Absorbent article with corrugated elastomer laminate and method for making corrugated elastomer laminate

Abstract

The present disclosure relates to absorbent articles and methods for making absorbent articles, as well as elastomer laminates and methods for making corrugated elastomer laminates useful as components of absorbent articles.

Description

Technical Field

[0001] The present disclosure relates to absorbent articles and methods for making absorbent articles, and more particularly to elastomeric laminates and methods for making corrugated elastomeric laminates that can be used as components of absorbent articles. Background Art

[0002] Various types of articles, such as diapers and other absorbent articles, can be assembled by adding each component to the continuous material web of advancement and / or otherwise changing the continuous material web of advancement along the assembly line. For example, in some processes, the material web of advancement is combined with other material webs of advancement. In other examples, each component produced by the material web of advancement is combined with the material web of advancement, and then combined with other material webs of advancement. In some cases, each component produced by one or more fiber webs of advancement is combined with other each component produced by other fiber webs of advancement. The material web and components used to make diapers may include: backsheet, topsheet, leg cuff, waistband, absorbent core components, front ear piece and / or back ear piece, fastening components, and various types of elastic fiber webs and components such as leg elastic components, barrier leg cuff elastic components, stretch side pieces and waist elastic components. After the desired components are assembled, the fiber web of advancement and the components are finally cut to separate the fiber web into discrete diapers or other absorbent articles.

[0003] Some absorbent articles have parts including elastic laminates. Such elastic laminates may include an elastic material bonded between two substrates. The elastic material may include an elastic film and / or an elastic strand. In some laminates, two nonwovens may be deformed to produce corrugations, and when the elastic strand is in a stretched state, the elastic strand is engaged between two corrugated nonwovens. Therefore, the nonwoven is gathered between the position where the nonwoven is bonded to each other and the elastic strand. The resulting elastic laminate may be stretched to the extent that the corrugation allows the elastic strand to extend. However, the process for assembling such laminates may utilize an adhesive applied to the full length of the elastic strand to anchor the elastic strand and connect two nonwovens together. Therefore, a relatively large amount of adhesive may be used to help ensure the attachment of the elastic strand to the corrugation. As a result, when the laminate is stretched at a relatively high rate, a relatively large adhesive coating may hinder the shrinkage rate of the elastic component.

[0004] It would therefore be beneficial to provide elastic laminates and methods and apparatus for producing such elastic laminates in which elastic strands can be bonded between corrugated substrates at desired locations to help reduce negative effects on the shrinkage rate of the laminate. Summary of the invention

[0005] In one form, a method for preparing an elastomeric laminate includes the following steps: providing a first corrugated substrate by forming ridges alternating with depressions in a first substrate along a machine direction; providing a second corrugated substrate by forming ridges alternating with the depressions in a second substrate along the machine direction; advancing the elastic strand in the machine direction; stretching the elastic strand in the machine direction; after the step of stretching the elastic strand, intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand; bonding discrete lengths of the elastic strand to the first corrugated substrate and the second corrugated substrate and bonding the elastic strand between the first corrugated substrate and the second corrugated substrate using a first bond formed by the discrete areas of the first adhesive; and bonding the depressions of the first corrugated substrate directly to the depressions of the second corrugated substrate using a second bond located between consecutive first bonds along the machine direction.

[0006] In another form, a method for preparing an elastomeric laminate includes the following steps: providing a first corrugated substrate by forming ridges alternating with depressions in the first substrate along a machine direction; providing a second substrate, wherein the second substrate is not corrugated; advancing the elastic strand in the machine direction; stretching the elastic strand in the machine direction; after stretching the elastic strand, intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand; bonding discrete lengths of the elastic strand to the first corrugated substrate and the second substrate and bonding the elastic strand between the first corrugated substrate and the second substrate using a first bond formed by the discrete areas of the first adhesive; and bonding the depressions of the first corrugated substrate directly to the second substrate using a second bond located between consecutive first bonds along the machine direction.

[0007] In yet another form, a method for preparing an elastomeric laminate includes the steps of providing a first substrate and a second substrate; corrugating at least one of the first substrate and the second substrate by forming ridges alternating with depressions in at least one of the first substrate and the second substrate along a machine direction; advancing the elastic strand in the machine direction; stretching the elastic strand in the machine direction; bonding discrete lengths of the elastic strand between the first substrate and the second substrate using a first bond; and bonding the first substrate directly to the second substrate using a second bond located between consecutive first bonds along the machine direction.

[0008] In still another form, an elastomeric laminate comprises: a first substrate; a second substrate, wherein at least one of the first substrate and the second substrate is corrugated; an elastic strand positioned between the first substrate and the second substrate; wherein discrete lengths of the elastic strand are bonded to the first substrate and the second substrate using a first bond; wherein the first substrate and the second substrate are directly bonded to each other using a second bond positioned between continuous first bonds; and wherein the elastic strand extends through the second bond, and the elastic strand is capable of retracting and stretching through the second bond. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1A A front perspective view of the diaper pants.

[0010] Figure 1B A rear perspective view of the diaper pants.

[0011] Figure 2 In a flat, uncontracted state Figure 1A and Figure 1B A plan view of the diaper pants shown after partial cut-away.

[0012] Figure 3A Taken along Route 3A-3A Figure 2 A cross-sectional view of a diaper pants.

[0013] Figure 3B Taken along line 3B-3B Figure 2 A cross-sectional view of a diaper pants.

[0014] Figure 4A is a schematic side view of converting equipment suitable for assembling a corrugated elastic laminate.

[0015] Fig.4A1 Isometric view of the corrugation forming roller.

[0016] Figure 4A2 Is an isometric view of a corrugating roller with bonding elements.

[0017] Figure 4B is a schematic side view of another configuration of converting equipment suitable for making corrugated elastic laminates.

[0018] Figure 4B1 An isometric view of the anvil roll.

[0019] Figure 4B2 is an isometric view of an anvil roll with bonding elements.

[0020] Figure 4C A schematic side view of another configuration of a converting apparatus suitable for making corrugating rollers.

[0021] Fig.4C1 is an isometric view of an ultrasonic horn having an energy transfer surface including a raised engagement region.

[0022] Figure 5 For along Figure 4A , Figure 4B and Figure 4C A view of the first substrate taken at section 5-5 in FIG.

[0023] Figure 6 For along Figure 4A , Figure 4B and Figure 4C A view of a first substrate having corrugations taken at section 6-6 in FIG.

[0024] Figure 7 For along Figure 4A , Figure 4B and Figure 4C A view of the second substrate taken at section 7-7 in FIG.

[0025] Figure 8 For along Figure 4A A view of a second substrate with corrugations taken at section 8-8 in FIG.

[0026] Fig. 9 For along Figure 4A , Figure 4B and Figure 4C A view of the elastic strand taken at section 9-9 in FIG.

[0027] Fig.10 is a view of the elastic laminate taken along section 10 - 10 in FIG. 4 .

[0028] Fig. 10A For along Fig.10 A view of the elastic laminate taken at section 10A-10A in FIG.

[0029] Fig. 10B For along Fig.10 A view of the elastic laminate taken at section 10B-10B in FIG.

[0030] Fig.11 for Fig.10 Perspective view of an elastic laminate.

[0031] Fig.12 In contracted state Fig.11 Perspective view of an elastic laminate.

[0032] Fig.13 For along Figure 4B and Figure 4C A view of the elastic laminate taken at section 13-13 in FIG.

[0033] Fig.13A For along Fig.13 A view of the elastic laminate taken at section 13A-13A in FIG.

[0034] Fig. 13B For along Fig.13 A view of the elastic laminate taken at section 13B-13B in FIG.

[0035] Fig.14 For along Figure 4B and Figure 4C A view of the elastic laminate taken at section 14-14 in FIG.

[0036] Fig.14A For along Fig.14 A view of the elastic laminate taken at section 14A-14A in FIG.

[0037] Fig. 14B For along Fig.14 A view of the elastic laminate taken at section 14B-14B in FIG.

[0038] Fig.15 for Fig.13 and Fig.14 Perspective view of an elastic laminate.

[0039] Fig.16 In contracted state Fig.15 Perspective view of an elastic laminate.

[0040] Fig.17 Schematic diagram of the belly-shaped elastic cutting process.

[0041] Fig.18 Schematic diagram of the diaper pants assembly process. DETAILED DESCRIPTION

[0042] The following term explanations may help understand the present disclosure:

[0043] "Absorbent article" refers herein to consumer products whose primary function is to absorb and retain soil and waste. Absorbent articles may include sanitary napkins; tampons; panty liners; interlabial devices; wound dressings; wipes; disposable diapers, including taped diapers and diaper pants, inserts for diapers with reusable outer covers, adult incontinence diapers, adult incontinence pads, and adult incontinence pants. The term "disposable" is used herein to describe absorbent articles that are not generally intended to be laundered or otherwise restored or reused as absorbent articles (e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted, or disposed of in other environmentally compatible manners).

[0044] "Elastic", "elastomeric" or "elastomeric" refer to materials that exhibit elastic properties and include any material that can be stretched or elongated to an elongation of more than 10% of its original length when a force is applied to its relaxed original length, and will substantially recover to about its original length when the applied force is released.

[0045] As used herein, the term “joined” includes configurations in which an element is directly secured to another element by being directly attached to the other element, as well as configurations in which the element is indirectly secured to another element by being attached to an intermediate member which is in turn attached to the other element.

[0046] As used herein, the terms "registration process," "registration system," "registration," "registered," or "registered" refer to a machine controlled process or system used to control a substrate or laminate (which may have a plurality of preformed objects, such as openings or, bonds, graphics, patterns, design elements, and / or logos, spaced apart at pitches that can vary along the processing direction) in a converting line for producing articles by adjusting the position of the preformed objects on the substrate or laminated object to a target position constant associated with a pitch-line unit operation of the converting line.

[0047] The term "substrate" is used herein to describe a material that is primarily two-dimensional (i.e., in the XY plane) and whose thickness (in the Z direction) is relatively small (i.e., 1 / 10 or less) compared to its length (in the X direction) and width (in the Y direction). Non-limiting examples of substrates include fiber webs, one or more layers of fiber materials, nonwovens, films, and foils (such as polymer films or metal foils). These materials may be used alone or may include two or more layers laminated together. Thus, a fiber web is a substrate.

[0048] The term "nonwoven" herein refers to a material made from continuous (long) filaments (fibers) and / or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, etc. Nonwovens do not have a woven or knitted filament pattern.

[0049] The term "machine direction" (MD) is used herein to refer to the direction of material flow during a process. Additionally, the relative placement and movement of materials can be described as flowing through a process from upstream to downstream in the machine direction.

[0050] The term "cross direction" (CD) is used herein to refer to a direction generally perpendicular to the machine direction.

[0051] The term "taped diaper" (also referred to as an "open diaper") refers to a disposable absorbent article that has an initial front waist region and an initial rear waist region that are not fastened, not prefastened, or not connected to each other when packaged before being put on the wearer. A taped diaper can be folded about a lateral centerline with the interior of one waist region contacting the interior of the opposing waist region in a surface-to-surface manner without fastening or joining the waist regions together. Exemplary taped diapers of various suitable configurations are disclosed in U.S. Pat. No. 5,167,897, U.S. Pat. No. 5,360,420, U.S. Pat. No. 5,599,335, U.S. Pat. No. 5,643,588, U.S. Pat. No. 5,674,216, U.S. Pat. No. 5,702,551, U.S. Pat. No. 5,968,025, U.S. Pat. No. 6,107,537, U.S. Pat. No. 6,118,041, U.S. Pat. No. 6,153,209, U.S. Pat. No. 6,410,1 29, U.S. Pat. No. 6,426,444, U.S. Pat. No. 6,586,652, U.S. Pat. No. 6,627,787, U.S. Pat. No. 6,617,016, U.S. Pat. No. 6,825,393, and U.S. Pat. No. 6,861,571; and U.S. Patent Publication No. 2013 / 0072887A1, U.S. Patent Publication No. 2013 / 0211356A1, and U.S. Patent Publication No. 2013 / 0306226A1, all of which are incorporated herein by reference.

[0052] The term "pants" (also referred to as "training pants," "pre-closed diapers," "diaper pants," "pant diapers," and "pull-on diapers") refers herein to disposable absorbent articles designed for infants or adult wearers having a continuous peripheral waist opening and continuous peripheral leg openings. Pants can be constructed with a continuous or closed waist opening and at least one continuous closed leg opening before the article is put on by the wearer. Pants can be preformed or prefastened using a variety of techniques, including but not limited to joining the parts of the article together using any refastenable closure members and / or permanent closure members (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). Pants can be preformed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, back waist fastened or seamed). Exemplary diaper pants of various configurations are disclosed in U.S. Pat. No. 4,940,464, U.S. Pat. No. 5,092,861, U.S. Pat. No. 5,246,433, U.S. Pat. No. 5,569,234, U.S. Pat. No. 5,897,545, U.S. Pat. No. 5,957,908, U.S. Pat. No. 6,120,487, U.S. Pat. No. 6,120,489, U.S. Pat. No. 7,569,039, and U.S. Patent Publication No. 2003 / 0233082A1, U.S. Patent Publication No. 2005 / 0107764A1, U.S. Patent Publication No. 2012 / 0061016A1, U.S. Patent Publication No. 2012 / 0061015A1, U.S. Patent Publication No. 2013 / 0255861A1, U.S. Patent Publication No. 2013 / 0255862A1, U.S. Patent Publication No. 2013 / 0255863A1, U.S. Patent Publication No. 2013 / 0255864A1 and U.S. Patent Publication No. 2013 / 0255865A1, all of which are incorporated herein by reference.

[0053] The present disclosure relates to methods for making absorbent articles, and in particular to elastic laminates and methods for preparing elastic laminates that can be used as components of absorbent articles. With respect to some assembly processes described herein, a first corrugated substrate is provided by forming ridges alternating with depressions in a first substrate along a machine direction, and a second corrugated substrate is provided by forming ridges alternating with depressions in a second substrate along a machine direction. The elastic strands are advanced and stretched in the machine direction. After stretching the elastic strands, a first adhesive is intermittently applied to the elastic strands to form discrete areas of the first adhesive on the elastic strands. Discrete lengths of elastic strands are bonded to the first corrugated substrate and the second corrugated substrate using a first bonding portion formed by discrete areas of the first adhesive and the elastic strands are bonded between the first corrugated substrate and the second corrugated substrate. The depressions of the first corrugated substrate are directly bonded to the depressions of the second corrugated substrate using a second bonding portion located between consecutive first bonding portions along the machine direction. In some assembly processes, one of the first substrate and the second substrate is corrugated, and the other of the first substrate and the second substrate is not corrugated. With respect to the elastic laminate discussed herein, at least one of the first substrate and the second substrate is corrugated, and the elastic strands are positioned between the first substrate and the second substrate. Discrete lengths of elastic strands are bonded to the first substrate and the second substrate using a first bond, and the first substrate and the second substrate are directly bonded to each other using a second bond positioned between continuous first bonds. The elastic strands extend through the second bond, and the elastic strands are able to retract and stretch through the second bond.

[0054] Figure 1A , Figure 1B and Figure 2 An example of an absorbent article 100 in the form of a diaper pant 100P is shown, which may include components composed of elastic laminates assembled according to the apparatus and methods disclosed herein. Specifically, Figure 1A and Figure 1B A perspective view of a diaper pant 100P in a pre-fastened configuration is shown, and Figure 2 A plan view of a diaper pant 100P is shown with a diaper portion facing away from a wearer, who is oriented toward a viewer. The diaper pant 100P includes a chassis 102 and an annular elastic belt 104. As discussed in more detail below, a first elastic belt 106 and a second elastic belt 108 are bonded together to form the annular elastic belt 104.

[0055] Continue to refer to Figure 2, the diaper pants 100P and the chassis 102 each include a first waist region 116, a second waist region 118, and a crotch region 119 disposed between the first waist region and the second waist region. The first waist region 116 can be configured as a front waist region, and the second waist region 118 can be configured as a rear waist region. The diaper 100P can also include a laterally extending front waist edge 121 in the front waist region 116 and a longitudinally opposite and laterally extending rear waist edge 122 in the rear waist region 118. To provide a frame of reference for this discussion, Figure 2 A diaper 100P and chassis 102 are shown having a longitudinal axis 124 and a lateral axis 126. In some embodiments, the longitudinal axis 124 can extend through the front waist edge 121 and through the back waist edge 122. And the lateral axis 126 can extend through the first longitudinal or right side edge 128 and through the midpoint of the second longitudinal or left side edge 130 of the chassis 102.

[0056] like Figure 1A , Figure 1B and Figure 2 As shown, the diaper pant 100P may include an inner body-facing surface 132 and an outer garment-facing surface 134. The chassis 102 may include a backsheet 136 and a topsheet 138. The chassis 102 may also include an absorbent assembly 140 having an absorbent core 142 disposed between a portion of the topsheet 138 and the backsheet 136. As discussed in more detail below, the diaper 100P may also include other structures, such as leg elastics and / or leg cuffs to enhance the fit around the wearer's legs.

[0057] like Figure 2 As shown, the perimeter of the chassis 102 can be defined by a first longitudinal side edge 128, a second longitudinal side edge 130, a first laterally extending end edge 144 disposed in the first waist region 116, and a second laterally extending end edge 146 disposed in the second waist region 118. Both side edges 128 and 130 extend longitudinally between the first end edge 144 and the second end edge 146. Figure 2 As shown, the end edges 144 and 146 extending laterally are located at the longitudinal inner side of the laterally extending front waist edge 121 in the front waist region 116 and the laterally extending back waist edge 122 in the back waist region 118. When the diaper pants 100P is worn on the lower body of the wearer, the front waist edge 121 and the back waist edge 122 can surround a part of the wearer's waist. At the same time, the side edges 128 and 130 can surround at least a part of the wearer's legs. And the crotch region 119 can generally be positioned between the legs of the wearer, wherein the absorbent core 142 extends from the front waist region 116 through the crotch region 119 to the back waist region 118.

[0058] As previously mentioned, diaper pants 100P may include backsheet 136. Backsheet 136 may also define the outer surface 134 of base structure 102. Backsheet 136 may also include woven or nonwoven material, polymer film (such as thermoplastic film of polyethylene or polypropylene) and / or multiple layers or composite materials including film and nonwoven material. Backsheet may also include elastomeric film. Example backsheet 136 may be a polyethylene film with a thickness of about 0.012mm (0.5 mil) to about 0.051mm (2.0 mil). In addition, backsheet 136 may also allow steam to escape from absorbent core (that is, backsheet is breathable), while still preventing effluent from penetrating backsheet 136.

[0059] As also described above, the diaper pants 100P may include a top sheet 138. The top sheet 138 may also define all or part of the interior surface 132 of the base structure 102. In addition, the top sheet 138 may be liquid permeable, thereby allowing liquids (e.g., menstrual fluid, urine and / or loose stools) to penetrate its thickness. The top sheet 138 may be made of various materials (such as woven materials and nonwoven materials); open or hydraulically formed thermoplastic films; open-cell nonwovens, porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Woven materials and nonwoven materials may include natural fibers such as wood fibers or cotton fibers; synthetic fibers such as polyester fibers, polypropylene fibers or polyethylene fibers; or combinations thereof. If the top sheet 138 includes fibers, the fibers may be processed by spunbonding, carding, wet-laid, meltblown, spunlace or other methods known in the art. The top sheet 138 may be selected from high-loft nonwoven top sheets, open-cell film top sheets and open-cell nonwoven top sheets. Exemplary apertured films may include those described in U.S. Pat. No. 5,628,097, U.S. Pat. No. 5,916,661, U.S. Pat. No. 6,545,197, and U.S. Pat. No. 6,107,539, all of which are incorporated herein by reference.

[0060] As mentioned above, the diaper pant 100P may also include an absorbent assembly 140 joined to the chassis 102. Figure 2As shown, absorbent assembly 140 may have a front edge 148 extending laterally in front waist region 116, and may have a rear edge 150 extending laterally longitudinally in rear waist region 118. Absorbent assembly may have a right edge 152 extending longitudinally, and may have a left edge 154 extending laterally relative and longitudinally, and these two absorbent assembly side edges 152 and 154 may extend longitudinally between front edge 148 and rear edge 150. Absorbent assembly 140 may additionally include one or more absorbent cores 142 or absorbent core layers. Absorbent core 142 may be at least partially arranged between top sheet 138 and back sheet 136, and may be formed in various sizes and shapes compatible with diapers. Exemplary absorbent structures used as absorbent cores of the present disclosure are described in U.S. Patent No. 4,610,678, U.S. Patent No. 4,673,402, U.S. Patent No. 4,888,231 and U.S. Patent No. 4,834,735, all of which are incorporated herein by reference.

[0061] Some absorbent core embodiments may include a fluid storage core that includes a reduced amount of cellulose air felt material. For example, such a core may include less than about 40%, 30%, 20%, 10%, 5% or even 1% cellulose air felt material. Such a core may mainly include an absorbent gelling material having a content of at least about 60%, 70%, 80%, 85%, 90%, 95% or even about 100%, wherein the remainder of the core includes microfiber glue (if applicable). Such cores, microfiber glue and absorbent gelling materials are described in U.S. Patent No. 5,599,335, U.S. Patent No. 5,562,646, U.S. Patent No. 5,669,894 and U.S. Patent No. 6,790,798 and U.S. Patent Publication No. 2004 / 0158212A1 and U.S. Patent Publication No. 2004 / 0097895A1, all of which are incorporated herein by reference.

[0062] As previously mentioned, the diaper 100P may also include elasticized leg cuffs 156. It should be understood that the leg cuffs 156 may be and are sometimes referred to as leg circumferences, side wings, barrier cuffs, elastic cuffs, or gasket cuffs. The elasticized leg cuffs 156 may be constructed in various ways to help reduce leakage of body exudates in the leg regions. Exemplary leg cuffs 156 may include those described in U.S. Patent No. 3,860,003, U.S. Patent No. 4,909,803, U.S. Patent No. 4,695,278, U.S. Patent No. 4,795,454, U.S. Patent No. 4,704,115, U.S. Patent No. 4,909,803; and those in U.S. Patent Publication No. 2009 / 0312730A1, all of which are incorporated herein by reference.

[0063] As mentioned above, the diaper pants can be manufactured with the loop elastic band 104 and provided to the consumer in a configuration where the front waist region 116 and the back waist region 118 are connected to each other as packaged before being applied to the wearer. Thus, the diaper pants can have a continuous peripheral waist opening 110 and continuous peripheral leg openings 112, such as Figure 1A and Figure 1B The looped elastic band may be formed by joining a first elastic band to a second elastic band with permanent side seams or with an openable and reclosable fastening system disposed at or adjacent laterally opposite sides of the bands.

[0064] As previously mentioned, the annular elastic band 104 may be defined by a first elastic band 106 connected to a second elastic band 108. Figure 2 As shown, the first elastic band 106 extends between the first longitudinal side edge 111a and the second longitudinal side edge 111b, and defines the first opposite end regions 106a and the second opposite end regions 106b and the central region 106c. And the second elastic band 108 extends between the first longitudinal side edge 113a and the second longitudinal side edge 113b, and defines the first opposite end regions 108a and the second opposite end regions 108b and the central region 108c. The distance between the first longitudinal side edge 111a and the second longitudinal side edge 111b defines the pitch PL of the first elastic band 106, and the distance between the first longitudinal side edge 113a and the second longitudinal side edge 113b defines the pitch PL of the second elastic band 108. The central region 106c of the first elastic band is connected to the first waist region 116 of the chassis 102, and the central region 108c of the second elastic band 108 is connected to the second waist region 118 of the chassis 102. As shown Figure 1A and Figure 1B As shown, the first end region 106a of the first elastic belt 106 is connected to the first end region 108a of the second elastic belt 108 at the first side seam 178, and the second end region 106b of the first elastic belt 106 is connected to the second end region 108b of the second elastic belt 108 at the second side seam 180 to define the annular elastic belt 104 and the waist opening 110 and the leg openings 112.

[0065] like Figure 2 , Figure 3A and Figure 3BAs shown, the first elastic belt 106 also defines an outer side extending edge 107a and an inner side extending edge 107b, and the second elastic belt 108 defines an outer side extending edge 109a and an inner side extending edge 109b. Thus, the peripheral edge 112a of one leg opening can be defined by a portion of the inner side extending edge 107b of the first elastic belt 106, a portion of the inner side extending edge 109b of the second elastic belt 108, and a portion of the first longitudinal or right side edge 128 of the chassis 102. And the peripheral edge 112b of the other leg opening can be defined by a portion of the inner side extending edge 107b, a portion of the inner side extending edge 109b, and a portion of the second longitudinal or left side edge 130 of the chassis 102. The outer side extending edges 107a, 109a can also define a front waist edge 121 and a laterally extending back waist edge 122 of the diaper pant 100P. The first elastic belt and the second elastic belt can also each include a garment-facing outer layer 162 and a wearer-facing inner layer 164. It should be understood that the first elastic band 106 and the second elastic band 108 may contain the same material and / or may have the same structure. In some embodiments, the first elastic band 106 and the second elastic band may contain different materials and / or may have different structures. It should be understood that the first elastic band 106 and the second elastic band 108 may be constructed of various materials. For example, the first band and the second band may be made of the following materials: such as plastic film; open-cell plastic film; woven or nonwoven fiber webs of the following fibers: natural materials (e.g., wood fibers or cotton fibers), synthetic fibers (e.g., polyolefin, polyamide, polyester, polyethylene, or polypropylene fibers), or a combination of natural fibers and / or synthetic fibers; or coated woven or nonwoven fiber webs. In some embodiments, the first elastic band and the second elastic band include a nonwoven fiber web of synthetic fibers, and may include a stretchable nonwoven material. In other embodiments, the first elastic band and the second elastic band include an inner hydrophobic, non-stretchable nonwoven material and an outer hydrophobic, non-stretchable nonwoven material.

[0066] The first elastic band 106 and the second elastic band 108 may also each include a band elastic material interposed between the outer base layer 162 and the inner base layer 164. The band elastic material may include one or more elastic elements, such as strands, ribbons, films, or sheets extending along the length of the elastic band. Figure 2 , Figure 3A and Figure 3BAs shown, the belt elastic material may include a plurality of elastic strands 168, which may be referred to herein as outer waist elastic components 170 and inner waist elastic components 172. Elastic strands 168 (such as outer waist elastic components 170) may extend laterally continuously between the first opposite end region 106a and the second opposite end region 106b of the first elastic belt 106 and between the first opposite end region 10Sa and the second opposite end region 108b of the second elastic belt 108. In some embodiments, some elastic strands 168 (such as inner waist elastic strands 172) may be configured to be discontinuous in certain areas (such as, for example, where the first elastic belt 106 and the second elastic belt 108 overlap with the absorbent assembly 140). In some embodiments, the elastic strands 168 may be arranged at constant intervals in the longitudinal direction. In other embodiments, the elastic strands 168 may be arranged at different intervals in the longitudinal direction. The belt elastic material in a stretched state may be inserted and joined between the uncontracted outer layer and the uncontracted inner layer. When the belt elastic material is relaxed, the belt elastic material returns to an unstretched state and causes the outer layer and the inner layer to contract. The belt elastic material can provide a desired variable contraction force in the area of ​​the annular elastic band. It should be understood that the belt elastic material can be adjusted in a manner different from that described above. Figure 2 The chassis 102 and elastic belts 106, 108 are constructed in the manner shown. The belt elastic material may be continuously or intermittently joined to the outer layer and / or the inner layer along the joints between the belt elastic material and the inner belt layer and / or the outer belt layer.

[0067] In some configurations, the first elastic band 106 and / or the second elastic band 108 may define a curved profile. For example, the inner lateral edges 107b, 109b of the first elastic band 106 and / or the second elastic band 108 may include non-linear portions or curved portions in the first and second opposite end regions. Such curved profiles may help define a desired shape for the leg opening 112, such as, for example, a relatively rounded leg opening. In addition to having a curved profile, the elastic bands 106, 108 may also include elastic strands 168, 172 extending along a non-linear path or a curved path that may correspond to the curved profile of the inner lateral edges 107b, 109b.

[0068] It should be understood that the assembly apparatus and method of the elastic laminate and absorbent article described herein and shown in the drawings are non-limiting example configurations. Features illustrated or described in conjunction with one non-limiting configuration may be combined with features of other non-limiting configurations. Such modifications and variations are intended to be included within the scope of the present disclosure.

[0069] As previously mentioned, the apparatus and methods according to the present disclosure can be used to produce elastic laminates that can be used to construct various components of absorbent articles, such as elastic bands, leg cuffs, etc. For example, FIG. 4A to FIG. 4CA schematic diagram of a conversion processing device 300 suitable for manufacturing an elastic laminate 200 is shown. As described in more detail below, the conversion processing device 300 operates to advance a continuous length of a first substrate 202, a continuous length of a second substrate 204, and a continuous length of an elastic material 206 along a machine direction MD. It should also be understood that in some configurations, the first substrate 202 and the second substrate 204 herein may be defined by two discrete single-layer substrates, or may be defined by a multi-layer laminate. And in some configurations, the first substrate 202 and / or the second substrate 204 may include a nonwoven. The device 300 may include one or more corrugation forming devices 302 having corrugation forming rollers 306, 308 suitable for rotating around axes 314, 320. Each corrugation forming roller 306, 308 may include protrusions 318, 324 protruding outwardly from an outer circumferential surface 316, 322. The protrusions 318, 324 are configured in a meshing relationship to form the corrugations 210 in either or both of the first substrate 202 and / or the second substrate 204. The apparatus can also stretch the elastic material 206 and join the stretched elastic material 206 with the first substrate 202 and the second substrate 204 to produce the elastomeric laminate 200. Although the elastic material 206 is illustrated and referred to herein as elastic strands 208, it should be understood that the elastic material 206 can include one or more continuous lengths of elastic strands, ribbons, and / or films.

[0070] like Figure 4A As shown, a converting apparatus 300 for producing an elastic laminate 200 may include a first corrugating device 302a and a second corrugating device 302b. During operation, the first corrugating device 302a corrugates the first substrate 202, and the second corrugating device 302b corrugates the second substrate 204. Subsequently, the first corrugated substrate 202c is advanced from the first corrugating device 302a through the combined nip 304, and the second corrugated substrate 204c is advanced from the second corrugating device 302b through the combined nip 304. In addition, the elastic strand 208 is also advanced in the machine direction MD through the combined nip 304 between the first corrugated substrate 202c and the second corrugated substrate 204c to form the laminate 200. The elastic strand 208 may also be stretched in the machine direction MD before or while being advanced through the combined nip 304. As described below with reference to FIG. 4A to FIG. 16Discussed in more detail, discrete lengths of elastic strands 208 are bonded to and between the first corrugated substrate 202c and the second corrugated substrate 204c using first bonds 230, and the first corrugated substrate 202c is directly bonded to the second corrugated substrate 204c using second bonds 232 intermittently positioned along the machine direction MD between the first bonds 230. Thus, the elastic strands 208 can extend through the second bonds 232, and when the elastic laminate 200 is stretched and retracted, the elastic strands 208 can retract and stretch through the second bonds 232 accordingly.

[0071] The first corrugating device 302a may be positioned adjacent to the second corrugating device 302b to define a combined nip 304 therebetween. Figure 4A , Figure 5 and Figure 6 As shown, the first corrugation forming device 302a is configured to form the first corrugation 210a in the first substrate 202, and the second corrugation forming device 302b is configured to form the second corrugation 210b in the second substrate 204. Figure 4A , Figure 5 and Figure 6 As shown, the first substrate 202 includes a first longitudinal edge 214 and a second longitudinal edge 216, the second longitudinal edge being separated from the first longitudinal edge 214 in the cross direction CD to define a width. The first substrate 202 also includes a first surface 218 and an opposite second surface 220. Similarly, as shown in FIG. Figure 4A , Figure 7 and Figure 8 As shown, the second substrate 204 includes a first longitudinal edge 222 and a second longitudinal edge 224 separated from the first longitudinal edge 222 in the cross direction CD to define a width. The second substrate 204 also includes a first surface 226 and an opposing second surface 228.

[0072] like Figure 4AAs shown, the first corrugation forming device 302a may include a first corrugation forming roller 306a, which is adjacent to the second corrugation forming roller 308a to define a first corrugation forming roller gap 310 therebetween. The first corrugation forming roller 306a may be adapted to rotate about an axis 314a and include an outer circumferential surface 316a and a radially outwardly protruding protrusion 318a. The second corrugation forming roller 308a may be adapted to rotate about an axis 320a in a direction opposite to the first corrugation forming roller 306a. The second corrugation forming roller 308a may include an outer circumferential surface 322a and a radially outwardly protruding protrusion 324a. The protrusion 318a of the first corrugation forming roller 308a is configured to be in meshing relationship with the protrusion 324a of the second corrugation forming roller 306a at the first corrugation forming roller gap 310. The first substrate 202 can be advanced to the first corrugating device 302a in the machine direction MD, wherein the second surface 220 of the first substrate 202 is in a facing relationship with the outer circumferential surface 316a and the protrusions 318a of the first corrugating roller 306a. As the first corrugating roller 306a rotates about the axis 314a, the first substrate 202 is advanced through the first corrugating roller gap 310 and between the meshing portions of the protrusions 318a of the first corrugating roller 306a and the protrusions 324a of the second corrugating roller 308a. Subsequently, the first substrate 202 is corrugated by generally conforming to the periphery of the second corrugating roller 308a to form corrugations 310a defined by ridges 234 alternating with depressions 236 along the machine direction MD of the first corrugated substrate 202c. Continuing with reference to Figure 4A , the first substrate 202 is corrugated and transferred to the second corrugating roller 308a at the first corrugating roller nip 310. Thus, the first substrate 202 is transferred to the second corrugating roller 306a, wherein the first surface 218 of the first substrate 202 is in a facing relationship with the outer circumferential surface 322a and the protrusions 324a of the second corrugating roller 308a. Subsequently, the first corrugated substrate 202c can be advanced from the first corrugating roller nip 310 and through the combined roller nip 304 on the outer circumferential surface 322a and the protrusions 324a of the second corrugating roller 308a.

[0073] Continue to refer to Figure 4A, the second corrugation forming device 302b may include a first corrugation forming roller 306b, which is adjacent to the second corrugation forming roller 308b to define a second corrugation forming roller gap 312 therebetween. The first corrugation forming roller 306b may be adapted to rotate about an axis 314b, and include an outer circumferential surface 316b and a radially outwardly protruding protrusion 318b. The second corrugation forming roller 308b may be adapted to rotate about an axis 320b in a direction opposite to the first corrugation forming roller 306b. The second corrugation forming roller 308b may include an outer circumferential surface 322b and a radially outwardly protruding protrusion 324b. The protrusion 318b of the first corrugation forming roller 306b is configured to be in meshing relationship with the protrusion 324b of the second corrugation forming roller 308b at the second corrugation forming roller gap 312. The second substrate 204 can be advanced to the second corrugating device 302b in the machine direction MD, wherein the first surface 226 of the second substrate 204 is in a facing relationship with the outer circumferential surface 316b and the protrusions 318b of the first corrugating roller 306b. As the first corrugating roller 306b rotates about the axis 314b, the second substrate 204 is advanced through the second corrugating roller gap 312 and between the meshing portions of the protrusions 318b of the first corrugating roller 308b and the protrusions 324b of the second corrugating roller 306b. Subsequently, the second substrate 204 is corrugated by generally conforming to the periphery of the second corrugating roller 308b to form corrugations 310b defined by ridges 234 alternating with depressions 236 along the machine direction MD of the second corrugated substrate 204c. Continuing with reference to Figure 4A , the second substrate 204 is corrugated and transferred to the second corrugating roller 308b at the second corrugating roller nip 312. Thus, the second substrate 204 is transferred to the second corrugating roller 306b, wherein the second surface 228 of the second substrate 204 is in a facing relationship with the outer circumferential surface 322b and the protrusions 324b of the second corrugating roller 308b. Subsequently, the second corrugated substrate 204c can be advanced from the second corrugating roller nip 312 and through the combined roller nip 304 on the outer circumferential surface 322b and the protrusions 324b of the second corrugating roller 308b.

[0074] It should be understood that the corrugating device 302 may include corrugating rollers 306, 308, which may be configured in a variety of ways. Fig.4A1 As shown, the first corrugating roller 306 and / or the second corrugating roller 308 can be configured in the form of a gear 342, wherein the protrusions 318, 324 can be configured as gear teeth 344. Therefore, the gear teeth 344 of the first corrugating roller 306 and the gear teeth 344 of the second corrugating roller 308 can mesh with each other at the corrugating roller nips 310, 312 to form corrugations in the first substrate 202 and / or the second substrate 204, such as described above with reference to Figure 4AAs stated. Fig.4A1 As shown, the gear teeth 344 may also include an outer radial surface 346. Thus, the outer radial surface 346 of the second corrugating roller 308 may be in a relative relationship to press the first substrate 202, the second substrate 204, and the elastic strands 208 together at the combining nip 304, such as described above with reference to Figure 4A It should be understood that Fig.4A1 342, and it should be understood that the gear 342 herein can be constructed with various numbers and geometries of gear teeth, such as described in PCT Patent Publication No. Wo95 / 34264A1 and PCT Patent Publication No. Wo2020 / 230012A1, both of which are incorporated herein by reference. It should also be understood that the corrugating rollers 306, 308 can be constructed of various types of materials, such as, for example, plastics, silicone, rubber and / or various types of metals. In some configurations, for example, some corrugating rollers 306, 308 can include a non-stick coating, such as a plasma coating. In some configurations, some corrugating rollers 306, 308 can operate under vacuum pressure, which can be operated to force and / or hold the first substrate and / or the second substrate onto the corrugating rollers 306, 308. Such vacuum pressure may also help secure the formation of corrugations in the first substrate 202 and / or the second substrate 204 by maintaining conformity of the first substrate 202 and / or the second substrate 204 to the shape of the corrugation forming rollers 306 , 308 .

[0075] It should also be understood that the gear teeth 344 of the meshing corrugating rollers 306, 308 can be configured to maintain a gap gap large enough to allow the substrate to be advanced between them without being compressed. In some configurations, the geometry of the teeth can be modified to create a gap gap between the gear teeth, and / or the drive can be modified to maintain this gap, i.e., without rolling contact. In some configurations, each corrugating roller can include a drive gear to drive and maintain the gap between the meshing corrugating rollers.

[0076] As previously mentioned, the advancing elastic strands 208 may be bonded between the first corrugated substrate 202c and the second corrugated substrate 204c at the combining nip 304. Figure 4A and Fig. 9As shown, the converting equipment 300 may include an elastic strand supply device 326, such as one or more unwinders, which are generally represented by dashed rectangles and may include one or more reels of elastic strands 208. During operation, the elastic strands 208 are advanced from the unwinder 326 to the combined roll gap 304 in the machine direction MD. In addition, when advancing between the unwinder 326 and the combined roll gap 304, the elastic strands 208 can be stretched along the machine direction MD. The stretched elastic strands 208 are also joined with the first corrugated substrate 202c and the second corrugated substrate 204c at the combined roll gap 304 to produce the elastomeric laminate 200. It should be understood that the elastic strands 208 can be advanced along and / or around one or more guide rollers. It should also be understood that the elastic strands 208 can be stretched along a continuous path while advancing in the machine direction MD, or can be stretched in various steps that provide multiple elongation increases while advancing in the machine direction MD.

[0077] In some configurations, a component of the converting equipment may be characterized as a metering device 301 that is adapted to advance and stretch the elastic strand 208 in the machine direction. Thus, the elastic strand may be advanced from a first metering device 301a at a first speed to a second metering device 301b at a second speed, wherein the second speed is greater than the first speed. For example, the unwinder 326 may be characterized as a first metering device 301a, and the combing nip 304 defined between the first corrugating device 302a and the second corrugating device 302b may be characterized as a second metering device 301b. Figure 4A As shown, the second corrugating roller 308a of the first corrugating device 302a can be rotated so that the protrusion 324a has a surface speed S1, and the second corrugating roller 308b of the second corrugating device 302b can be rotated so that the protrusion 324b has the same or substantially the same surface speed S1. Therefore, the first corrugated substrate 202c and the second corrugated substrate 204c can be advanced through the combined roll gap 304 at a speed S1. It should be understood that the first corrugated substrate 202c and / or the second corrugated substrate 204c can be advanced at various speeds S1. In some configurations, the first corrugated substrate 202c and / or the second corrugated substrate 204c can be advanced at a speed S1 of about 150 meters / minute to about 500 meters / minute, specifically reciting all 1 meter / minute increments in the above ranges and all ranges formed therein or thereby.

[0078] In some configurations, the elastic strands 208 can also be stretched in the machine direction MD and combined with the first corrugated substrate 202c and the second corrugated substrate 204c in a stretched state. Figure 4A and Fig. 9, the unwinder 326 can unwind or otherwise supply the elastic strand 208 advancing at a speed S2 in the machine direction MD to the combining nip 304. In some configurations, the speed S2 is less than the speed S1, and therefore, the elastic strand 208 is stretched in the machine direction MD. Subsequently, the stretched elastic strand 208 is advanced through the combining nip 328 and bonded between the first corrugated substrate 202c and the second corrugated substrate 204c to produce a continuous length of the elastomeric laminate 200.

[0079] As previously mentioned, the apparatus 301 may include an elastic strand supply apparatus 326, such as one or more unwinders, which supply a plurality of elastic strands 208. It should be understood that the unwinder 326 herein may be configured in various ways. For example, the unwinder 326 may be configured with a separate reel, an unwinder with a spindle and / or a surface drive, an over-the-end unwinder, and / or a cross-beam unwinder (also referred to as a warp beam). Various types of unwinders are disclosed in U.S. Pat. Nos. 6,676,054, 7,878,447, 7,905,446, 9,156,648, 4,525,905, 5,060,881, and 5,775,380; U.S. Patent Application No. 17 / 189,476 filed on March 2, 2021; and U.S. Patent Publication No. 2004 / 0219854A1, U.S. Patent Publication No. 2018 / 0168879A1, and U.S. Patent Publication No. 2018 / 0170026A1, all of which are incorporated herein by reference. Additional examples of elastic components and associated handling equipment are available from Karl Mayer Corporation. It should be understood that the converting apparatus 300 can be configured to assemble the elastomeric laminate 200 using elastic strands 208 that are unwound from more than one unwinder 326, in combination with elastic strands supplied by the same and / or different types of elastic unwinder configurations. It should also be understood that the elastic strands 208 can include various types of spun finishes (also referred to herein as yarn finishes) that are configured as coatings on the elastic strands 208 and can be intended to help prevent the elastic strands from adhering to themselves, to each other, and / or to downstream handling equipment. Thus, the apparatus can also be configured to remove or partially remove spun finishes from the elastic strands, such as disclosed, for example, in U.S. Patent Publication No. 2018 / 0168877A1, which is incorporated herein by reference.

[0080] It should also be understood that the converting apparatus 300 may include one or more unwinders 326 that may supply various amounts of elastic strands 208. In some configurations, the unwinder 302 herein may include 1 to about 3000 spools positioned thereon, and thus may have 1 to about 3000 elastic strands 208 advancing therefrom, specifically reciting all 1 spool and 1 strand increments within the above ranges and all ranges therein or formed therefrom. In turn, the elastomeric laminate 200 herein may include 1 to about 3000 elastic strands 208 spaced apart from one another in the cross direction CD, specifically reciting all 1 elastic strand increments within the above ranges and all ranges therein or formed therefrom.

[0081] It should also be understood that the apparatus and process can be configured such that the elastic strand 208 can be advanced from the unwinder 326 and directly advanced to the assembly process without having to contact additional machine components, such as, for example, guide rollers. It should also be understood that in some configurations, the elastic strand 208 can be advanced from the unwinder 326 and can be redirected and / or otherwise contacted and / or redirected by machine components (such as, for example, guide rollers) before being advanced to the assembly process.

[0082] like Figure 4A and Fig. 9 As shown, the elastic strands 208 can also be advanced through the strand guides 328 before being combined with the first substrate 204 and the second substrate 206. The strand guides 328 can space or separate adjacent elastic strands 208 from each other by a desired distance in the cross-direction CD before being combined with the first substrate 204 and the second substrate 206. Figure 4A and Fig. 9As shown, the elastic strands 208 may be advanced through a strand guide 328 positioned between the unwinder 326 and the nip 304. The strand guide 328 may be operable to change and / or indicate and / or fix the transverse direction CD separation distance between adjacent elastic strands 208 advanced into the nip 304 and the assembled elastomeric laminate 200. It should be understood that the elastic strands 208 may be separated from each other by various distances along the transverse direction CD advanced into the nip 304 and the assembled elastomeric laminate 200. In some configurations, adjacent elastic strands 208 may be separated from each other in the transverse direction CD by about 0.5 mm to about 4 mm, specifically reciting all 0.1 mm increments within the above ranges and all ranges formed therein or thereby. It should be understood that the strand guide 328 may be constructed in various ways. In some configurations, the strand guide 328 may be constructed as a comb, which may include a plurality of tines or reeds. Then, the advancing elastic strands 208 are separated and spaced apart from each other in the cross direction CD by the tines or reeds.In some configurations, the strand guide 328 may include a plurality of rollers that separate and space the elastic strands from each other in the cross direction CD.

[0083] It should be understood that different components can be used to construct the elastomeric laminate 200 according to the methods and apparatuses herein. For example, the first substrate 204 and / or the second substrate 206 can include a nonwoven and / or a film. In addition, the elastic strands 208 can be constructed in various ways and can have various decitex values. In some configurations, the elastic strands 208 can be configured to have a decitex value ranging from about 10 decitex to about 1000 decitex, specifically reciting all 1 decitex increments within the above ranges and all ranges formed therein or thereby.

[0084] Refer again Figure 4A , the converting apparatus 300 may include one or more adhesive applicator devices 330 that may apply adhesive 238 to the elastic strands 208, the first substrate 202, and the second substrate 204 prior to combination to form the elastomeric laminate 200. It should be understood that the adhesive applicator device 300 herein is constructed in various ways, such as, for example, a spray nozzle, a strand coating, and / or a slot coating device. In some configurations, the adhesive applicator device 330 may be constructed according to the apparatus and / or method disclosed in U.S. Pat. No. 8,186,296, U.S. Pat. No. 9,265,672, U.S. Pat. No. 9,248,054, and U.S. Pat. No. 9,295,590; and U.S. Patent Publication No. 2014 / 0148773A1, all of which are incorporated herein by reference.

[0085] like Figure 4A and Fig. 9As shown, the first adhesive applicator device 330a can be adapted to apply the first adhesive 238a to the advancing elastic strand 208, and the elastic strand 208 can be in a stretched state when the first adhesive 238a is applied. The first adhesive applicator device 330a can be operated to intermittently apply the first adhesive 238a to discrete lengths of the elastic strand 208 along the machine direction MD before the elastic strand 208 is advanced to the combining nip 304. Fig.10 and Fig.11 A view of the elastic laminate 200 is shown advancing from the combining nip 304. For clarity, Fig.10 and Fig.11 Five elastic strands 208 are illustrated in the elastic laminate 200, however, it should be understood that the elastic laminate 200 may include more or less than five elastic strands 208, as discussed above. Fig.10 and Fig. 10A As shown, the first adhesive 238a forms a first bond 230 in the elastic laminate 200, which bonds the first corrugated substrate 202c, the second corrugated substrate 204c, and the elastic strands 208 together. Specifically, the first bonds 230 are intermittently spaced along the machine direction MD and bond discrete lengths of the stretched elastic strands 208 to the first corrugated substrate 202c and the second corrugated substrate 204c.

[0086] like Figure 4A As shown, the converting apparatus 300 may also include a second adhesive applicator device 330b and / or a third adhesive applicator device 330c. The second adhesive applicator device 330b may be adapted to apply the second adhesive 238b to the first substrate 202. For example, the second adhesive applicator device 330b may be operable to intermittently apply the second adhesive 238b to the first corrugated substrate 202c advancing on the second corrugating roller 308a. In some configurations, the second adhesive applicator device 330b may apply the second adhesive 238b to the depressions 236 of the first corrugated substrate 202c without applying the second adhesive 238b to the ridges 234 of the first corrugated substrate 202c. The third adhesive applicator device 330c may be adapted to apply the third adhesive 238c to the second substrate 204. For example, the third adhesive applicator device 330c may be operable to intermittently apply the third adhesive 238c to the second corrugated substrate 204c advancing on the second corrugating roller 308b. In some configurations, the third adhesive applicator device 330c can apply the third adhesive 238c to the depressions 236 of the second corrugated substrate 204c without applying the third adhesive 238c to the ridges 234 of the second corrugated substrate 204c.

[0087] like Fig.10 and Fig. 10BAs shown, the second adhesive 238b and / or the third adhesive 238c can form a second bonding portion 232 in the elastic laminate 200, which bonds the first corrugated substrate 202c to the second corrugated substrate 204c. Specifically, the second bonding portion 232 can be intermittently spaced along the machine direction MD, and the recessed portion 236 of the first corrugated substrate 202c is bonded to the recessed portion 236 of the second corrugated substrate 204c. The second bonding portion 232 can also be intermittently spaced along the cross direction CD. The elastic strand 208 can extend through the second bonding portion 232 and extend between the second bonding portions. Therefore, when the elastic laminate 200 is stretched and retracted, the elastic strand 208 can be retracted and stretched accordingly without being significantly inhibited by the second bonding portion 232. Compared with the second bonding portion 232, the elastic strand 208 of discrete length is anchored to the first corrugated substrate 202c and the second corrugated substrate 204c by the first bonding portion 230. Thus, when the elastic laminate 200 is stretched and retracted, the anchored discrete lengths of elastic strands 208 will move with the portions of the first corrugated substrate 202c and the second corrugated substrate 204c bonded to the first bonding portion 230, as shown in FIG. Fig.11 and Fig.12 As shown. It should be understood that the first adhesive 238a, the second adhesive 238b and / or the third adhesive 238c can be the same adhesive or different adhesives. In addition, the first adhesive 238a, the second adhesive 238b and / or the third adhesive 238c can be applied with the same basis weight or different basis weights. For example, the first adhesive 238a can be applied with a first basis weight, the second adhesive 238b can be applied with a second basis weight, and / or the third adhesive 238c can be applied with a third basis weight. In some configurations, the second basis weight and / or basis weight may be less than the first basis weight.

[0088] It should be understood that the second bonding portion 232 can be an adhesive bonding portion and / or a mechanical bonding portion. Figure 4A The converting apparatus 300 shown in FIG. 3 can be configured to mechanically bond the first corrugated substrate 202c to the second corrugated substrate 204c to form the second bond 232. In some configurations, the second corrugating roller 308 of the first corrugating device 302a and the second corrugating roller 308b of the second corrugating device can be configured to operate as a mechanical bonding device. For example, Figure 4A2As shown, the second corrugating roller 308 and / or the second corrugating roller 308b of the first corrugating device 302a may include bonding elements 348 positioned on the protrusions 324 or gear teeth 344. For example, the bonding elements 348 may extend radially outward from the outer radial surface 346 of the gear teeth 344 to define a pressing surface 350. As the second corrugating rollers 308a, 308b rotate, the elastic laminate 200 is advanced at the combined nip 304 between the pressing surface 350 of one corrugating roller 308 and the outer radial surface 346 of the opposing corrugating roller 308. Thus, the pressure generated by the interaction between the pressing surface 350 and the outer radial surface 346 operates to mechanically bond or weld the first corrugated substrate 202c and the second corrugated substrate 204c together, thereby creating the second bond 232 between the recessed portion 234 of the first corrugated substrate 202c and the recessed portion 234 of the second corrugated substrate 204c. The heat and / or pressure between the pressing surfaces 350 of the protrusions 324a, 324b of the second corrugating rollers 308a, 308b can melt in the area supported by the pressing surfaces 350 of the protrusions 324a, 324b on the second corrugating rollers 308a, 308b and bond the first corrugated substrate 202c and the second corrugated substrate 204c together in the area. Thus, the second bonding portion 232 can have a shape that corresponds to the shape of the pressing surface 350 and can mirror its shape. In some configurations, the second corrugating roller 308a of the first corrugating device 302a and / or the second corrugating roller 308b of the second corrugating device 302b can also be heated. It should be understood that the second corrugated rollers 308a, 308b and / or the protrusions 324a, 324b can be configured to apply heat and pressure in various ways to perform mechanical bonding, such as, for example, the mechanical bonding apparatus and methods disclosed in U.S. Pat. Nos. 4,854,984, 6,248,195, 8,778,127, 9,005,392, 9,962,297, and 10,052,237, all of which are incorporated herein by reference. It should also be understood that Figure 4A2 344, bonding elements 348, and extrusion surfaces 350, and it should be understood that such gears 342 may be constructed of a variety of materials and may be configured with a variety of different numbers and geometries of gear teeth 344, bonding elements 348, and extrusion surfaces 350, such as described above with reference to Fig.4A1 discussed.

[0089] In some configurations, the converting apparatus 300 herein can be configured to assemble the elastic laminate 200 by combining a corrugated substrate and a substrate that has not been corrugated. For example, Figure 4BA converting apparatus 300 is shown with a corrugating device 302 including a first corrugating roller 306 and a second corrugating roller 308, the first corrugating roller and the second corrugating roller being constructed similarly to those described above with reference to Figure 4A The first corrugating device 302a and the associated first corrugating roller 306a and second corrugating roller 608a. Figure 4B The converting apparatus does not include the second corrugating device 302b. Instead, the corrugating device 302 may be positioned adjacent to the anvil roll 332 to define a combined roll gap 304 therebetween. Figure 4B and Figure 4B1 As shown, the anvil roller 332 may include an outer circumferential surface 334 and may be adapted to rotate about an axis 336 .

[0090] like Figure 4B As shown, the corrugation forming device 302 may include a second corrugation forming roller 306 positioned adjacent to the second corrugation forming roller 308 to define a corrugation forming roller gap 310 therebetween. The first corrugation forming roller 306 may be adapted to rotate about an axis 314 and include an outer circumferential surface 316 and a radially outwardly projecting protrusion 318. The second corrugation forming roller 308 may be adapted to rotate about an axis 320 in a direction opposite to the first corrugation forming roller 306. The second corrugation forming roller 308 may include an outer circumferential surface 322 and a radially outwardly projecting protrusion 324. The protrusion 318 of the first corrugation forming roller 306 is configured to be in meshing relationship with the protrusion 324 of the second corrugation forming roller 308 at the corrugation forming roller gap 310. The first substrate 202 may be advanced to the corrugation forming device 302 in the machine direction MD, wherein the second surface 220 of the first substrate 202 is in a facing relationship with the outer circumferential surface 316 and the protrusion 318 of the first corrugation forming roller 306. As the first corrugating roller 306 rotates about the axis 314, the first substrate 202 is advanced through the corrugating roller nip 310 and between the meshing portions of the protrusions 318 of the first corrugating roller 306 and the protrusions 324 of the second corrugating roller 308. Subsequently, the first substrate 202 is corrugated by generally conforming to the periphery of the second corrugating roller 308 to form corrugations 310a defined by ridges 234 alternating with depressions 236 along the machine direction MD of the first corrugated substrate 202c. Continuing with reference to Figure 4B, the first substrate 202 is corrugated and transferred to the second corrugating roller 308 at the corrugating roller nip 310. Thus, the first substrate 202 is transferred to the second corrugating roller 306, wherein the first surface 218 of the first substrate 202 is in a facing relationship with the outer circumferential surface 322 and the protrusion 324 of the second corrugating roller 308. Subsequently, the first corrugated substrate 202c can be advanced from the corrugating roller nip 310 and through the combined roller nip 304 on the outer circumferential surface 322 and the protrusion 324 of the second corrugating roller 308.

[0091] The second substrate 204 can be advanced to the anvil roll 332 in the machine direction MD, wherein the second surface 228 of the second substrate 204 is in facing relationship with the outer circumferential surface 334 of the anvil roll 332. As the anvil roll 332 rotates about the axis 336, the second substrate 204 is advanced on the outer circumferential surface 334 and passes through the combining nip 304. Thus, the second substrate 204 is not corrugated prior to bonding with the first corrugated substrate 202c and the elastic strands 208 at the combining nip 304.

[0092] like Figure 4B As shown, the advancing elastic strand 208 can be bonded between the first corrugated substrate 202c and the second substrate 204 at the combining nip 304. The elastic strand 208 can be configured to be advanced from an elastic strand supply device 326, such as described above with reference to Figure 4A and Fig. 9 Therefore, Figure 4B The elastic strands 208 in the first corrugated substrate 202c and the second substrate 204 can be advanced from the unwinder 326 to the combining nip 304 in the machine direction MD. In addition, the elastic strands 208 can be stretched along the machine direction MD when advancing between the unwinder 326 and the combining nip 304, as discussed above. The stretched elastic strands 208 are also joined with the first corrugated substrate 202c and the second substrate 204 at the combining nip 304 to produce the elastomeric laminate 200.

[0093] As discussed above, the component of the converting apparatus can be characterized as a metering device 301 adapted to advance and stretch the elastic strand 208 in a machine direction, wherein the elastic strand can be advanced from a first metering device 301a at a first speed to a second metering device 301b at a second speed, wherein the second speed is greater than the first speed. Figure 4B , the unwinder 326 can be characterized as a first metering device 301a, and the combing nip 304 defined between the corrugating device 302 and the anvil roll 332 can be characterized as a second metering device 301b. Figure 4BAs shown, the second corrugating roller 308 of the corrugating device 302 can be rotated so that the protrusion 324a has a surface speed S1, and the anvil roller 332 can be rotated so that the outer circumferential surface 334 has the same or substantially the same surface speed S1. Therefore, the first corrugated substrate 202c and the second substrate 204 can be advanced through the combined roller gap 304 at a speed S1. It should be understood that the first corrugated substrate 202c and / or the second substrate 204 can be advanced at various speeds S1. In some configurations, the first corrugated substrate 202c and / or the second substrate 204 can be advanced at a speed S1 of about 150 meters / minute to about 500 meters / minute, specifically reciting all 1 meter / minute increments in the above ranges and all ranges formed therein or thereby.

[0094] As discussed above, the elastic strands 208 can also be stretched in the machine direction MD and combined with the first corrugated substrate 202c and the second substrate 204 in a stretched state. Figure 4B and Fig. 9 , the unwinder 326 can unwind or otherwise supply the elastic strand 208 advancing at a speed S2 in the machine direction MD to the combining nip 304. In some configurations, the speed S2 is less than the speed S1, and therefore, the elastic strand 208 is stretched in the machine direction MD. Subsequently, the stretched elastic strand 208 is advanced through the combining nip 328 and bonded between the first corrugated substrate 202c and the second substrate 204 to produce a continuous length of the elastomeric laminate 200.

[0095] Refer again Figure 4B , the converting apparatus 300 may include one or more adhesive applicator devices 330 that can apply adhesive 238 to the elastic strands 208, the first substrate 202, and / or the second substrate 204 prior to combination to form the elastomeric laminate 200. As discussed above, the adhesive applicator devices 330 herein are configured in various ways, such as, for example, spray nozzles, strand coating, and / or slot coating devices. In some configurations, the adhesive applicator device 330 can be constructed according to the apparatus and / or methods disclosed in U.S. Pat. No. 8,186,296, U.S. Pat. No. 9,265,672, U.S. Pat. No. 9,248,054, and U.S. Pat. No. 9,295,590; and U.S. Patent Publication No. 2014 / 0148773A1, all of which are incorporated herein by reference.

[0096] like Figure 4B and Fig. 9As shown, the first adhesive applicator device 330a can be adapted to apply the first adhesive 238a to the advancing elastic strand 208, and the elastic strand 208 can be in a stretched state when the first adhesive 238a is applied. The first adhesive applicator device 330a can be operated to intermittently apply the first adhesive 238a to discrete lengths of the elastic strand 208 along the machine direction MD before the elastic strand 208 is advanced to the combining nip 304. Fig.13 and Fig.15 A view of the elastic laminate 200 is shown advancing from the combining nip 304. For clarity, Fig.13 and Fig.15 Five elastic strands 208 are illustrated in the elastic laminate 200, however, it should be understood that the elastic laminate 200 may include more or less than five elastic strands 208, as discussed above. Fig.13 and Fig.13A As shown, the first adhesive 238a forms a first bond 230 in the elastic laminate 200, which bonds the first corrugated substrate 202c, the second substrate 204, and the elastic strands 208 together. Specifically, the first bonds 230 are intermittently spaced along the machine direction MD and bond discrete lengths of the stretched elastic strands 208 to the first corrugated substrate 202c and the second substrate 204.

[0097] like Figure 4B As shown, the converting apparatus 300 may also include a second adhesive applicator device 330b and / or a third adhesive applicator device 330c. The second adhesive applicator device 330b may be adapted to apply the second adhesive 238b to the first substrate 202. For example, the second adhesive applicator device 330b may be operable to intermittently apply the second adhesive 238b to the first corrugated substrate 202c advanced on the second corrugated forming roller 308a. In some configurations, the second adhesive applicator device 330b may apply the second adhesive 238b to the depressions 236 of the first corrugated substrate 202c without applying the second adhesive 238b to the ridges 234 of the first corrugated substrate 202c. The third adhesive applicator device 330c may be adapted to apply the third adhesive 238c to the second substrate 204. For example, the third adhesive applicator device 330c may be operable to intermittently apply the third adhesive 238c to the second substrate 204 before advancing to the combining nip 304. In some configurations, the third adhesive applicator device 330c can intermittently apply the third adhesive 238c to the second substrate 204 along the machine direction MD in locations corresponding to the recesses 236 of the first corrugated substrate 202c.

[0098] like Fig.13 and Fig. 13BAs shown, the second adhesive 238b and / or the third adhesive 238c can form a second bonding portion 232 in the elastic laminate 200, and the second bonding portion bonds the first corrugated substrate 202c with the second corrugated substrate 204c. Specifically, the second bonding portion 232 can be intermittently spaced along the machine direction MD, and the recessed portion 236 of the first corrugated substrate 202c is bonded to the second substrate 204. The second bonding portion 232 can also be intermittently spaced along the cross direction CD. The elastic strand 208 can extend through the second bonding portion 232 and extend between the second bonding portions. Therefore, when the elastic laminate 200 is stretched and retracted, the elastic strand 208 can be retracted and stretched accordingly without being significantly inhibited by the second bonding portion 232. Compared with the second bonding portion 232, the elastic strand 208 of discrete length is anchored to the first corrugated substrate 202c and the second substrate 204 by the first bonding portion 230. Thus, when the elastic laminate 200 is stretched and retracted, the anchored discrete lengths of elastic strands 208 will move with the portions of the first corrugated substrate 202c and the second substrate 204 bonded to the first bonding portion 230, as shown in FIG. Fig.15 and Fig.16 shown.

[0099] Continue to refer to Figure 4B , Fig.15 and Fig.16 , the second substrate 204 is not corrugated before being combined with the first corrugated substrate 202c and the elastic strands 208 at the combining nip 304. Therefore, when the elastic laminate 200 is fully stretched, the second substrate 204 can be in a substantially flat state, such as Fig.15 However, Fig.16 As shown, when the elastic laminate 200 contracts from a fully stretched state, the second substrate 204 may flex and / or bend between the locations of the first and second bonds 230 , 232 to form corrugations 210 b defined by alternating ridges 234 and valleys 236 .

[0100] Although the above Figure 4B The third adhesive 238c is described as being intermittently applied to the second substrate 204, but it should be understood that the third adhesive 238c can be applied in different ways. Fig.14 , Fig.14A and Fig. 14BAs shown, the third adhesive 238c can be applied continuously along the machine direction MD and / or the cross direction CD of the second substrate 204. Although the third adhesive 238c extends continuously along the machine direction MD of the second substrate 204, the intermittently spaced second bonding portions 232 are formed by the intermittent pressing of the protrusions 324 of the second corrugated roller 308 against the outer circumferential surface 334 of the anvil roller 332 at the combined roller gap 304. In addition, although the elastic strand 208 can extend through the third adhesive 238c between the recessed portion 236 of the first corrugated substrate 202c and the second substrate 204, the third adhesive can be constructed and / or applied to allow the elastic strand 208 to retract and stretch without being significantly inhibited by the second bonding portions 232.

[0101] As discussed above, it should be understood that the first adhesive 238a, the second adhesive 238b and / or the third adhesive 238c can be the same adhesive or different adhesives. In addition, the first adhesive 238a, the second adhesive 238b and / or the third adhesive 238c can be applied with the same basis weight or different basis weights. For example, the first adhesive 238a can be applied with the first basis weight, the second adhesive 238b can be applied with the second basis weight, and / or the third adhesive 238c can be applied with the third basis weight. In some configurations, the second basis weight and / or basis weight can be less than the first basis weight.

[0102] It should be understood that Figure 4B The corrugated rollers 306, 308 shown in FIG. 3 may also be configured as gears 342, such as described above with reference to FIG. Fig.4A1 Thus, the gear teeth 344 of the first corrugating roller 306 and the gear teeth 344 of the second corrugating roller 308 may engage with each other at the corrugating roller nips 310, 312 to form corrugations in the first substrate 202 and / or the second substrate 204, such as described above with reference to Figure 4B Additionally, the outer radial surface 346 of the second corrugating roller 308 can be in relative relation to the outer circumferential surface 334 of the anvil roller 332 to squeeze the first substrate 202, the second substrate 204, and the elastic strands 208 together at the combined nip 304, such as described above with reference to Figure 4B described.

[0103] As mentioned above Figure 4A It should also be understood that Figure 4B The second bonding portion 232 formed by the device 300 may be an adhesive bonding portion and / or a mechanical bonding portion. For example, Figure 4BThe converting apparatus 300 shown in FIG. 3 can be configured to mechanically bond the first corrugated substrate 202c to the second substrate 204 to form the second bond 232. In some configurations, the second corrugating roller 308 and the anvil roller 332 of the corrugating apparatus 302 can be adapted to mechanically bond the recessed portion 234 of the first corrugated substrate 202c to the second substrate 204 at the combined nip 304.

[0104] For example, Figure 4B The second corrugating roller 308 may be configured to include a bonding element 348 positioned on the protrusion 324 or the gear teeth 344, as described above with reference to Figure 4A2 As described. When the second corrugating roller 308 and the anvil roller 332 rotate, the elastic laminate 200 is advanced between the pressing surface 350 and the outer circumferential surface 334 of the anvil roller 332 to mechanically bond or weld the first corrugated substrate 202c and the second substrate 204 together, thereby creating a second bond 232 between the recessed portion 234 of the first corrugated substrate 202c and the second substrate 204. The heat and / or pressure between the pressing surface 350 of the protrusion 324 of the second corrugating roller 308 and the outer circumferential surface 334 of the anvil roller 332 may melt in the area supported by the pressing surface 350 of the protrusion 324 on the second corrugating roller 308, and bond the first corrugated substrate 202c and the second substrate 204 together in the area. In another example, the anvil roller 332 may be configured to include a bonding element 348 with a pressing surface 350 positioned on the outer circumferential surface 344, such as Figure 4B2 As shown. Then, the heat and / or pressure between the extrusion surface 350 of the second anvil roller 332 and the outer radial surface 346 of the protrusion 324 or the gear teeth 344 of the second corrugating roller 332 can melt in the area supported by the extrusion surface 350 on the anvil roller 308 and bond the first corrugated substrate 202c and the second substrate 204 together in the area. Therefore, the second bonding portion 232 can have a shape that corresponds to the shape of the extrusion surface and can mirror its shape. In some configurations, the second corrugating roller 308 and / or the anvil roller 332 of the corrugating device 302 can also be heated. It should also be understood that the second corrugated forming roller 308 and the anvil roller 324 and / or the protrusions 324 and the outer circumferential surface 334 can be configured to apply heat and pressure in various ways to perform mechanical bonding, such as, for example, the mechanical bonding apparatus and methods disclosed in U.S. Pat. No. 4,854,984, U.S. Pat. No. 6,248,195, U.S. Pat. No. 8,778,127, U.S. Pat. No. 9,005,392, U.S. Pat. No. 9,962,297 and U.S. Pat. No. 10,052,237, all of which are incorporated herein by reference.

[0105] In another configuration, Figure 4BThe converting apparatus 300 may be adapted to produce the second bond 232 in the form of an ultrasonic bond. For example, Figure 4C The converting apparatus 300 includes an energy transfer surface 338 of an ultrasonic bonding device 340. The energy transfer surface 338 is adjacent to the second corrugating roller 308 to form a combined roll gap 304. Therefore, the combing roll gap 304 defined between the ultrasonic bonding device 340 and the corrugating device 302 can be characterized as a second metering device 301b, as discussed above. The ultrasonic bonding device 340 may include a horn 342 and may be configured to impart ultrasonic energy to the elastic laminate 200 on the second corrugating roller 308 to produce a second bond 232 at the combined roll gap 304. It should be understood that aspects of the ultrasonic bonding device 340 can be configured in various ways, such as, for example, a linear or rotational configuration, and such as disclosed in, for example, U.S. Pat. No. 3,113,225, U.S. Pat. No. 3,562,041, U.S. Pat. No. 3,733,238, U.S. Pat. No. 5,110,403, U.S. Pat. No. 6,036,796, U.S. Pat. No. 6,508,641, and U.S. Pat. No. 6,645,330, all of which are incorporated herein by reference. In some configurations, the ultrasonic bonding device 340 can be configured as a linear oscillating sonotrode, such as, for example, available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode can include a plurality of sonotrodes nested together in the cross direction CD.

[0106] It should be understood that the energy transfer surface 338 of the ultrasonic bonding device 340 and the protrusions 324 of the second corrugated forming roller 308 can be configured in various ways to interact at the combined roll gap 304 to produce the second bond 232. For example, the energy transfer surface 338 can be configured as a flat surface, and the second corrugated forming roller 308 can be configured to include bonding elements 348 positioned on the protrusions 324 or gear teeth 344, as described above with reference to Figure 4A2 As the second corrugating roller 308 rotates, the elastic laminate 200 is advanced between the pressing surface 350 on the protrusion 324 or the gear teeth 344 and the energy transfer surface 338 to mechanically bond or weld the first corrugated substrate 202c and the second substrate 204 together, thereby creating a second bond 232 between the recessed portion 234 of the first corrugated substrate 202c and the second substrate 204. In another example, the energy transfer surface 338 of the ultrasonic bonding device 340 may include a raised engagement area 352, such as Fig.4C1Thus, when the second corrugating roller 308 rotates, the elastic laminate 200 is advanced between the outer radial surface 346 of the protrusion 324 or the gear teeth 344 and the raised engagement area 352 of the energy transfer surface 338 to mechanically bond or weld the first corrugated substrate 202c and the second substrate 204 together, thereby creating a second bond 232 between the recessed portion 234 of the first corrugated substrate 202c and the second substrate 204.

[0107] Further about the elastic laminate 200 in this article being incorporated into various diaper assembly processes, it should also be understood that the first bonding portion 230 and the second bonding portion 232 discussed herein with reference to the accompanying drawings can be constructed in various ways. For example, the first bonding portion 230 can be configured as an anchoring bonding portion, and the second bonding portion 232 can be configured as a capture bonding portion or a guide bonding portion. More specifically, the anchoring bonding portion can be configured to anchor and bond the elastic strand 208 of the stretch of discrete lengths to the first substrate 202 and the second substrate 204, and anchor and bond between the first substrate and the second substrate, and the capture bonding portion can be configured to directly bond the first substrate 202 and the second substrate 204 to each other, wherein the capture bonding portion is separated from each other in the transverse direction by at least one elastic strand 208, and therefore, the elastic strand 208 can be captured between the capture bonding portions. In some configurations, the capture bonding portion can be arranged to directly bond the first substrate 202 and the second substrate 204 together, without bonding the elastic strand 208 to any substrate. Thus, the capture bonds can be configured to capture and secure discrete lengths of elastic strands 208 between the capture bonds after the elastic strands 208 have contracted, such as disclosed, for example, in U.S. Patent No. 6,291,039 and U.S. Patent Publication No. 2016 / 0331600A1, U.S. Patent Publication No. 2018 / 0168880A1, U.S. Patent Publication No. 2018 / 0170027A1, and U.S. Patent Publication No. 2018 / 0168879A1, all of which are incorporated herein by reference.

[0108] It should also be understood that the elastic laminate 200 herein can be configured to undergo various elastic strand cutting processes (sometimes referred to as belly elastic cutting) to produce deactivated regions 242 in the elastic laminate located in the machine direction MD between elasticized regions by severing at least one stretched elastic strand 208, wherein the at least one severed elastic strand 208 is retracted to at least one anchor bond 230. For example, Fig.17As shown, the elastic strands 208 can be severed between the anchor bonds 230 in the elastic laminate 200, and thus, the severed elastic strands 208 can be retracted to the anchor bonds 230 (indicated by dashed arrows "A") to form deactivated areas 242. In some assembly operations, the absorbent chassis 102 can be connected to the elastic laminate 200 in such deactivated areas 242. Therefore, it should also be understood that the methods and apparatus herein may be suitable for operation with various types of absorbent article assembly processes that may include elastic laminates assembled thereby, such as, for example, those disclosed in U.S. Patent No. 8,186,296, U.S. Patent No. 9,265,672, U.S. Patent No. 9,248,054 and U.S. Patent No. 9,730,839, as well as U.S. Patent Publication No. 2013 / 0255861A1, U.S. Patent Publication No. 2013 / 0255862A1, U.S. Patent Publication No. 2013 / 0255863A1, U.S. Patent Publication No. 2013 / 0255864A1, U.S. Patent Publication No. 2013 / 0255865A1, U.S. Patent Publication No. 2018 / 0169964A1 and U.S. Patent Publication No. 2018 / 0168879A1, all of which are incorporated herein by reference. In other examples, the elastic laminate 200 herein can be used to construct various types of leg cuffs, backsheets and / or topsheet configurations. In other examples, the elastic laminate can be used to construct waistbands and / or side panels in a taped diaper configuration.

[0109] As described above, it should be understood that the elastic laminate 200 herein can be used to construct various types of absorbent article components. For example, the elastic laminate 200 can be used as a continuous length of elastomeric belt material that can be converted into the absorbent article components described above with reference to FIGS. Figure 3B The first elastic band 106 and the second elastic band 108 discussed above. Thus, the elastic material 206 may correspond to the band elastic material 168 interposed between the outer layer 162 and the inner layer 164, which in turn may correspond to the first substrate 202 and / or the second substrate 204. For example, Fig.18As shown, when assembling the diaper pants 100P, the elastic laminate 200 can be converted into a first elastic belt laminate 200a and / or a second elastic belt laminate 200b (indicated by the dashed arrow "A"). The first elastic belt laminate 200a and the second elastic belt laminate 200b can be separated from each other in the cross-direction CD and can be connected to each other using multiple base structures 102 intermittently spaced along the machine direction MD. During the subsequent assembly operation, the base structure 102 can be folded (indicated by the dashed arrow "B") so as to position the first elastic belt laminate 200a to be in a facing relationship with the second elastic belt laminate 200b. The bonding member 240 can be applied to the overlapping belt laminates 200a, 200b. It should also be understood that the anchoring bond 230 can also be located in the area where the bonding portion 240 is located. Subsequently, a discrete diaper pant 100P may be formed by separating the first and second belt laminates 200a, 200b into the first and second belts 106, 108 by cutting through the first and second belt laminates 200a, 200b at the bonds 240 and anchor bonds 230 in the cross-direction CD (indicated by dashed arrows "C"). Thus, the bonds 240 may be separated into the first and second side seams 178, 180, respectively. It should also be understood that the elastic laminate 200 converted into the first and second elastic belts 106, 108 may be subjected to other types of cutting operations (such as leg cut-out or contour cutting operations), such as, for example, disclosed in U.S. Pat. No. 10,098,792, which is incorporated by reference. Thus, the laminate 200 may be configured to position the anchor bonds 230 at the location where the cutting operation occurs to help ensure that the elastic strands remain in place after the laminate has been cut. In some configurations, the elastic laminate herein can be converted to define the first elastic band 106 and the second elastic band 108 described herein, and can also be converted to define one or more components of a multi-component band assembly, such as disclosed in U.S. Patent Publication No. 2022 / 0142828A1, which is incorporated by reference.

[0110] combination

[0111] A1. A method for preparing an elastomeric laminate, the method comprising the following steps: providing a first corrugated substrate by forming ridges alternating with depressions in a first substrate along a machine direction; providing a second corrugated substrate by forming ridges alternating with the depressions in a second substrate along the machine direction; advancing an elastic strand in the machine direction; stretching the elastic strand in the machine direction; after the step of stretching the elastic strand, intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand; utilizing the first bonding portion formed by the discrete areas of the first adhesive to bond discrete lengths of the elastic strand to the first corrugated substrate and the second corrugated substrate and to bond the elastic strand between the first corrugated substrate and the second corrugated substrate; and utilizing a second bonding portion located between consecutive first bonding portions along the machine direction to directly bond the depressions of the first corrugated substrate to the depressions of the second corrugated substrate.

[0112] A2. The method of paragraph A1, wherein the elastic strands extend through the second bonds, and wherein the elastic strands are capable of retracting and stretching through the second bonds.

[0113] A3. The method of paragraph A1 or A2, wherein the second bond comprises a second adhesive.

[0114] A4. The method of paragraph A3, further comprising the step of applying the second adhesive to at least one of the first corrugated substrate and the second corrugated substrate.

[0115] A5. The method of paragraph A4, wherein the step of applying the second adhesive to at least one of the first corrugated substrate and the second corrugated substrate further comprises applying the second adhesive to a recessed portion of at least one of the first corrugated substrate and the second corrugated substrate.

[0116] A6. The method of any of paragraphs A4 or A5, wherein the first adhesive is applied at a first basis weight, and wherein the second adhesive is applied at a second basis weight, and wherein the second basis weight is less than the first basis weight.

[0117] A7. A method according to any of paragraphs A4 to A6, wherein the second adhesive is positioned between the elastic strand and at least one of the first corrugated substrate and the second corrugated substrate without adhering the elastic strand to at least one of the first corrugated substrate and the second corrugated substrate.

[0118] A8. The method of any of paragraphs A1 to A7, wherein the second bond comprises a mechanical bond.

[0119] A9. The method of paragraph A8, wherein the mechanical bond comprises an ultrasonic bond.

[0120] A10. The method of paragraph A8, wherein the mechanical bond comprises a heat bond or a pressure bond.

[0121] A11. The method of any of paragraphs A1 to A10, wherein the stretching step comprises advancing the elastic strand from a first metering device at a first speed to a second metering device at a second speed, wherein the second speed is greater than the first speed.

[0122] A12. The method of paragraph A11, wherein the first metering device comprises separate spools of elastic strands.

[0123] A13. The method of paragraph A11, wherein the first metering device includes a beam having a plurality of elastic strands wound thereon.

[0124] A14. The method of paragraph A11, wherein the second metering device includes a first roller adjacent to a second roller defining a nip therebetween, and wherein the elastic strand is advanced through the nip and is sandwiched between the first corrugated substrate and the second corrugated substrate.

[0125] A15. A method according to paragraph A14, wherein the first roller is adjacent to the third roller, wherein the first roller and the third roller each include a plurality of protrusions that engage with each other when the first roller and the third roller rotate in opposite directions, and wherein the step of providing the first corrugated substrate also includes: advancing the first substrate between the mutually engaging protrusions of the first roller and the third roller.

[0126] A16. The method of any of paragraphs A1 to A15, wherein the elastic strands comprise less than about 300 decitex.

[0127] A17. The method of any of paragraphs A1 to A16, further comprising the step of separating the elastic strands from each other in the transverse direction by about 0.5 mm to about 3 mm.

[0128] A18. The method described in any of paragraphs A1 to A17 further comprises the following steps: forming a deactivation area by cutting the elastic strands between continuous first bonding portions, wherein the cut elastic strands retract to the continuous anchoring bonding portions; and bonding the absorbent base structure to the deactivation area.

[0129] A19. The method described in any one of paragraphs A1 to A18 further includes the following steps: bonding the elastic laminate to a second elastic laminate using a side seam bonding portion, wherein the first bonding portion is located in the area where the side seam bonding portion is located; and cutting the elastic laminate and the second elastic laminate through the side seam bonding portion and the first bonding portion to form discrete diaper pants.

[0130] B1. A method for preparing an elastomeric laminate, the method comprising the following steps: providing a first corrugated substrate by forming ridges alternating with depressions in the first substrate along a machine direction; providing a second substrate, wherein the second substrate is not corrugated; advancing the elastic strand in the machine direction; stretching the elastic strand in the machine direction; after stretching the elastic strand, intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand; utilizing a first bonding portion formed by the discrete areas of the first adhesive to bond discrete lengths of the elastic strand to the first corrugated substrate and the second substrate and to bond the elastic strand between the first corrugated substrate and the second substrate; and utilizing a second bonding portion located between continuous first bonding portions along the machine direction to directly bond the depressions of the first corrugated substrate to the second substrate.

[0131] B2. The method of paragraph B1, wherein the elastic strands extend through the second bonds, and wherein the elastic strands are capable of retracting and stretching through the second bonds.

[0132] B3. The method of paragraph B1 or B2, wherein the second bond comprises a second adhesive.

[0133] B4. The method of paragraph B3, further comprising the step of applying the second adhesive to the first corrugated substrate.

[0134] B5. The method according to paragraph B3, further comprising the step of applying the second adhesive to the second substrate.

[0135] B6. The method of any of paragraphs B2 to B5, wherein the first adhesive is applied at a first basis weight, and wherein the second adhesive is applied at a second basis weight, and wherein the second basis weight is less than the first basis weight.

[0136] B7. The method of any of paragraphs B1 to B6, wherein the second bond comprises a mechanical bond.

[0137] B8. The method of paragraph B7, wherein the mechanical bond comprises an ultrasonic bond.

[0138] B9. A method according to paragraph B7, wherein the mechanical bond comprises a heat bond or a pressure bond.

[0139] B10. The method of any of paragraphs B1 to B9, wherein the stretching step comprises advancing the elastic strand from a first metering device at a first speed to a second metering device at a second speed, wherein the second speed is greater than the first speed.

[0140] B11. The method of paragraph B10, wherein the first metering device comprises separate spools of elastic strands.

[0141] B12. The method of paragraph B10, wherein the first metering device includes a beam having a plurality of elastic strands wound thereon.

[0142] B13. The method of paragraph B10, wherein the second metering device includes a first roller adjacent to a second roller defining a nip therebetween, and wherein the elastic strand is advanced through the nip and is sandwiched between the first corrugated substrate and the second corrugated substrate.

[0143] B14. A method according to paragraph B13, wherein the first roller is adjacent to the third roller, wherein the first roller and the third roller each include a plurality of protrusions that engage with each other when the first roller and the third roller rotate in opposite directions, and wherein the step of providing the first corrugated substrate also includes: advancing the first substrate between the mutually engaging protrusions of the first roller and the third roller.

[0144] B15. The method of any of paragraphs B1 to B14, wherein the elastic strands comprise less than about 300 dtex.

[0145] B16. The method of any of paragraphs B1 to B15, further comprising the step of separating the elastic strands from each other by about 0.5 mm to about 3 mm in the transverse direction.

[0146] C1. A method for preparing an elastomeric laminate, the method comprising the following steps: providing a first substrate and a second substrate; corrugating at least one of the first substrate and the second substrate by forming ridges alternating with depressions in at least one of the first substrate and the second substrate along a machine direction; advancing the elastic strand in the machine direction; stretching the elastic strand in the machine direction; bonding discrete lengths of the elastic strand between the first substrate and the second substrate using a first bonding portion; and directly bonding the first substrate to the second substrate using a second bonding portion located between consecutive first bonding portions along the machine direction.

[0147] C2. According to the method described in paragraph C1, the method also includes a step of intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand, and wherein the first bonding portion is formed by the discrete areas of the first adhesive, and wherein the second bonding portion includes a second adhesive.

[0148] C3. The method of paragraph C2, further comprising the step of applying the second adhesive to at least one of the first substrate and the second substrate.

[0149] C4. The method of paragraph C3, wherein the first adhesive is applied at a first basis weight, and wherein the second adhesive is applied at a second basis weight, and wherein the second basis weight is less than the first basis weight.

[0150] C5. According to the method described in paragraph C4, the method also includes a step of intermittently applying a first adhesive to the elastic strand to form discrete areas of the first adhesive on the elastic strand, and wherein the first bonding portion is formed by the discrete areas of the first adhesive, and wherein the second bonding portion includes a mechanical bonding portion.

[0151] C6. A method according to paragraph C5, wherein the mechanical bond comprises an ultrasonic bond.

[0152] C7. A method according to paragraph C5, wherein the mechanical bond comprises a heat bond or a pressure bond.

[0153] C8. The method of any of paragraphs C1 to C7, wherein the first bond comprises a mechanical bond, and wherein the second bond comprises at least one of an adhesive bond and a mechanical bond.

[0154] C9. The method of paragraph C8, wherein the first bonding portion further comprises an adhesive.

[0155] D1. An elastomeric laminate comprising: a first substrate; a second substrate, wherein at least one of the first substrate and the second substrate is corrugated; elastic strands, which are positioned between the first substrate and the second substrate; wherein discrete lengths of the elastic strands are bonded to the first substrate and the second substrate using a first bonding portion; wherein the first substrate and the second substrate are directly bonded to each other using a second bonding portion positioned between continuous first bonding portions; and wherein the elastic strands extend through the second bonding portion, and the elastic strands are capable of retracting and stretching through the second bonding portion.

[0156] D2. The elastomeric laminate of paragraph D1, wherein the first bonds comprise discrete areas of a first adhesive on the elastic strands.

[0157] D3. The elastomeric laminate of paragraph D2, wherein the second bonding portion comprises a second adhesive on at least one of the first substrate and the second substrate.

[0158] D4. The elastomeric laminate of paragraph D2, wherein the second bond comprises a mechanical bond.

[0159] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise indicated, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0160] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art to any of the present invention disclosed or claimed herein, or an admission that it, by itself or in combination with any one or more of the references, proposes, suggests, or discloses any such invention. In addition, to the extent that any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this invention shall govern.

[0161] Although specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be covered in the appended claims.

Claims

1. A method for preparing an elastomeric laminate (200), the method comprising the following steps: Providing a first corrugated substrate (202c) by forming ridges (234) alternating with depressions (236) in a first substrate (202) along a machine direction; providing a second corrugated substrate (204c) by forming ridges (234) alternating with depressions (236) in the second substrate (204) along a machine direction; advancing the elastic strands (208) in the machine direction; stretching the elastic strands (208) in the machine direction; After the step of stretching the elastic strand (208), intermittently applying a first adhesive (238a) to the elastic strand (208) to form discrete areas of the first adhesive (238a) on the elastic strand (208); bonding discrete lengths of the elastic strands (208) to and between the first corrugated substrate (202c) and the second corrugated substrate (204c) using first bonds (230) formed by discrete areas of the first adhesive (238a); as well as The recessed portion (236) of the first corrugated substrate (202c) is directly bonded to the recessed portion (236) of the second corrugated substrate (204c) using a second bonding portion (232) located between consecutive first bonding portions (230) along the machine direction.

2. The method of claim 1, wherein an elastic strand (208) extends through the second bond (232), and wherein the elastic strand (208) is capable of retracting and stretching through the second bond (232).

3. The method according to claim 1 or 2, wherein the second bonding portion (232) comprises a second adhesive (238b).

4. The method of claim 3, further comprising the step of applying the second adhesive (238b) to at least one of the first corrugated substrate (202c) and the second corrugated substrate (204c).

5. The method of claim 4, wherein the step of applying the second adhesive to at least one of the first corrugated substrate (202c) and the second corrugated substrate (204c) further comprises: The second adhesive (238b) is applied to the recessed portion (236) of at least one of the first corrugated substrate (202c) and the second corrugated substrate (204c).

6. The method of claim 4, wherein the first adhesive (238a) is applied at a first basis weight, and wherein the second adhesive (238b) is applied at a second basis weight, and wherein the second basis weight is less than the first basis weight.

7. A method according to claim 4, wherein the second adhesive (238b) is positioned between the elastic strand (208) and at least one of the first corrugated substrate (202c) and the second corrugated substrate (204c) without adhering the elastic strand (208) to the at least one of the first corrugated substrate (202c) and the second corrugated substrate (204c).

8. The method of claim 1, wherein the second bond (232) comprises a mechanical bond including at least one of an ultrasonic bond and a heat bond or a pressure bond.

9. The method of claim 1, wherein the stretching step comprises advancing the elastic strand (208) from a first metering device (301a) at a first speed to a second metering device (301b) at a second speed, wherein the second speed is greater than the first speed.

10. The method of claim 9, wherein the first metering device (301a) comprises a separate spool of elastic strands.

11. The method of claim 9, wherein the second metering device (301b) comprises a first roller (308a) adjacent to a second roller (308b), defining a nip (304) between the first roller and the second roller, and wherein the elastic strand (208) is advanced through the nip (304) and is sandwiched between the first corrugated substrate (202c) and the second corrugated substrate (204c).

12. The method of claim 9, wherein the first roller (308a) is adjacent to a third roller (306a), wherein the first roller (308a) and the third roller (306a) each include a plurality of protrusions (318a, 324a) that engage with each other when the first roller (308a) and the third roller (306a) rotate in opposite directions, and wherein the step of providing the first corrugated base (202c) further comprises: The first substrate (202) is advanced between the intermeshing protrusions (318a, 324a) of the first roller (308a) and the third roller (306a).

13. The method according to any of the preceding claims, wherein the elastic strands (208) comprise less than about 300 dtex, and the method further comprises the step of separating the elastic strands from each other in a transverse direction by about 0.5 mm to about 3 mm.

14. The method according to any one of the preceding claims, further comprising the steps of: forming a deactivated region (242) by cutting the elastic strands (208) between consecutive first bonds (230), wherein the cut elastic strands are retracted to the consecutive first bonds (230); and An absorbent chassis (102) is bonded to the deactivated area (242).

15. The method according to any one of the preceding claims, further comprising the steps of: bonding the elastic laminate (200) to a second elastic laminate (200b) using a side seam bond (240), wherein the first bond (230) is located in the region where the side seam bond (240) is located; The elastic laminate (200) and the second elastic laminate (200b) are cut through the side seam bonds (240) and the first bonds (230) to form discrete diaper pants (100P).

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