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

An absorbent article in the form of feminine hygiene product or adult incontinence product, comprising a liquid permeable continuous topsheet, a liquid impermeable backsheet, and an absorbent structure comprising an open cell foam disposed between the continuous topsheet and the backsheet,

• the article having a central longitudinally elongate absorbent portion comprising the absorbent structure;
• wherein the continuous topsheet is formed of a section of formed through air bonded 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 weights corresponding to disposition of filaments according to the ordered arrangement;
• wherein the article comprises a hinge portion following a path extending generally longitudinally along one of the wing portions, and
• wherein the hinge portion is defined by one or more of the attenuated regions.

An absorbent article comprising a liquid permeable continuous topsheet, a liquid impermeable backsheet, and an absorbent structure comprising an open cell foam disposed at least partially between the continuous topsheet and the backsheet, the continuous topsheet having a lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,

• the article having a central longitudinally elongate absorbent portion comprising the absorbent structure, flanked by two wing portions opposingly laterally extending from the absorbent portion and being substantially without any portion of the absorbent structure, the continuous topsheet at least partially forming the wing portions;
• wherein the continuous 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 weights corresponding to disposition of the filaments according to the ordered arrangement;
• wherein the attenuated regions comprise one or more channel portions following one or more paths that are not longitudinally centered about the lateral axis.