Method for deforming a web

A process for deforming a multilayer web, the process comprising the steps of:

• a) providing a precursor web comprising a first layer, a second layer, a first area where the first and second layers exist and a second area where the second layer does not exist and a third area disposed between the first area and the second area where the first layer and the second layer exist,
• b) forming a plurality of first features and a plurality of second features and a plurality of third features in the precursor web simultaneously,
• wherein the plurality of first features are formed in the first area of the precursor web and the plurality of second features are formed in the second area of the precursor web and the plurality of third features are formed in the third area, by feeding the precursor web in a machine direction into a nip that is formed between two intermeshing rolls comprising;
• a first roll having a surface, a circumference and an axis, and comprising a first region comprising a plurality of first forming elements and a second region comprising a plurality of second forming elements on its surface, and a third region comprising a plurality of third forming elements on its surface;
• and
• a second roll having a surface, a circumference and an axis, and comprising a first region comprising a plurality of circumferentially-extending ridges separated by grooves, and a second region comprising a plurality of circumferentially-extending ridges separated by grooves on its surface, and
• when the precursor web is fed into the nip, at least some of the plurality of first forming elements in the region of the first roll extend inward toward the axis of the second roll beyond at least some of the plurality of circumferentially-extending ridges in the first region of the second roll to form the plurality of first features;
• and at least some of the second forming elements in the second region of the first roll extend inward toward the axis of the second roll beyond at least some of the plurality of circumferentially-extending ridges in the second region of the second roll to form the plurality of second features, and wherein the second layer forms a portion of an outer-facing surface on an absorbent article, at least some of the third forming elements in the second roll extend inward toward the axis of the first roll beyond at least some of the plurality of circumferentially-extending ridges in the third region of the first roll to form the plurality of third features.

A process for fabricating an absorbent article, the absorbent article comprising a liquid permeable topsheet and a liquid impermeable backsheet, the method comprising the steps of:

• a) providing a precursor topsheet comprising a first layer and a second layer, the precursor topsheet comprising a first surface and an opposing second surface;
• b) weakening the precursor topsheet at a plurality of locations to create a plurality of weakened, melt-stabilized locations in a first area of the precursor topsheet where both the first layer and the second layer exist;
• c) forming a plurality of first features and a plurality of second features and a pluralty of third features in the precursor topsheet simultaneously;
• d) supplying a precursor backsheet onto the second layer of the precursor topsheet and integrating the precursor topsheet and the precursor backsheet to form an absorbent article assembly;
• and
• e) severing the absorbent article assembly into individual absorbent articles,
• wherein the plurality of first features are formed coincident with the plurality of weakened, melt-stabilized locations in the first area of the precursor topsheet, and
• wherein the plurality of second features are formed in a second area of the precursor topsheet where the second layer does not exist, and
• wherein the plurality of third features are formed in a third area of the precursor topsheet disposed between the second area and the first area, wherein the plurality of third features are created in both the first layer and second layer, wherein the plurality of second features extend in a first direction away from the first surface, wherein the plurality of third features extend in a second direction away from the first surface, and wherein the first direction is opposite the second direction.