes an upper nonwoven layer comprising polymer fibers; a lower nonwoven layer comprising polymer fibers; and an inner core layer disposed between the upper and lower nonwoven layers. The inner core layer may include from about 50% to about 85% cellulosic fibers, by weight of the inner core layer, and from about 15% to about 50% superabsorbent particles, by weight of the inner core layer. The absorbent article may have a CD Dry Bending Stiffness between about 10 N mm2 to about 30 N·mm2 as measured according to the Wet and Dry CD and MD 3 Point Bend Method and a 5th Cycle Wet % Recovery of between about 29% and about 40% as measured according to the Wet and Dry Bunched Compression Method.

Abstract: A disposable absorbent article having a front end region, a back end region, and a middle region disposed between the front and back end regions. The absorbent article includes a topsheet; a backsheet; an absorbent core structure disposed between the topsheet and backsheet; and a flex bond channel region formed in at least the middle region. The absorbent core structure includes an upper nonwoven layer having polymer fibers; a lower nonwoven layer having polymer fibers; and an inner core layer disposed between the upper and lower nonwoven layers. The flex bond channel region has a dry channel depth of at least 1.0 mm and a channel width of from about 1.0 mm to about 3.0 mm. The flex bond channel region has a CD Bending Resistance Index of from about 1.1 to about 3.0, and a Dry MD Bending Resistance of less than about 0.04 N/mm.

Abstract: A disposable absorbent article having a topsheet, a backsheet, and an absorbent core structure disposed therebetween. The absorbent core structure includes an upper nonwoven layer comprising polymer fibers and having a basis weight of from about 35 to about 85 gsm; a lower nonwoven layer comprising polymer fibers and having a basis weight of from about 10 to about gsm; and an inner core layer disposed between the upper and lower nonwoven layers. The inner core layer comprises from about 50% to about 85% cellulosic fibers, by weight of the inner core layer, and from about 15% to about 50% superabsorbent particles, by weight of the inner core layer. The absorbent core structure has an average density of between about 0.045 g/cm3 and about 0.15 g/cm3. The inner core layer is contained within the nonwoven layers by substantially sealing at least a left and right side region of the upper and lower nonwoven layers.

Abstract: Aspects of the present disclosure relate to methods and apparatuses for relofting nonwoven substrates. During the relofting process, a substrate is directed to advance in a first direction such that a length of the substrate is in a facing relationship with a radiation source. The advancing substrate is relofted by irradiating the length of the substrate with infrared radiation from the infrared radiation source. The substrate comprises a first caliper upstream of the radiation source and the substrate comprises a second caliper downstream of the radiation source greater than the first caliper. The substrate may also be redirected around an axis to advance the substrate in a second direction, wherein the second direction is different than the first direction. The axis may be selectively movable between a first position and a second position to selectively subject the substrate to infrared radiation and remove the substrate from the infrared radiation.

Abstract: An apertured nonwoven substrate is disclosed. The apertured nonwoven substrate has a first area having a first caliper, a second area having a plurality of apertures, and wherein the second area has a second caliper. A ratio of the first caliper to the second caliper is at least about 1.35, as measured according to Caliper Test, and the first area has an airy index no less than about 270%, as measured according to Caliper Test.

Abstract: A process for deforming a web is disclosed. The steps include forming a plurality of microscopic aberrations in a first layer and/or second layer of a precursor web. The microscopic aberrations comprising sidewalls and an aperture disposed at a distal end of the sidewalls. The first layer extends laterally outboard more than the second layer. The precursor web is advanced to a forming unit. The plurality of macroscopic features is simultaneously formed in the precursor web, including first and second features; the first features are disposed in an area of overlap between the first and second layer; the second features are disposed in an area laterally outboard of the second layer; the microscopic aberrations extend in a first direction from the precursor web; the first and second features extend in a second direction from the precursor web; and wherein the first direction is opposite the second direction.

Abstract: Methods for deforming a multilayer web are disclosed. Steps of the method include: supplying a first layer of a precursor web; supplying a second layer of the precursor web onto at least the first area of the first layer; forming a plurality of first features and a plurality of second features in the precursor web. The plurality of first features are apertures formed in a first area of the precursor web, and the plurality of second features are formed in a second area of the precursor web in a positive and/or negative Z-direction. The plurality of first features and the plurality of second features are formed simultaneously.

Abstract: Aspects of the present disclosure relate to methods and apparatuses for relofting nonwoven substrates. During the relofting process, a substrate is directed to advance in a first direction such that a length of the substrate is in a facing relationship with a radiation source. The advancing substrate is relofted by irradiating the length of the substrate with infrared radiation from the infrared radiation source. The substrate comprises a first caliper upstream of the radiation source and the substrate comprises a second caliper downstream of the radiation source greater than the first caliper. The substrate may also be redirected around an axis to advance the substrate in a second direction, wherein the second direction is different than the first direction. The axis may be selectively movable between a first position and a second position to selectively subject the substrate to infrared radiation and remove the substrate from the infrared radiation.

Abstract: A disposable absorbent article having a topsheet, a backsheet, and an absorbent core disposed therebetween is described herein. The topsheet includes a first zone disposed between a second zone and a third zone; a first end area and a second end area; and an array of features which includes one of apertures, tufts, ridges, or grooves disposed in the first zone. A plurality of bond sites are disposed in the second and third zones. The plurality of bond sites are configured in a curvilinear manner in at least the first end area or the second end area and mask a boundary of the first zone.

Abstract: A process for deforming a web is disclosed. The steps include forming a plurality of microscopic aberrations in a first layer and/or second layer of a precursor web. The microscopic aberrations comprising sidewalls and an aperture disposed at a distal end of the sidewalls. The first layer extends laterally outboard more than the second layer. The precursor web is advanced to a forming unit. The plurality of macroscopic features is simultaneously formed in the precursor web, including first and second features; the first features are disposed in an area of overlap between the first and second layer; the second features are disposed in an area laterally outboard of the second layer; the microscopic aberrations extend in a first direction from the precursor web; the first and second features extend in a second direction from the precursor web; and wherein the first direction is opposite the second direction.

Abstract: The present invention is directed to methods for deforming a web comprising the steps of supplying a precursor web; weakening the precursor web at a plurality of locations to create a plurality of weakened, melt-stabilized locations in precursor web; and forming a plurality of first features and a plurality of second features throughout the first and second layers of the web in the z-direction, wherein the plurality of first and second features are formed simultaneously.

Abstract: Methods for deforming a multilayer web are disclosed. Steps of the method include: supplying a first layer of a precursor web; supplying a second layer of the precursor web onto at least the first area of the first layer; forming a plurality of first features and a plurality of second features in the precursor web. The plurality of first features are apertures formed in a first area of the precursor web, and the plurality of second features are formed in a second area of the precursor web in a positive and/or negative Z-direction. The plurality of first features and the plurality of second features are formed simultaneously.

Abstract: The present invention is directed to methods for deforming a web comprising the steps of supplying a first layer of a web; weakening the first layer at a plurality of locations to create a plurality of weakened, melt-stabilized locations in the first layer; supplying a second layer of the web onto at least part of the first layer; and forming a plurality of first features in the first layer and a plurality of second features throughout the first and second layers of the web in the z-direction, wherein the plurality of first and second features are formed simultaneously.

Abstract: An unwind apparatus for obtaining, loading, splicing, and unwinding convolutely wound rolls of web material and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind apparatus provides for a multi-axis robot and an end effector operatively connected to the multi-axis robot. The end effector provides for a stationary motor, a rotational coupling mechanically coupled to the stationary motor, and, a mandrel mechanically coupled to the rotational coupling. The mandrel is capable of releasably engaging the convolutley wound rolls of web material.

Abstract: A web unwind stand for obtaining, loading, splicing, and unwinding convolutely wound rolls of web material and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind stand comprises splicing means, a first positionable roll grasping apparatus for obtaining and disposing a first of the convolutely wound rolls proximate to, and relative to, the splicing means, and, second positionable roll grasping apparatus for obtaining and disposing a second of the convolutely wound rolls proximate to, and relative to, the splicing means.

Abstract: A web unwind stand for obtaining, loading, splicing, and unwinding a web material from a plurality of convolutely wound rolls and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind stand has a frame, a positionable roll grasping apparatus having a mandrel connectively engaged thereto and, splicing means. The positionable roll grasping apparatus is capable of obtaining and disposing the convolutely wound rolls proximate to the splicing means relative to the frame.

Abstract: A mandrel suitable for supporting and unwinding a convolutely wound web material is disclosed. The mandrel has a mandrel shaft with a longitudinal axis, a plurality of mandrel arms extending from the mandrel shaft, and at least one expansion element disposed upon one of the mandrel arms. The mandrel shaft is capable of rotating about the longitudinal axis. Each of the mandrel arms is disposed and rotatable about the longitudinal axis. The at least one expansion element is expandable radially away from the mandrel arm relative to the longitudinal axis. The convolutely wound web material is disposable about each of the mandrel arms. Further, the at least one expansion element is expandable into contacting and releasable engagement with the convolutely wound web material. The convolutely wound web material is fixably and releasably disposed about each of the mandrel arms.