Absorbent article with function-formed topsheet, and method for manufacturing

An absorbent article in the form of a feminine hygiene pad, comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent structure disposed between the topsheet and the backsheet, the topsheet having a central lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,

• wherein the topsheet is formed of a section of formed nonwoven web material comprising an accumulation of filaments and having an absorbent-facing side and a wearer-facing side, the wearer-facing side comprising an ordered arrangement of zones, each zone comprising one or more attenuated regions adjacent to one or more built-up regions,
• wherein the attenuated regions have a first average basis weight and the built-up regions have a second average basis weight, wherein the first average basis weight is less than the second average basis weight, the difference in basis weight corresponding to disposition of the filaments according to the ordered arrangement;
• wherein the attenuated regions comprise a plurality of discrete low bulk portions arranged in a pattern disposed in a direction generally along the longitudinal axis;
• wherein the article is configured to exhibit a Rewet of no greater than 0.50 g;
• wherein the article is configured to exhibit an Acquisition Time of no greater than 25 seconds;
• wherein the attenuated regions comprise a configuration of one or more channel portions predominately circumscribing a discharge locus on the longitudinal axis;
• and
• wherein the one or more channel portions are centered about the discharge locus, and wherein the one or more channel portions extend a full length of the topsheet.

An absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent structure disposed between the topsheet and the backsheet, the topsheet having a central lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,

• wherein the topsheet is formed of a section of formed nonwoven web material comprising an accumulation of filaments and having an absorbent-facing surface and a wearer-facing surface,
• wherein the nonwoven web material has been formed via continuous deposition of spun filaments onto a forming belt having an outer receiving side and an inner side and moving along a machine direction through a working location, to form a batt of filaments deposited on the receiving side of the forming belt, the forming belt comprising an airflow permeable substrate belt and an ordered arrangement of airflow blocking structures disposed on the substrate belt, thereby imparting to the forming belt an ordered arrangement of airflow-permeable regions and airflow-blocked regions coextensive with the airflow blocking structures, the airflow blocking structures extending in a z-direction outward from the substrate belt so as to have a z-direction depth on the receiving side of the forming belt;
• wherein before and as they contact the forming belt the filaments are entrained in air flow directed at and through the belt generally along the z-direction, such that the filaments accumulate on the forming belt to a greater second average basis weight over the airflow-permeable regions and to a lesser first average basis weight over the airflow- blocked regions, to create built-up regions of the batt over the airflow-permeable portions and attenuated regions of the batt over the airflow-blocked regions;
• wherein the batt is consolidated into a nonwoven web material following its formation on the forming belt;
• whereby the attenuated regions form a plurality of z-direction depressions predominately in the wearer-facing surface of the section of formed nonwoven web material, the plurality depressions defining a configuration of one or more channel portions following one or a plurality of paths, the one or plurality of paths being substantially symmetric about the longitudinal axis and predominately circumscribing a discharge locus on the longitudinal axis;
• and the plurality of depressions defining a pattern of discrete low bulk portions arranged in a direction generally along the longitudinal axis;
• and
• wherein the one or more channel portions are centered about the discharge locus, and wherein the one or more channel portions extend a full length of the topsheet.