Shaped Nonwoven

Abstract

A spunbond nonwoven fabric. The fabric has a first surface and a second surface and a visually discernible of three-dimensional features on one of the first and second surface, each of the three-dimensional features defining a microzone. Each microzone has a first region and a second region, the first and second regions having a difference in values for an intensive property. Fibers of the spunbond nonwoven fabric are thermally bonded at the second regions. The second regions are fluid permeable. The fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof

What is claimed is: 
     
         1 . A spunbond nonwoven fabric comprising:
 a first surface and a second surface and a visually discernible pattern of three-dimensional features on at least one of the first and second surface, each of the three-dimensional features defining a microzone comprising a first region and a second region, the first region having a first basis weight and the second region having second basis weight, wherein the first basis weight is different than the second basis weight, and wherein the first basis weight and the second basis weight are both greater than zero;   wherein fibers of the spunbond nonwoven fabric are thermally bonded at the second regions, wherein the second regions are fluid permeable, and wherein the fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof.   
     
     
         2 . The spunbond nonwoven fabric of  claim 1 , wherein the first basis weight is 1.2× different than the second basis weight. 
     
     
         3 . The spunbond nonwoven fabric of  claim 1 , wherein the first basis weight is 1.2× to 10× different than the second basis weight. 
     
     
         4 . The spunbond nonwoven fabric of  claim 1 , wherein the first basis weight is 3× to 50× different than the second basis weight. 
     
     
         5 . The spunbond nonwoven fabric of  claim 1 , wherein fibers of the spunbond nonwoven fabric are thermally bonded at the second regions on the first surface. 
     
     
         6 . The spunbond nonwoven fabric of  claim 1 , wherein the first region has a first thickness, wherein the second region has a second thickness, wherein the first thickness is different than the second thickness, and wherein the first thickness and the second thickness are greater than zero. 
     
     
         7 . The spunbond nonwoven fabric of  claim 1 , wherein the first region has a first volumetric density, wherein the second region has a second volumetric density, wherein the first volumetric density is different than the second volumetric density, and wherein the first volumetric density and the second volumetric density are greater than zero. 
     
     
         8 . An absorbent article comprising the spunbond nonwoven fabric of  claim 1 . 
     
     
         9 . The absorbent article of  claim 8 , wherein the spunbond nonwoven fabric forms a portion of a topsheet. 
     
     
         10 . The absorbent article of  claim 8 , wherein the spunbond nonwoven fabric forms a portion of an outer cover nonwoven. 
     
     
         11 . The spunbond nonwoven fabric of  claim 1 , wherein the spunbond nonwoven fabric has an MD Fuzz Value of less than 0.25 mg/cm 2  when tested according to the Fuzz Level Test. 
     
     
         12 . The spunbond nonwoven substrate of  claim 1 , consisting essentially of continuous spunbond fibers that are bicomponent fibers. 
     
     
         13 . The spunbond nonwoven substrate of  claim 1 , further comprising meltblown fibers. 
     
     
         14 . A spunbond nonwoven fabric comprising:
 a first surface and a second surface and a visually discernible pattern of three-dimensional features on at least one of the first and second surface, each of the three-dimensional features defining a microzone comprising a first region and a second region, the first region having a first thickness and the second region having second thickness, wherein the first thickness is different than the second thickness, and wherein the first thickness and the second thickness are both greater than zero;   wherein fibers of the spunbond nonwoven fabric are thermally bonded at the second regions on the first surface, wherein the second regions are fluid permeable, and wherein the fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof.   
     
     
         15 . The spunbond nonwoven fabric of  claim 14 , wherein the spunbond nonwoven fabric has an MD Fuzz Value of less than 0.25 mg/cm 2  when tested according to the Fuzz Level Test. 
     
     
         16 . The spunbond nonwoven substrate of  claim 15 , comprising bicomponent fibers. 
     
     
         17 . The spunbond nonwoven substrate of  claim 15 , consisting essentially of continuous spunbond fibers that are bicomponent fibers. 
     
     
         18 . A spunbond nonwoven fabric comprising:
 a first surface and a second surface and a visually discernible pattern of three-dimensional features on at least one of the first and second surface, each of the three-dimensional features defining a microzone comprising a first region and a second region, the first region having a first volumetric density and the second region having second volumetric density, wherein the first volumetric density is different than the second volumetric density, and wherein the first volumetric density and the second volumetric density are both greater than zero;   wherein fibers of the spunbond nonwoven fabric are thermally bonded at the second. regions on the first surface, wherein the second regions are fluid permeable, and wherein the fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof.   
     
     
         19 . The spunbond nonwoven fabric of  claim 18 , wherein the spunbond nonwoven fabric has an MD Fuzz Value of less than 0.25 mg/cm 2  when tested according to the Fuzz Level Test. 
     
     
         20 . An absorbent article comprising the spunbond nonwoven fabric of  claim 19 .