Abstract: The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps.

Abstract: Disclosed is an improved process for attaching and protecting a mechanical fastener on a disposable absorbent article and a disposable absorbent article produced by the same. The process comprises the following steps: (1) providing a disposable absorbent article which includes an outer cover, a bodyside liner, and an absorbent core disposed between the outer cover and the bodyside liner; (2) providing a mechanical fastener which includes a first fastening element; (3) attaching the first fastening element of the mechanical fastener to the disposable absorbent article; (4) releasably engaging the first fastening element with the disposable absorbent article to protect the first fastening element; and (5) subsequently packaging the disposable absorbent article for commercial sale. The first fastening element and a portion of the disposable absorbent article may be releasably engaged by constrictively passing them between a pair of rotatable nip rolls.

Abstract: The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps.

Abstract: The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps.

Abstract: An integral absorbent article has a longitudinal article length and a lateral article width. The article includes an absorbent composite having first and second longitudinally opposed end regions, laterally opposed side regions, a bodyside surface, an outward surface, and a first longitudinally terminal end edge. The absorbent composite further includes a substantially liquid-impermeable backsheet layer; a liquid permeable topsheet layer; and a retention portion sandwiched between said backsheet and topsheet layers. An extensible outercover is joined to extend over a major portion of said outward surface of the said absorbent composite. The extensible outercover is desirably capable of providing a the selected elongation when subjected to a tensile force. The extensible outercover is also desirably capable of providing a selected, sustained deformation, when subjected to an applied tensile force and then allowed to relax after a removal of the applied force.

Abstract: The present invention provides a combination roller, a machine and process for cutting workpieces from a web moving at a first speed and depositing them on and bonding them to a substrate web moving at a second speed with the functions of cutting, transferring, and bonding all carried out on a single roller. The reduction in roller mass achieved by this roller and machine design permits driving the combination roller at variable speeds by means of a servomotor and servomotor controller. The resulting machine permits electronic rather than machine grade changes as the machine and process are used to produce products having different configurations.

Abstract: A distinctive technique for creating a shaped article (90, 100) includes a pivoting of a first portion (56) of a cooperating web layer (26) substantially about a first joining region (40) to lie laterally adjacent to a first portion (52) of a primary web layer (24). The cooperating web layer (26) has been positioned in a superposed facing relation with the primary web layer (24) with the primary web layer having a first and second, lateral side edge regions (32, 34), and the cooperating web layer having third and fourth, lateral side edge regions (36, 38). The first side edge region (32) of the primary web layer (24) has been synchronized to the third side edge region (36) of the cooperating web layer (26) along the first joining region (40), and the second side edge region (34) of the primary web layer (24) has been synchronized to the fourth side edge region (38) of the cooperating web layer (26) along a second joining region (42) to provide a synchronized laminated web (44).

Abstract: Disclosed is an improved process for attaching and protecting a mechanical fastener on a disposable absorbent article and a disposable absorbent article produced by the same. The process comprises the following steps: (1) providing a disposable absorbent article which includes an outer cover, a bodyside liner, and an absorbent core disposed between the outer cover and the bodyside liner; (2) providing a mechanical fastener which includes a first fastening element; (3) attaching the first fastening element of the mechanical fastener to the disposable absorbent article; (4) releasably engaging the first fastening element with the disposable absorbent article to protect the first fastening element; and (5) subsequently packaging the disposable absorbent article for commercial sale. The first fastening element and a portion of the disposable absorbent article may be releasably engaged by constrictively passing them between a pair of rotatable nip rolls.

Abstract: The invention relates to methods of applying adhesive to a lateral edge of a first web. The method includes transporting the first web along a first path and transporting a second web along a second path generally in surface-to-surface relationship with the first web at the lateral edge, with the second web extending outwardly from the first web. When adhesive is applied such as by spraying to the first web at the lateral edge, at least some adhesive passes outwardly of the lateral edge as overspray and is received by the second web. Thus, adhesive applied to the edge of the first web is received in combination by both of the first and second webs. Both of the first and second webs can be utilized in manufacturing articles. In some embodiments, adhesive is applied at both first and second lateral edges of the first web. In some embodiments, spaced leg cutouts are formed in lateral edges of the web.

Abstract: The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps.

Abstract: This invention relates to apparatus and methods for fabricating a composite web having transverse stretch. In one embodiment a forming plow forms at least one groove in a first web of material. An applicator roll applies a second web of transversely stretchable material to the first web while maintaining a facing portion of the second web in facing relationship with, and spaced from, the portion of the first web formed in the groove. Urging apparatus, such as a push roll having an axis, can intermittently urge the second web into the groove and thereby into surface-to-surface relationship with the first web over substantially the entirety of the facing portion of the second web. The webs can be secured by an adhesive, applied to portions of the first and/or second web, or by ultrasonic bonding, to thereby fabricate the composite web.