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: 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: Apparatuses and processes for aperturing and stretching a web are disclosed. In one embodiment, the method involves feeding a web into a nip that is formed between at least one pair of intermeshing rolls. The first roll is a raised ridge rotary knife aperturing roll and the second roll is a ring roll; both rolls comprise ridges and grooves. The first roll comprises a plurality of spaced-apart teeth extending outwardly from the top surface of the ridges, said teeth having tips, wherein the top surface of said ridges are disposed between the tips of said teeth and the bottom surface of said grooves. These apparatuses and processes enable a web to be formed which comprises apertures having greater open area than previously achievable with traditional processes and apparatuses.

Abstract: Processes for making micro-textured webs are disclosed. The present process includes the steps of providing a precursor web; providing a first pair of mated forming members including a first forming member and a second forming member forming a first deformation zone therebetween; moving the precursor web through the first deformation zone forming a first plurality of structures; providing a second pair of mated forming members including a third forming member and a fourth forming member forming a second deformation zone therebetween; moving the precursor web through the second deformation zone forming a second plurality of structures, and wherein the first plurality of structures is different than the second plurality of structures.

Abstract: The present invention relates to a method for fabricating absorbent article having multiple layers, and deformed zones of targeted performance, and colored regions, the method comprising the steps of forming discrete features on at least one layer, printing colored regions on at least one layer, integrating multiple layers to form an absorbent assembly, and cutting the absorbent assembly into individual absorbent articles, wherein the steps are carried out continuously.

Abstract: An absorbent article comprising a topsheet and laterally extending wings is disclosed. The topsheet having a plurality of clefts is disclosed. The plurality of clefts of the first type can be formed by urging discrete portions of the topsheet in a first direction and the plurality of clefts of the second type are formed by urging discrete portions of the topsheet in a second direction that is different than the first direction. The first or second plurality of clefts can be positioned proximate to a wing or flap of the absorbent article.

Abstract: The present invention relates to a method for fabricating absorbent article having multiple layers, and deformed zones of targeted performance, and colored regions, the method comprising the steps of forming discrete features on at least one layer, printing colored regions on at least one layer, integrating multiple layers to form an absorbent assembly, and cutting the absorbent assembly into individual absorbent articles, wherein the steps are carried out continuously.

Abstract: The present invention relates to a method for fabricating absorbent article having multiple layers, and deformed zones of targeted performance, and colored regions, the method comprising the steps of forming discrete features on at least one layer, printing colored regions on at least one layer, integrating multiple layers to form an absorbent assembly, and cutting the absorbent assembly into individual absorbent articles, wherein the steps are carried out continuously.

Abstract: The present invention relates to a method for fabricating absorbent article having multiple layers, and deformed zones of targeted performance, and colored regions, the method comprising the steps of forming discrete features on at least one layer, printing colored regions on at least one layer, integrating multiple layers to form an absorbent assembly, and cutting the absorbent assembly into individual absorbent articles, wherein the steps are carried out continuously.

Abstract: The present disclosure relates to methods and apparatuses for mechanically bonding substrates together. The apparatus comprises a bonding roll comprising a base surface and plurality of nubs extending from the base surface, each of the plurality of nubs comprising: a sidewall; a bonding surface; and a shoulder connecting the sidewall to the bonding surface. The shoulder comprises a single chamfer or a radius to, inter alia, reduce tearing of the substrates.

Abstract: Processes for making micro-textured webs. The process comprises providing a precursor web; providing a pair of mated forming structures, including a first forming structure and a second forming structure, wherein at least the first forming structure comprises voids, and wherein at least the second forming structure comprises protrusions; and moving the web through a deformation zone of the mated forming structures, wherein the voids of the first forming structure engage with the protrusions of the second forming structure at an engagement position. Discrete three-dimensional elements are formed in the web as the protrusions on the second forming structure engage with the voids on the first mating structure. At least one protrusion has center-to-center spacings of less than about 800 microns with at least three of its adjacent protrusions.

Abstract: A process for making an embossed web. A precursor web is provided between a forming structure and a static pressure plenum. The forming structure has a plurality of discrete protruded elements. Pressure is provided by the static pressure plenum against the precursor web and the forming structure to conform the precursor web to the discrete protruded elements of the forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements having open proximal ends.

Abstract: A process for making an embossed web. A precursor web is provided between a forming structure and a static pressure plenum. The forming structure has a plurality of discrete apertures or depressions. Pressure is provided by the static pressure plenum against the precursor web and the forming structure to force the precursor web into the apertures or depressions of forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements.

Abstract: An apparatus for embossing a web having a static gas pressure plenum and a forming structure disposed in contact to the static gas pressure plenum. The static gas pressure plenum provides a static gas pressure of from about 0.1 MPa to about 25 MPa.

Abstract: A process for making an embossed web. A precursor web is provided between a forming structure and a static pressure plenum. The forming structure has a plurality of discrete protruded elements. Pressure is provided by the static pressure plenum against the precursor web and the forming structure to conform the precursor web to the discrete protruded elements of the forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements having open proximal ends.

Abstract: Included are embodiments for predicting an expected life of a pliable material. Some embodiments of a method include modeling, by a computing device, the pliable material and simulating strain on the pliable material, wherein simulating strain on the pliable material includes creating a strain results file. Similarly, some embodiments of the method include identifying, from the strain results file, a point of strain energy density on the pliable material, accessing a life prediction curve associated with the pliable material to determine a material file, and creating a strain-material file by combining the strain results file and the material file. Still some embodiments of the method include executing software to predict the expected life of the pliable material and predicting the expected life of the pliable material.

Abstract: Apparatus for making micro-textured webs. The apparatus comprises a pair of mated forming structures having a first forming structure, a second forming structure, and a deformation zone; wherein at least the first forming structure comprises voids, and wherein at least the second forming structure comprises protrusions wherein at least one protrusion has center-to-center spacings of less than about 800 microns with at least three of its adjacent protrusions. The voids of the first forming structure are engagable with the protrusions of the second forming structure at an engagement position to form a micro-textured web. In another embodiment, the apparatus comprises a pair of counter-rotating rollers wherein the first roller comprises grooves having a length, wherein the length of the grooves are oriented at an angle different from the machine direction.

Abstract: A process for making an embossed web. A precursor web is provided between a forming structure and a compliant substrate. The forming structure has a plurality of discrete apertures or depressions. Pressure is provided between the compliant substrate and the forming structure to force the precursor web into the apertures or depressions of forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements.

Abstract: A process for making an embossed web. A precursor web is provided between a forming structure and a static pressure plenum. The forming structure has a plurality of discrete apertures or depressions. Pressure is provided by the static pressure plenum against the precursor web and the forming structure to force the precursor web into the apertures or depressions of forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements.

Abstract: A process for making an embossed web includes providing a precursor web a first forming structure having a plurality of discrete first forming elements and a first pressure source and applying pressure between the first pressure source and the first forming structure to force the precursor web to conform to the first forming elements of to form a first embossed web having a plurality of first discrete extended elements. The first embossed web is then provided between a second forming structure having a plurality of discrete second forming elements and a second pressure source and pressure is applied between the second pressure source and the second forming structure to force the first embossed web to conform to the second forming elements to form a second embossed web having a plurality of second discrete extended elements. The resulting embossed web has a plurality of first and second discrete extended elements.