Pre-strained laminates and methods for making the same

1. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising:

providing a first nonwoven layer configured to be an outer cover in the absorbent article;

providing a second film layer configured to be a backsheet in the absorbent article;

wherein only the first nonwoven layer has a plurality of apertures defined therein;

wherein the second film layer is free of apertures;

applying a pre-strain force to only one of the first nonwoven layer or the second film layer;

joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition;

releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the outer cover and backsheet three-dimensional laminate; and

wherein the laminate is free of elastic strands.

2. The method of claim 1 , wherein at least some of the plurality of apertures are non-homogenous apertures.

3. The method of claim 1 , comprising:

providing a third layer; and

joining the third layer to the first nonwoven layer or to the second film layer.

4. The method of claim 1 , comprising:

applying a pigmented patterned adhesive or an ink to the first nonwoven layer or to the second film layer.

5. The method of claim 1 , wherein the pre-strain force is applied substantially in a machine direction, and wherein the pre-strain force causes the first nonwoven layer or the second film layer to elongate by at least 5%.

6. The method of claim 1 , wherein the plurality of apertures have a plurality of Interaperture Distances, according to the Aperture Test herein, wherein the Interaperture Distances have a distribution having a median and a mean, and wherein the mean is different than the median.

7. The method of claim 1 , comprising only applying the pre-strain force to the first nonwoven layer.

8. The method of claim 2 , wherein the at least some of the plurality of apertures have an Aspect Ratio greater than 2.

9. The method of claim 2 , wherein the at least some of the plurality of apertures have an Average Absolute Feret Angle of at least 20 degrees.

10. The method of claim 9 , wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.

11. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising:

providing a first nonwoven layer configured to be an outer cover of the absorbent article;

providing a second film layer configured to be a backsheet of the absorbent article, wherein the second film layer is free of apertures, wherein only the first nonwoven layer has a plurality of apertures defined therein, and wherein at least some of the plurality of apertures are non-homogenous apertures;

applying a pre-strain force to only one of the first nonwoven layer or the second film layer;

joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition; and

releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the outer cover and backsheet three-dimensional laminate.

12. The method of claim 11 , wherein the at least some of the plurality of apertures have an Average Absolute Feret Angle of at least 20 degrees.

13. The method of claim 12 , wherein the at least some of the plurality of apertures have an Aspect Ratio greater than 2.5.

14. The method of claim 13 , wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.

15. The method of claim 11 , comprising only applying the pre-strain force to the first nonwoven layer.

16. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising:

providing a first nonwoven layer that forms the outer cover;

providing a second film layer that forms the backsheet, wherein the second film layer is free of apertures, wherein only the first nonwoven layer has a plurality of apertures defined therein, wherein at least some of the plurality of apertures are non-homogenous apertures, and wherein the laminate is free of elastic strands;

applying a pre-strain force to only one of the first nonwoven layer or the second film layer, wherein the pre-strain force causes the first nonwoven layer or the second film layer to elongate by at least 5%;

joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition; and

releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the three-dimensional laminate.

17. The method of claim 16 , wherein the plurality of non-homogenous apertures have a plurality of Interaperture Distances, according to the Aperture Test herein, wherein the Interaperture Distances have a distribution having a median and a mean, and wherein the mean is greater than the median.

18. The method of claim 17 , wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.

19. The method of claim 16 , comprising only applying the pre-strain force to the first nonwoven layer.