Shaped Nonwoven

Abstract

A nonwoven fabric including continuous filaments forms the nonwoven fabric. The nonwoven fabric having a first surface, a second surface, and a visually discernible zone on the second surface and extending from the first surface. The visually discernible zone has a pattern of three-dimensional features. The first surface is relatively flat. A first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface. A second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface. Each of the three-dimensional features define a microzone comprising a first region and a second region. The first and second regions have a difference in values for an intensive property.

What is claimed is: 
     
         1 . A nonwoven fabric comprising:
 continuous filaments forming the nonwoven fabric, comprising:
 a first surface, a second surface, and a visually discernible zone on the second surface and extending from the first surface, the visually discernible zone having a pattern of three-dimensional features, wherein the first surface is relatively flat; 
 wherein a first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, or wherein a second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface; and 
 each of the three-dimensional features defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for an intensive property. 
   
     
     
         2 . The nonwoven fabric of  claim 1 , wherein the intensive property is thickness, and wherein the thickness of every region is greater than zero. 
     
     
         3 . The nonwoven fabric of  claim 1 , wherein the intensive property is basis weight, and wherein the basis weight of every region is greater than zero. 
     
     
         4 . The nonwoven fabric of  claim 1 , wherein the intensive property is volumetric density, and wherein the volumetric density of every region is greater than zero. 
     
     
         5 . The nonwoven fabric of  claim 1 , wherein filaments of the nonwoven fabric are thermally bonded at the second regions on the first surface. 
     
     
         6 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric is hot-air through bonded. 
     
     
         7 . The nonwoven fabric of  claim 1 , wherein the second regions are fluid permeable. 
     
     
         8 . The nonwoven fabric of  claim 1 , wherein the continuous filaments are continuous spunbond filaments. 
     
     
         9 . The nonwoven fabric of  claim 1 , wherein the first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, and wherein the second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface. 
     
     
         10 . An absorbent article comprising the nonwoven fabric of  claim 1 . 
     
     
         11 . The absorbent article of  claim 10 , wherein the nonwoven fabric is a topsheet. 
     
     
         12 . The absorbent article of  claim 10 , wherein the nonwoven fabric is an outer cover. 
     
     
         13 . A nonwoven fabric comprising:
 continuous filaments forming the nonwoven fabric, comprising:
 a first surface, a second surface, and a visually discernible zone on the second surface and extending from the first surface, the visually discernible zone having a pattern of three-dimensional features, wherein the first surface is relatively flat; 
 wherein a first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, or wherein a second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface; and 
 each of the three-dimensional features defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for an intensive property, wherein the nonwoven fabric is hot-air through bonded. 
   
     
     
         14 . The nonwoven fabric of  claim 13 , wherein the intensive property is basis weight, and wherein the basis weight of every region is greater than zero. 
     
     
         15 . The nonwoven fabric of  claim 13 , wherein the nonwoven fabric is formed on a drum. 
     
     
         16 . The nonwoven fabric of  claim 13 , wherein the first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, and wherein the second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface. 
     
     
         17 . The nonwoven fabric of  claim 13 , wherein the nonwoven fabric is thermally bonded at the second regions on the first surface, and wherein the second regions are fluid permeable. 
     
     
         18 . An absorbent article comprising the nonwoven fabric of  claim 13 . 
     
     
         19 . A nonwoven fabric comprising:
 continuous filaments forming the nonwoven fabric, comprising:
 a first surface, a second surface, and a visually discernible zone on the second surface and extending from the first surface, the visually discernible zone having a pattern of three-dimensional features, wherein the first surface is relatively flat; 
 wherein a first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, or wherein a second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface; and 
 each of the three-dimensional features defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for basis weight, wherein the basis weight of the first region and the second region are both greater than zero, and wherein the nonwoven fabric is hot-air through bonded. 
   
     
     
         20 . The nonwoven fabric of  claim 19 , wherein the first plurality of the three-dimensional features have different Z-direction maximum dimensions relative to the first surface, and wherein the second plurality of the three-dimensional features have substantially the same Z-direction maximum dimensions relative to the first surface.