Shaped nonwoven fabrics and articles including the same

Abstract

A three-dimensional, nonwoven substrate having at least a non-apertured zone and an apertured zone, and articles or absorbent articles including one of more of such substrates are provided.

What is claimed is: 
     
         1 . A three-dimensional, nonwoven substrate comprising:
 a first surface;   a second surface;   a first side edge;   a second side edge;   a first end edge;   a second end edge;   a central lateral axis; and   a central longitudinal axis extending perpendicular to the central lateral axis;   wherein a line taken in a direction parallel to or perpendicular to the central lateral axis of the three-dimensional, nonwoven substrate comprises:
 a non-apertured, first visually discernible zone in the nonwoven substrate; and 
 a second visually discernible zone in the nonwoven substrate; 
 wherein the first visually discernable zone comprises a pattern of three-dimensional features on the first surface or the second surface; 
 wherein at least some of the three-dimensional features define a microzone comprising a first region and a second region, and wherein the first region and the second region have a difference in value for an intensive property; and 
 wherein the second visually discernable zone defines apertures, wherein the apertures have an Effective Aperture Area in a range of about 0.3 mm 2  to about 15 mm 2 , according to the Aperture Test herein, and wherein the second visually discernable zone has an Effective Open Area in a range of about 3% to about 50%, according to the Aperture Test herein. 
   
     
     
         2 . The nonwoven substrate of  claim 1 , wherein the second visually discernable zone comprises a pattern of second three-dimensional features on the first surface or the second surface, wherein at least some of the second three-dimensional features define a second microzone comprising a third region and a fourth region, and wherein the third region and the fourth region have a difference in value for an intensive property. 
     
     
         3 . The nonwoven substrate of  claim 1 , wherein the apertures have an Effective Aperture Area in a range of about 0.5 mm 2  to about 8 mm 2 , according to the Aperture Test herein, and wherein the second zone has an Effective Open Area in a range of about 5% to about 25%, according to the Aperture Test herein. 
     
     
         4 . The nonwoven substrate of  claim 1 , wherein the first visually discernable zone is positioned proximate to the first end edge, and wherein the second visually discernable zone is positioned proximate to the second end edge. 
     
     
         5 . The nonwoven substrate of  claim 1 , wherein the first visually discernable zone is positioned proximate to the second end edge, and wherein the second visually discernable zone is positioned proximate to the first end edge. 
     
     
         6 . The nonwoven substrate of  claim 1 , wherein portions of perimeters of at least some of the apertures comprise one or more melt lips. 
     
     
         7 . The nonwoven substrate of  claim 1 , wherein perimeters of at least some of the apertures are free of melt lips. 
     
     
         8 . The nonwoven substrate of  claim 1 , wherein at least some of the apertures have an aspect ratio in a range of about 1.5 to about 10. 
     
     
         9 . The nonwoven substrate of  claim 1 , wherein at least some of the apertures have an aspect ratio of less than about 1.5. 
     
     
         10 . The nonwoven substrate of  claim 1 , wherein the difference in value for the intensive property for the first region and the second region is an order of magnitude. 
     
     
         11 . The nonwoven substrate of  claim 1 , wherein the difference in value for the intensive property of the first region and the second region is about 1.2× to about 10×. 
     
     
         12 . The nonwoven substrate of  claim 1 , wherein the intensive property of the first visually discernable zone is basis weight, and wherein the basis weight of every region is greater than zero. 
     
     
         13 . The nonwoven substrate of  claim 1 , wherein the intensive property of the first visually discernable zone is thickness, and wherein the thickness of every region is greater than zero. 
     
     
         14 . The nonwoven substrate of  claim 1 , wherein the intensive property of the first visually discernable zone is volumetric density, and wherein the volumetric density of every region is greater than zero. 
     
     
         15 . The nonwoven substrate of  claim 1 , wherein the line taken in the direction parallel to or perpendicular to the central lateral axis of the three-dimensional, nonwoven substrate comprises:
 a non-apertured, third visually discernible zone in the nonwoven substrate; and   wherein the third visually discernable zone comprises a pattern of third three-dimensional features on the first surface or the second surface;   wherein at least some of the third three-dimensional features in the third discernable zone define a microzone comprising a fifth region and a sixth region, and wherein the fifth region and the sixth region have a difference in value for an intensive property; and   wherein the second visually discernable zone is positioned intermediate the first visually discernable zone and the third visually discernable zone.   
     
     
         16 . The nonwoven substrate of  claim 15 , wherein a portion of the first visually discernable zone is positioned proximate to the first side edge, and wherein a portion of the third visually discernable zone is positioned proximate to the second side edge. 
     
     
         17 . The nonwoven substrate of  claim 15 , wherein a portion of the first visually discernable zone is positioned proximate to the first end edge, and wherein a portion of the third visually discernable zone is positioned proximate to the second end edge. 
     
     
         18 . The nonwoven substrate  claim 1 , wherein the nonwoven substrate is a spunbond nonwoven substrate. 
     
     
         19 . The nonwoven substrate of  claim 2 , wherein the difference in values for the intensive property for the third region and the fourth region is about 1.2× to about 10×. 
     
     
         20 . The nonwoven substrate of  claim 2 , wherein the intensive property for the second visually discernable zone is basis weight, thickness, or volumetric density, and wherein the basis weight, thickness, or volumetric density of every region is greater than zero. 
     
     
         21 . An absorbent article comprising:
 a liquid permeable material comprising the three-dimensional, nonwoven substrate of any one of the preceding claims;   a liquid impermeable material; and   an absorbent core comprising an absorbent material, wherein the absorbent core is positioned intermediate the liquid permeable material and the liquid impermeable material.   
     
     
         22 . A package comprising a plurality of the absorbent articles of  claim 21 , wherein the In-Bag Stack Height is in the range of about 70 mm to about 90 mm, according to the In-Bag Stack Height Test herein. 
     
     
         23 . A three-dimensional, nonwoven substrate comprising:
 a first surface;   a second surface;   a first side edge;   a second side edge;   a first end edge;   a second end edge;   a central lateral axis; and   a central longitudinal axis extending perpendicular to the central lateral axis;   wherein a line taken in a direction parallel to or perpendicular to the central lateral axis of the three-dimensional, nonwoven substrate comprises:
 a non-apertured, first visually discernible zone in the nonwoven substrate; and 
 a second visually discernible zone in the nonwoven substrate; 
 wherein the first visually discernable zone comprises a pattern of three-dimensional features on the first surface or the second surface; 
 wherein at least some of the three-dimensional features define a microzone comprising a first region and a second region, and wherein the first region and the second region have a difference in value for an intensive property; and 
 wherein the second visually discernable zone defines apertures, wherein the apertures have an Effective Aperture Area in a range of about 0.5 mm 2  to about 8 mm 2 , according to the Aperture Test herein, and wherein the second visually discernable zone has an Effective Open Area in a range of about 5% to about 25%, according to the Aperture Test herein. 
   
     
     
         24 . A three-dimensional, nonwoven substrate comprising:
 a first surface;   a second surface;   a first side edge;   a second side edge;   a first end edge;   a second end edge;   a central lateral axis; and   a central longitudinal axis extending perpendicular to the central lateral axis;   wherein a line taken in a direction parallel to or perpendicular to the central lateral axis of the three-dimensional, nonwoven substrate comprises:
 a non-apertured, first visually discernible zone in the nonwoven substrate; and 
 a second visually discernible zone in the nonwoven substrate; 
 wherein the first visually discernable zone comprises a pattern of three-dimensional features on the first surface or the second surface; 
 wherein at least some of the three-dimensional features define a microzone comprising a first region and a second region, and wherein the first region and the second region have a difference in value for an intensive property; 
 wherein the second visually discernable zone defines apertures, wherein the apertures have an Effective Aperture Area in a range of about 0.5 mm 2  to about 10 mm 2 , according to the Aperture Test herein, and wherein the second visually discernable zone has an Effective Open Area in a range of about 5% to about 25%, according to the Aperture Test herein; and 
 wherein the second visually discernable zone comprises a pattern of second three-dimensional features on the first surface or the second surface, wherein at least some of the second three-dimensional features define a second microzone comprising a third region and a fourth region, and wherein the third region and the fourth region have a difference in value for an intensive property.