Absorbent articles including front and back waist panels with different stretch characteristics

Abstract

To provide absorbent articles including front and back waist panels with different stretch characteristics.SOLUTION: A first waist panel 158a may be connected with a chassis 102 and positioned in a first waist region 116, and a second waist panel 158b may be connected with the chassis and positioned in a second waist region 118. In some configurations, the first waist panel may comprise a first structural feature that is not included in the second waist panel or may comprise a first structural feature that is different from a second structural feature included in the second waist panel. As such, the first structural feature provides different stretch characteristics between the first waist panel and the second waist panel.SELECTED DRAWING: Figure 1B

Description

[Technical field]

[0001] SUMMARY The present disclosure relates to absorbent articles that include waist panels, and more particularly, to front and rear waist panels having different stretch characteristics. [Background technology]

[0002] Various types of articles, such as, for example, diapers and other absorbent articles, can be assembled by adding components to and / or otherwise modifying a continuous web of advancing material along an assembly line. For example, in some processes, an advancing web of material is combined with other advancing webs of material. In other examples, individual components created from an advancing web of material are combined with an advancing web of material, which are then combined with other advancing webs of material. In some examples, individual components created from an advancing web(s) are combined with other individual components created from other advancing webs. The webs of material and component portions used to manufacture diapers may include various types of elastic webs and portions, such as backsheets, topsheets, leg cuffs, waistbands, absorbent core components, front and / or back ears, fastening components, and leg elastics, barrier leg cuff elastics, stretch side panels, and waist elastics. Once the desired component parts have been assembled, the advancing web and component parts are subjected to a final knife cut to separate the web into separate diapers or other absorbent articles.

[0003] Some absorbent articles, such as diapers, have components that include elastic portions, such as waistbands. In some configurations, the waistband may be provided as a single layer of elastic material, such as an elastic film. In some configurations, the waistband may be provided as an elastic laminate, which may include an elastic material bonded to one or more substrates, such as a nonwoven, and the elastic material may include an elastic film and / or elastic strands. In some assembly operations, the waistband is connected to an advancing carrier web, such as a continuous topsheet or backsheet web, and the waistband is in an extended state. Thus, when the waistband relaxes, the carrier web gathers form corrugations. The resulting laminate is stretchable to the extent that the corrugations allow the waistband to elongate.

[0004] When manufacturing diapers, the waistbands may be provided as a continuous length of waistband material that can be stretched, cut into separate waistbands, and joined to an advancing carrier web, such as a continuous topsheet or backsheet web, while the waistband is in a stretched state. In some diapers, it may be desirable to include a front waistband in the front waist region and a rear waistband in the opposing rear waist region. In some assembly operations, a piece of waistband material may be applied to the advancing carrier web, which is then cut into separate front and rear waistbands when the advancing carrier web is subjected to a final knife cut that separates the carrier web into separate diapers. The front and rear waistbands may then be produced from the same continuous length of waistband material.

[0005] In some configurations, it may be desirable to provide a diaper with front and rear waistbands having different stretch characteristics to help improve fit, comfort, and / or performance. To accommodate such requirements, manufacturing operations may need to create the front and back waistbands from different supplies of prefabricated waistband material with different stretch characteristics. However, requiring different supplies of waistband material may result in increased manufacturing costs and complexity. Summary of the Invention [Problem to be solved by the invention]

[0006] As a result, it would be beneficial to provide an absorbent article having front and back waist features with different stretch properties resulting from different structural and / or morphological features that can be imparted to a single source stretch laminate during the absorbent article assembly process. [Means for solving the problem]

[0007] In one form, the absorbent article includes a chassis including a first waist region, a second waist region, and a crotch region disposed between the front waist region and the second waist region, a first waist edge, a second waist edge, a first longitudinal side edge, and a second longitudinal edge, a topsheet, a backsheet, and an absorbent core positioned between the topsheet and the backsheet, leg gasket elements extending from the first waist region to the second waist region, a first waist panel including an inner lateral edge, an outer lateral edge, and two longitudinal edges, the first waist panel including a first elastic film joined in a stretched state to a first nonwoven, the first waist panel being connected to the chassis. and a second lumbar panel having an inner lateral edge, an outer lateral edge, and two longitudinal edges, the second lumbar panel comprising a second elastic film joined to a second nonwoven in a stretched state, the second lumbar panel connected to the chassis and positioned in the second lumbar region, the first lumbar panel including a first structural feature that is not included in the second lumbar panel or that is different from a second structural feature included in the second lumbar panel, the first structural feature or the second structural feature providing different stretch characteristics between the first lumbar panel and the second lumbar panel.

[0008] In another form, an absorbent article includes a chassis including a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region, a first waist edge, a second waist edge, a first longitudinal side edge, and a second longitudinal edge, a topsheet, a backsheet, and an absorbent core positioned between the topsheet and the backsheet, leg gasket elements extending from the first waist region to the second waist region, and a first waist panel positioned in the first waist region, the first waist panel including an inner lateral edge, an outer lateral edge, and two longitudinal edges, the first waist panel having a lateral edge extending along the longitudinal edges. The garment comprises a first waist panel, an area of ​​the first waist panel extending therethrough being mechanically joined to the chassis, and a second waist panel positioned in the second waist region, the second waist panel having an inner lateral edge, an outer lateral edge, and two longitudinal edges, the second waist panel comprising an elastic film joined in a stretched state to a nonwoven fabric, wherein an area of ​​the second waist panel extending along the outer lateral edge and an area extending along the longitudinal edges are joined to the chassis in the second waist region, and at least a portion of the inner lateral edge of the second lumbar panel is not attached to the chassis.

[0009] In yet another form, an absorbent article includes a chassis having a front waist region, a rear waist region, and a crotch region disposed between the front waist region and the rear waist region, a front waist edge, a rear waist edge, a first longitudinal side edge, and a second longitudinal edge, a topsheet, a backsheet, and an absorbent core positioned between the topsheet and the backsheet, leg gasket elements extending from the first waist region to the second waist region, a first waist panel having an inner lateral edge, an outer lateral edge, and two longitudinal edges, the first waist panel being joined to a first nonwoven in a stretched state. The garment comprises a first waist panel comprising a first elastic film and positioned in the front waist region; and a second waist panel having an inner lateral edge, an outer lateral edge, and two longitudinal edges, the second waist panel comprising a second elastic film joined in a stretched state to a second nonwoven, the second waist panel being connected to the chassis and positioned in the rear waist region, wherein the first pressure bond defines a first stretch characteristic of the first waist panel and the second pressure bond defines a second stretch characteristic of the second lumbar panel that is different from the first stretch characteristic.

[0010] In yet another form, a method of providing an absorbent article having a first elastic waist panel and a second elastic waist panel, the first elastic waist panel and the second elastic waist panel having different stretch characteristics, the method includes the steps of providing a continuous length of chassis, applying the first elastic waist panel and the second elastic waist panel to the continuous length of chassis, creating a morphological difference between the first waist panel and the second waist panel, and separating the continuous length of chassis into individual absorbent articles. [Brief description of the drawings]

[0011] [Figure 1A] FIG. 2 is a partial cutaway plan view of an absorbent article in the form of a taped diaper, which may include one or more substrates constructed in accordance with the present disclosure, with the portion of the diaper facing away from the wearer oriented toward the viewer. [Figure 1B]FIG. 1B is a plan view of the absorbent article of FIG. 1A, which may include one or more substrates constructed in accordance with the present disclosure, with the portion of the diaper facing the wearer oriented toward the viewer. [Diagram 2] FIG. 2 is a detailed view of the first waist panel, with the wearer-facing portion of the diaper oriented towards the viewer. [Figure 2A] FIG. 3 is a detailed view of the first lumbar panel of FIG. 2 showing the joining arrangement. [Figure 2B] FIG. 3 is a detailed view of the first lumbar panel of FIG. 2 showing structural features. [Figure 2C] FIG. 3 is a detailed view of the first lumbar panel of FIG. 2 showing structural features with pressure bonding. [Diagram 3] FIG. 2 is a detailed view of the second waist panel, with the wearer-facing portion of the diaper oriented towards the viewer. [Figure 3A] FIG. 4 is a detailed view of the second lumbar panel of FIG. 3 showing the joining configuration. [Figure 3B] FIG. 4 is a detailed view of the second lumbar panel of FIG. 3 showing structural features. [Figure 3C] FIG. 4 is a detailed view of the second lumbar panel of FIG. 3 showing structural features with pressure bonding. [Figure 4] 1 is a schematic side view of an apparatus for joining an elastic portion to an advancing carrier web. [Figure 4A] FIG. 2 is a detailed schematic diagram of a bonding device having a pressing surface with an ultrasonic bonding device. [Diagram 5] 5 is a view of the carrier substrate taken along section 5-5 of FIG. 4. [Figure 5A] FIG. 5 is a view of the carrier substrate with leg cuffs taken along section 5-5 of FIG. 4. [Figure 6] 6 is a view of the continuous elastic substrate taken along section 6-6 of FIG. 4. [Figure 7] 7 is a view of a continuous elastic substrate having discrete patches of adhesive taken along section 7-7 of FIG. 4. [Figure 8] 8 is a view of a separate elastic portion laid flat with a zone of adhesive thereon, taken along section 8-8 of FIG. 4. FIG. [Figure 9] 9 is a view of the cutting device, the transport device, and the joining device taken along section 9-9 of FIG. 4. [Figure 10] 10 is a view of the transfer device and bonding device taken along section 10-10 of FIG. 9. [Figure 11] FIG. 11 is a detailed view of the spreader mechanism taken along line 11-11 of FIG. [Figure 11A] FIG. 13 is a detailed view of a radially protruding nub on the outer rim of the disk. [Figure 12] 12 is a view of the stretched separate elastic portions laid flat with zones of adhesive thereon taken along cross section 12-12 of FIG. 4. FIG. [Figure 13] 13 is a detailed cross-sectional view of the pattern roll of FIG. 9 taken along line 13-13 and showing interface elements extending radially outward from the outer circumferential surface. [Figure 13A] 13A is a detailed view of a portion of the outer peripheral surface of the pattern roll showing the joining elements of FIG. 13 taken along line 13A-13A. [Figure 14] 14 is a view of a laminate including an elastic portion and a carrier substrate taken along cross section 14-14 of FIG. 4. [Figure 14A] FIG. 15 is a view of the laminate of FIG. 14 including the elastic portions and carrier substrate after being subjected to a final knife cutting operation that applies cut lines through the carrier substrate and the separate elastic portions. [Figure 15] 15 is a view of a laminate including an elastic portion and a carrier substrate taken along section 15-15 of FIG. 14. [Figure 16] 16 is a view of the carrier substrate and adhesive taken along section 16-16 of FIG. 4. [Figure 17A] 1 is a schematic side view of an apparatus operative to assemble an elastic substrate; [Figure 17B] FIG. 17B is a left side view of the device of FIG. 17A taken along line 17B-17B. [Figure 17C] FIG. 17C is a top view of the device of FIG. 17A taken along line 17C-17C. [Figure 17D] FIG. 17D is a detailed view of the elastic material advancing over the spreader mechanism of FIG. 17B taken along line 17D-17D. [Figure 18] 18 is a cross-sectional view of the elastic substrate of FIG. 17A taken along line 18-18. [Figure 19] 19 is a cross-sectional view of the elastic substrate of FIG. 18 in a relaxed contracted state. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The following explanations of terms may be useful in understanding this disclosure.

[0013] "Absorbent article" is used herein to refer to consumer products whose primary function is to absorb and retain soilage 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 having 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 generally not intended to be washed or otherwise regenerated or reused as absorbent articles (e.g., they are intended to be discarded after a single use and may be configured to be recycled, composted, or otherwise disposed of in an environmentally compatible manner).

[0014] "Elastic," "elastomer," or "elastomeric" refers to a material exhibiting elastic properties, including any material that, upon application of a force to a relaxed initial length, can be stretched or extended to an extended length greater than 10% of the initial length, and will substantially recover to approximately the initial length when the applied force is released.

[0015] "Consolidation," "compaction," and "compacted" refer to a material that undergoes a reduction in elongation from a first stretched length to a second stretched length that is less than the first stretched length and greater than zero.

[0016] "Relaxed state" defines the length of a material when not stretched by an applied force.

[0017] In the context of this specification, 0% elongation refers to the material in a relaxed state having a relaxed length of L, and 150% elongation represents 2.5 times the relaxed length L of the material. For example, an elastic film having a relaxed length of 100 millimeters will have a length of 250 millimeters at 150% elongation, and an elastic film having a relaxed length of 100 millimeters will have a length of 180 millimeters at 80% elongation.

[0018] In the context of this specification, a 60% shrinkage represents a shrinkage of 0.6 times the initial stretched length L of the material. For example, an elastic film having an initial stretched length of 250 millimeters will have a shrinkage length of 100 millimeters at 60% shrinkage, and an elastic film having an initial stretched length of 180 millimeters will have a length of 100 millimeters at 44% shrinkage.

[0019] As used herein, the term "coupled" encompasses an arrangement in which an element is directly secured to another element by directly attaching the element to the other element, as well as an arrangement in which an element is indirectly secured to another element by attaching the element to an intermediate member(s) and then attaching the intermediate member(s) to the other element.

[0020] The term "substrate" is used herein to describe a material that is primarily two-dimensional (i.e., in the XY plane) and whose thickness (Z direction) is relatively small (i.e., 1 / 10 or less) compared to its length (X direction) and width (Y direction). Non-limiting examples of substrates include webs, layers or layers or films and foils, such as fibrous materials, nonwovens, polymeric films or metal foils. These materials may be used alone or may include two or more layers laminated together. Thus, a web is a substrate.

[0021] The term "nonwoven" as used herein refers to materials made from continuous (long) filaments (fibers) and / or non-continuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, etc. In some configurations, the nonwoven may include polyolefin-based nonwovens, including but not limited to nonwovens having polypropylene and / or polyethylene fibers, and / or bicomponent fibers that include polyolefins. Non-limiting examples of suitable fibers include spunbond, spunlaid, meltblown, spunmelt, solvent spun, electrospun, carded, film fibrillated, melt film fibrillated, airlaid, drylaid, wetlaid staple fibers, and other nonwoven web materials formed in part or in whole of polymeric fibers known in the art, and processable combinations thereof. Nonwovens do not have a woven or knitted filament pattern. It is understood that nonwovens having a variety of basis weights may be used according to the methods herein. For example, some nonwoven fabrics may have a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm, 30 gsm, 40 gsm, or 65 gsm. Some nonwoven fabrics may have a basis weight of from about 8 gsm to about 65 gsm, specifically recited in 1 gsm increments within the above ranges and all ranges formed by or within the ranges.

[0022] It is understood that films having a variety of basis weights may be used in accordance with the present disclosure. For example, some films may have a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm, 30 gsm, 40 gsm, or 60 gsm. Some films may have a basis weight of about 5 gsm to about 150 gsm, specifically recited in the above ranges and all ranges therein or formed by the ranges, all in 1 gsm increments.

[0023] It should be understood that the elastic films discussed herein may include a variety of materials and / or components. Some elastomeric compositions may include thermoplastic elastomers selected from the group consisting of styrenic block copolymers, polyesters, polyurethanes, polyetheramides, and combinations thereof. Suitable styrenic block copolymers may be diblock, triblock, tetrablock, or other multiblock copolymers having at least one styrenic block. Exemplary styrenic block copolymers include styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene / butylene-styrene, styrene-ethylene / propylene-styrene, and the like. Commercially available styrenic block copolymers include KRATON (styrenic block copolymer; available from Kraton Chemical Company, Houston, TX), SEPTON (styrenic block copolymer; available from Kuraray America, Inc., New York, NY), VECTOR (styrenic block copolymer; available from TSRC Dexco Chemical Company, Houston, TX), and may be used. Additional commercially available elastomers are ESTANE (a polyurethane; available from Lubrizol, Inc., Ohio), PEBAX (a polyether-based block amide; available from Arkema Chemicals, Philadelphia, Pa.), and HYTREL (a polyester; available from DuPont, Wilmington, Del.).

[0024] Semicrystalline polyolefins or metallocene polyolefins may be used in disposable absorbent products. Polyolefin elastomeric materials herein may include, but are not limited to, any polymer or copolymer of polyolefins, such as polyethylene and polypropylene. Examples of elastomeric polypropylenes include elastic random poly(propylene / olefin) copolymers, isotactic polypropylenes containing stereoirregularity, isotactic / atactic polypropylene block copolymers, isotactic polypropylene / random poly(propylene / olefin) copolymer block copolymers, stereoblock elastic polypropylenes, syndiotactic polypropylene block poly(ethylene-co-propylene) block syndiotactic polypropylene triblock copolymers, isotactic polypropylene block regioregular polypropylene block isotactic polypropylene triblock copolymers, polyethylene random (ethylene / olefin) copolymer block copolymers, reactor blend polypropylenes, very low density polypropylenes (or equivalently, ultra low density polypropylenes), metallocene polypropylenes, and blends or combinations thereof. Some homopolyolefins and random copolymers, as well as blends of such random copolymers, known by the trademark Vistamaxx™ available from ExxonMobil and VERSIFY™ available from Dow, tend to exhibit elastic performance. In some embodiments, two or more elastomers may be blended to achieve the desired elastic performance. For example, a styrene-based block copolymer may be blended with a polyolefin-based elastomer, or a polypropylene-based elastomer may be blended with another polyolefin-based elastomer.

[0025] Components of the disposable absorbent articles (i.e., diapers, disposable pants, adult incontinence articles, sanitary napkins, panty liners, etc.) described herein may be prepared using any of the methods and techniques described in U.S. Patent Application Publication Nos. 2007 / 0219521(A1) published on September 20, 2007 to Hird et al., 2011 / 0139658(A1) published on June 16, 2011 to Hird et al., and 2012 / 0139658(A1) published on June 16, 2011 to Hird et al. No. 2011 / 0139657(A1) to Hird et al., published June 23, 2011, No. 2011 / 0152812(A1) to Hird et al., published June 16, 2011, No. 2011 / 0139662(A1) to Hird et al., published June 16, 2011, and No. 2011 / 0139659(A1) to Hird et al., published June 16, 2011. These components include, but are not limited to, the topsheet nonwoven, backsheet film, backsheet nonwoven, side panel nonwoven, barrier leg cuff nonwoven, superabsorbent, nonwoven acquisition layer, core wrap nonwoven, adhesive, fastener hook, and fastener landing area nonwoven, and film base. In at least one embodiment, the disposable absorbent article component has a biobased content value of about 10% to about 100% using ASTM D6866-10, Test Method B, in another embodiment, about 25% to about 75%, and in yet another embodiment, about 50% to about 60% using ASTM D6866-10, Test Method B. To apply the ASTM D6866-10 method to determine the biobased content of any disposable absorbent article component, a representative sample of the disposable absorbent article component must be obtained for testing. In at least one embodiment, the disposable absorbent article component can be ground into fine particles of less than about 20 mesh using known grinding methods (e.g., a Wiley® mill) and a representative sample of suitable mass can be removed from the randomly mixed particles.

[0026] The term "machine direction" (MD) is used herein to refer to the direction of flow of material through a process. In addition, the relative placement and movement of material may be It can be described as flowing in a machine direction through a process from upstream in the process to downstream in the process.

[0027] The term "cross direction" (CD) is used herein to refer to a direction generally perpendicular to the machine direction.

[0028] Aspects of the present disclosure relate to an absorbent article having a front waist panel and a back waist panel with different stretch characteristics. As discussed below, the absorbent article may include a first waist region, a second waist region, and a crotch region disposed between the front waist region and the second waist region. The absorbent article may also include a chassis comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The first waist panel may be connected to the chassis and positioned in the first waist region, and the second waist panel may be connected to the chassis and positioned in the second waist region. In some configurations, the first waist panel may include a first structural feature that is not included in the second waist panel, or may include a first structural feature that is different from a second structural feature included in the second waist panel. Thus, the first structural feature provides different stretch characteristics between the first waist panel and the second waist panel. Examples of the first structural feature and / or the second structural feature may include embossing, apertures, slits, melted material, compressed material, plastic deformation, folding, adhesive bonding, and / or pressure bonding. It should be understood that such structural features may be formed in a variety of manners, such as, for example, folding, application of ultrasonic energy, pressure, and / or heat. Waist panels are discussed below in the context of absorbent articles that may be configured as taped or pant diapers.

[0029] The term "taped diaper" (also called "open diaper") refers to a disposable absorbent article having initial front and back waist regions that are not fastened, prefastened, or joined to one another during packaging prior to application to a wearer. A taped diaper may be folded about a lateral centerline with the interior of one waist region in surface-to-surface contact with the interior of the opposing waist region without fastening or connecting the waist regions together. Examples of tape diapers of various suitable configurations are shown in U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426, ,444, 6,586,652, 6,627,787, 6,617,016, 6,825,393, and 6,861,571, as well as U.S. Patent Publication Nos. 2013 / 0072887(A1), 2013 / 0211356(A1), and 2013 / 0306226(A1), all of which are incorporated herein by reference.

[0030] The term "pants" (also referred to herein as "training pants", "preclosed diapers", "diaper pants", "pant-type diapers", and "pull-on diapers") refers to a disposable absorbent article having a continuous waist opening at its perimeter and continuous leg openings at its perimeter designed for an infant or adult wearer. A pant may be constructed with a continuous or closed waist opening and at least one continuous closed leg opening before the article is applied to the wearer. A pant may be preformed or prefastened with a variety of techniques, including, but not limited to, connecting portions of the article together using any refastenable and / or permanent closure member (e.g., seams, heat bonds, pressure welding, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant may be preformed anywhere along the perimeter of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, back waist fastened or seamed). Examples of diaper pants of various configurations are found in U.S. Pat. Nos. 4,940,464, 5,092,861, 5,246,433, 5,569,234, 5,897,545, 5,957,908, 6,120,487, 6,120,489, and 7,569,039, as well as U.S. Patent Application Publication Nos. 2003 / 0233082(A1), 2005 / 01077(A1), and 2006 / 0233082(A1). 64(A1), 2012 / 0061016(A1), 2012 / 0061015(A1), 2013 / 0255861(A1), 2013 / 0255862(A1), 2013 / 0255863(A1), 2013 / 0255864(A1) and 2013 / 0255865(A1), all of which are incorporated herein by reference.

[0031] For illustrative purposes, Figures 1A and 1B show an example of an absorbent article 100 that may be constructed in accordance with the present disclosure. In particular, Figure 1A shows an example of a plan view of an absorbent article 100 configured as a taped diaper 100T, with the portion of the diaper facing away from the wearer oriented toward the viewer. Figure 1B also shows a plan view of the diaper 100 with the portion of the diaper facing the wearer oriented toward the viewer. The taped diaper 100T shown in Figures 1A and 1B includes an absorbent chassis 102, a first rear side panel 104 and a second rear side panel 106, and a first front side panel 108 and a second front side panel 110.

[0032] As shown in Figures 1A and 1B, the absorbent article 100 and the chassis 102 each include a first waist region 116, a second waist region 118, and a crotch region 119 disposed intermediate the first and second waist regions. The first waist region 116 may be configured as a front waist region, and the second waist region 118 may be configured as a back waist region. In some embodiments, the length of each of the front waist region, the back waist region, and the crotch region may be 1 / 3 of the length of the absorbent article 100. The absorbent article 100 may also include a laterally extending first waist edge 120 in the first waist region 116, which may be configured as a front waist edge. In addition, the absorbent article 100 may include a laterally extending second waist edge 122 in the second waist region 118, which may be configured as a back waist edge. To provide a frame of reference for this discussion, the diaper 100T in FIGS. 1A and 1B is shown with a longitudinal axis 124 and a lateral axis 126. The longitudinal axis 124 may extend through a midpoint of the front waist edge 120 and through a midpoint of the back waist edge 122. And, the lateral axis 126 may extend through a midpoint of the first longitudinal or right edge 128 and through the second longitudinal or left edge 130.

[0033] 1A and 1B, the absorbent article 100 includes an interior wearer-facing surface 132 and an exterior garment-facing surface 134. It should be understood, therefore, that each of the various components of the absorbent article described below may include an interior wearer-facing surface 132 and an exterior 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 including an absorbent core 142 disposed between a portion of the topsheet 138 and the backsheet 136. As described in more detail below, the absorbent article 100 may also include other features, such as leg elastics and / or leg gasket elements, waist gasket elements, and / or flaps, e.g., side panels and / or ears, to improve fit around the legs and waist of the wearer.

[0034] 1A and 1B, the periphery of the chassis 102 may be defined by a first longitudinal side edge 128, a second longitudinal side edge 130, a first laterally extending edge 144 disposed in the first waist region 116, and a second laterally extending edge 146 disposed in the second waist region 118. Both side edges 128 and 130 extend longitudinally between the first edge 144 and the second edge 146. As shown in FIG. 1A, the laterally extending edges 144 and 146 may form a portion of the laterally extending front waist edge 120 in the front waist region 116 and a portion of the longitudinally opposed laterally extending rear waist edge 122 in the rear waist region 118. The distance between the first lateral edge 144 and the second lateral edge 146 may define a pitch length (PL) of the chassis 102. When the absorbent article 100 is worn on the lower torso of a wearer, the front waist edge 120 and the back waist edge 122 may encircle a portion of the wearer's waist. At the same time, the side edges 128 and 130 may encircle at least a portion of the wearer's legs. Also, the crotch region 119 may be generally positioned between the wearer's legs, with the absorbent core 142 extending from the front waist region 116, through the crotch region 119, to the back waist region 118.

[0035] It should also be understood that a portion or the entire absorbent article 100 may be manufactured to have extensibility in the lateral direction. This additional extensibility may be useful to allow the absorbent article 100 to conform to the wearer's body while the wearer is moving. This additional extensibility may also assist a user of an absorbent article 100 that includes a chassis 102 having a particular size before stretching to stretch the front waist region 116, the back waist region 118, or both waist regions of the absorbent article 100 and / or the chassis 102, for example, to provide additional body coverage for wearers of various sizes, i.e., to tailor the absorbent article to the individual wearer. Such stretching of one or more waist regions, so long as the crotch region extends to a relatively lesser extent than the one or more waist regions, may impart a generally hourglass shape to the absorbent article and may impart a fitted appearance to the article when it is worn.

[0036] As mentioned above, the absorbent article 100 may include a backsheet 136. The backsheet 136 may also define the outer surface 134 of the chassis 102. The backsheet 136 may be impermeable to liquids (e.g., menses, urine, and / or liquid feces) and may be fabricated in part from a thin plastic film, although other flexible liquid impermeable materials may also be used. The backsheet 136 may prevent the exudates absorbed and contained in the absorbent core from wetting articles that come into contact with the absorbent article 100, such as bed sheets, pajamas, and undergarments. The backsheet 136 may also include woven or nonwoven materials, polymeric films, such as thermoplastic films of polyethylene or polypropylene, and / or multi-layer or composite materials including films and nonwoven materials (e.g., having an inner film layer and an outer nonwoven layer). The backsheet 136 may also include an elastomeric film. An exemplary backsheet 136 may be a polyethylene film having a thickness of about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mil). Exemplary polyethylene films are manufactured by Clopay Corporation, Cincinnati, Ohio, under the product names BR-120 and BR-121, and by Tredegar Film Products, Terre Haute, Ind., under the product name XP-39385. The backsheet 136 may also be embossed and / or matte finished to provide a more cloth-like appearance. Furthermore, the backsheet 136 may allow vapors to escape from the absorbent core (i.e., the backsheet is breathable), while still preventing exudates from passing through the backsheet 136. The size of the backsheet 136 may be determined by the size of the absorbent core 142 and / or the particular configuration or size of the absorbent article 100.

[0037] As also mentioned above, the absorbent article 100 may include a topsheet 138. The topsheet 138 may also define all or a portion of the inner surface 132 of the chassis 102. The topsheet 138 may be compliant, soft feeling, and non-irritating to the wearer's skin. The topsheet may be elastically stretchable in one or two directions. Additionally, the topsheet 138 may be liquid permeable, allowing liquids (e.g., menses, urine, and / or liquid feces) to penetrate through its thickness. The topsheet 138 may be manufactured from a wide range of materials, such as woven and nonwoven materials, perforated or hydroformed thermoplastic films, perforated nonwovens, porous foams, reticulated foams, reticulated thermoplastic films; and thermoplastic scrims. The woven or nonwoven materials may be manufactured from a wide range of materials, such as natural fibers, such as wood fibers or cotton fibers, synthetic fibers, such as polyester, polypropylene or polyethylene fibers, or combinations thereof. If the topsheet 138 comprises fibers, the fibers may be spunbonded, carded, wet-laid, meltblown, hydroentangled, or otherwise processed as known in the art.

[0038] The topsheet 138 may be selected from lofty nonwoven topsheets, apertured film topsheets, and apertured nonwoven topsheets. Apertured film topsheets may be permeable to body exudates, but may be substantially non-absorbent and have a reduced tendency to allow fluids to pass back through the topsheet and rewet the wearer's skin. Exemplary apertured films may include those described in U.S. Patent Nos. 5,628,097, 5,916,661, 6,545,197, and 6,107,539, all of which are incorporated herein by reference.

[0039] As mentioned above, the absorbent article 100 may also include an absorbent assembly 140 coupled to the chassis 102. As shown in Figures 1A and 1B, the absorbent assembly 140 may have a laterally extending front edge 148 in the front waist region 116 and a longitudinally opposed, laterally extending rear edge 150 in the rear waist region 118. The absorbent assembly may have a longitudinally extending right edge 152 and a laterally opposed, longitudinally extending left edge 154, both of which may extend longitudinally between the front edge 148 and the rear edge 150. The absorbent assembly 140 may additionally include one or more absorbent cores 142 or absorbent core layers. The absorbent core 142 may be at least partially disposed between the topsheet 138 and the backsheet 136 and may be formed in a variety of sizes and shapes compatible with absorbent articles. Exemplary absorbent structures for use as the absorbent core of the present disclosure are described in U.S. Patent Nos. 4,610,678, 4,673,402, 4,888,231 and 4,834,735, all of which are incorporated herein by reference.

[0040] Some absorbent core embodiments may comprise a fluid storage core containing a reduced amount of cellulosic airfelt material. For example, such cores may contain less than about 40%, 30%, 20%, 10%, 5%, or even less than about 1% cellulosic airfelt material. Such cores may comprise primarily absorbent gelling material in an amount of at least about 60%, 70%, 80%, 85%, 90%, 95%, or even about 100%, with the remainder of the core comprising microfiber adhesive (where applicable). Such cores, microfiber adhesives, and absorbent gelling materials are described in U.S. Pat. Nos. 5,599,335, 5,562,646, 5,669,894, and 6,790,798, and U.S. Patent Publication Nos. 2004 / 0158212(A1) and 2004 / 0097895(A1), all of which are incorporated herein by reference.

[0041] The taped diaper may be manufactured and provided to the consumer in a configuration in which the front and rear waist regions are not fastened, prefastened, or connected to one another when packaged prior to application to the wearer. For example, the taped diaper 100T may be folded about the lateral centerline with the inner surface 132 of the first waist region 116 in surface-to-surface contact with the inner surface 132 of the second waist region 118, without fastening or connecting the waist regions together. The rear side panels 104 and 106 and / or the front side panels 108 and 110 may also be folded laterally inward toward the inner surfaces 132 of the waist regions 116 and 118.

[0042] The absorbent article 100 may also include various configurations of fastening elements that allow the front waist region 116 and the back waist region 118 to be fastened together to form a closed waist perimeter and leg openings when the absorbent article is positioned on a wearer. For example, as shown in Figures 1A and 1B, the absorbent article 100 may include a first fastening member 162 and a second fastening member 164, also referred to as tabs, connected with the first back side panel 104 and the second back side panel 106, respectively. The absorbent article may also include a first front side panel 108 and a second front side panel 110, which may or may not include fastening members.

[0043] With continued reference to Figures 1A and 1B, each side panel 104, 106 and / or fastening members 162 and 164 may form part of the chassis 102 or may be permanently joined, adhered or otherwise connected, directly or indirectly, to the chassis 102, laterally inward from the side edges 128 and 130, in one of the front waist region 116 or the back waist region 118. Alternatively, the fastening members 162, 164 may form a portion of the first and second rear panels 104, 106 and / or the first and second front side panels 108, 110 or may be permanently joined, adhered or otherwise connected, directly or indirectly, to or adjacent the distal edges of the first and second rear panels 104, 106 and / or the first and second front side panels 108, 110. It should be understood that the fastening members and / or side panels may be assembled in a variety of ways, such as those disclosed in U.S. Patent No. 7,371,302, which is incorporated herein by reference. The fastening members 162, 164 and / or side panels 104, 106, 108, 110 may also be permanently joined or connected at or adjacent the side edges 128 and 130 of the chassis 102 in a variety of ways, such as, for example, adhesive bonding, sonic bonding, pressure bonding, thermal bonding, or combinations thereof, such as those disclosed in U.S. Pat. No. 5,702,551, which is incorporated herein by reference.

[0044] 1B, the first fastening member 162 and / or the second fastening member 164 may include various types of releasably engageable fasteners. The first fastening member 162 and / or the second fastening member 164 may also include various types of refastenable fastening structures. For example, the first fastening member 162 and the second fastening member 164 may include mechanical fasteners 166 in the form of hook-and-loop fasteners, hook-and-hook fasteners, macro fasteners, buttons, snaps, tab-and-slot fasteners, tape fasteners, adhesive fasteners, cohesive fasteners, magnetic fasteners, hermaphroditic fasteners, etc. Some examples of fastening systems and / or fastening members 162, 164 are discussed in U.S. Pat. Nos. 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092, 5,221,274, 5,242,436, 6,251,097, 6,669,618, 6,432,098, U.S. Patent Publication Nos. 2007 / 0078427(A1) and 2007 / 0093769(A1), and U.S. Patent Application No. 16 / 685,230, all of which are incorporated herein by reference.

[0045] As mentioned above, the fastening members 162 and 164 may be constructed from various materials and may be constructed as a laminated structure. The fastening members 162 and 164 may also be adapted to releasably and / or refastenably engage or connect with another portion of the absorbent article 100. For example, as shown in FIG. 1A, the absorbent article 100 may include a connection zone 168, sometimes referred to as a landing zone, in the first waist region 116. Thus, when the tape-type absorbent article 100 is placed on a wearer, the fastening members 162 and 164 may be pulled around the waist of the wearer and connected with the connection zone 168 in the first waist region 116 to form a closed waist perimeter and a pair of laterally opposed leg openings. It should be understood that the connection zone may be constructed from a separate substrate that is connected with the chassis 102 of the absorbent article. In some embodiments, the connection zone may be integrally formed as part of the backsheet 136 of the absorbent article 100, such as those described in U.S. Pat. Nos. 5,735,840 and 5,928,212, which are incorporated herein by reference, or may be formed as part of the first front panel 108 and the second front panel 110.

[0046] With continued reference to FIG. 1B, the absorbent article 100 may also include leg gasket elements 156. It will be understood that the leg gasket elements 156 may be, and are sometimes referred to as, leg cuffs, leg bands, side flaps, barrier cuffs, elastic cuffs, or gasket cuffs. The leg gasket elements 156 may be elasticized and configured in various ways to help reduce leakage of body exudates in the leg regions. Exemplary leg gasket elements 156 may include those described in U.S. Patent Nos. 3,860,003, 4,909,803, 4,695,278, 4,795,454, 4,704,115, and U.S. Patent Publication No. 2009 / 0312730(A1), all of which are incorporated herein by reference.

[0047] 1B, the absorbent article 100 may include longitudinally extending and laterally opposed leg gasket elements 156 disposed on the interior surface 132 of the chassis 102 that faces inwardly toward and contacts the wearer. Each leg gasket element 156 may have a first side edge 157 and a second side edge 159, with the first side edge 157 positioned laterally inward of the second side edge 159. The leg gasket elements 156 may also overlap the absorbent assembly 140, with the first side edge 157 extending laterally inward of the respective side edges 152 and 154 of the absorbent assembly 140. In some configurations, the leg gasket elements 156 may not overlap the absorbent assembly 140. It should be appreciated that the leg gasket elements 156 may be formed in a variety of ways, such as by folding a portion of the chassis 102 laterally, inwardly, i.e., toward the longitudinal axis 124, to form both the respective side gasket elements and the side edges 128 and 130 of the chassis 102. In another example, the leg gasket elements 156 may be formed by attaching an additional layer to the chassis 102 at or adjacent each of the corresponding side edges of the chassis 102. Each of the leg gasket elements 156 may be coupled to the chassis and / or the inner surface 132 of the absorbent assembly 140 at a leg gasket element attachment zone in the front waist region 116 and a leg gasket element attachment zone in the rear waist region 118. The leg gasket elements 156 may extend to the same longitudinal extent as the absorbent article 100, or alternatively, the leg gasket elements 156 may have a narrower longitudinal extent than the absorbent article 100. In some configurations, the leg gasketing elements may be configured to define an inner cuff, an outer cuff, or both an inner cuff and an outer cuff.

[0048] The absorbent article 100 may also include one or more waist panels 158, as shown in FIG. 1B. The waist panel 158 may provide improved fit and containment, and may be a portion or zone of the absorbent article 100 that may elastically expand and contract to dynamically fit the waist of the wearer. The absorbent article 100 may also include multiple waist panels 158, for example, having a first panel 158a positioned in the first waist region 116 and a second waistband 158b positioned in the second waist region 118, although other configurations may be configured with a single waist panel 158. The lumbar panel 158 may be constructed in many different configurations, including those described in U.S. Pat. Nos. 4,515,595 and 5,151,092, and U.S. patent application Ser. Nos. 16 / 864,267, 16 / 864,292, 62 / 855,001, 62 / 930,181, 62 / 930,198, and 62 / 930,808, all of which are incorporated herein by reference.

[0049] It should be understood that the lumbar panel 158 herein may be constructed in a variety of ways and may include one or more elastic materials, such as, for example, elastic films and / or strands. For example, the lumbar panel 158 may be constructed as a single layer of elastic film. In some configurations, the lumbar panel 158 may be constructed as a laminate of two or more substrates. For example, the lumbar panel 158 may be constructed as an elastic film bonded between two or more nonwoven substrates and / or may be bonded with one or more nonwoven substrates. For example, the lumbar panel 158 may be constructed as a bi-layer laminate with an elastic film bonded with a single nonwoven substrate. In another example, the lumbar panel 158 may be constructed as an elastic film bonded between two or more substrates, and the substrates may include nonwovens. It should also be understood that the nonwoven substrates of the lumbar panel 158 may be the same or different materials and / or basis weights and may be constructed as elastomeric nonwovens or non-elastic nonwovens. In some configurations, the one or more nonwoven substrates of the lumbar panel 158 may be the same or different material and / or basis weight as the one or more nonwoven substrates of the topsheet 138, the backsheet 136, and / or the leg gasket elements 156.

[0050] It should be understood that the lumbar panel 158 herein may be formed in a variety of ways, may be joined together in a variety of ways, and may include a variety of components with different or identical bond patterns. For example, the lumbar panel 158 herein may include a laminate of an elastic film joined with at least one nonwoven fabric in an extended state. For example, as discussed in more detail below, FIGS. 18 and 19 show cross-sectional views of a lumbar panel 158 configured as a laminate 400 including a first substrate 402, a second substrate 410, and an elastic film 408 positioned between the first substrate 402 and the second substrate 410, where the first substrate 402 and / or the second substrate 410 may be configured as a nonwoven fabric as described above. In some configurations, the laminate may be continuously or discontinuously bonded. In some configurations, the laminate may be joined with a plurality of individual bond sites, which may or may not form a visually distinguishable pattern.

[0051] It should be appreciated that the components of the lumbar panel 158 may be joined together in a variety of ways, such as, for example, by adhesive bonding, ultrasonic bonding, pressure bonding, heat bonding, or combinations thereof. It should be appreciated that the components of the lumbar panel 158 may be joined together with adhesive applied in a variety of ways, such as, for example, by a spray nozzle and / or a slot coating device. In some configurations, the components of the lumbar panel 158 may be continuously bonded with adhesive or continuously bonded with a patterned adhesive. In some configurations, the adhesive may be applied according to the apparatus and / or methods described in U.S. Pat. Nos. 8,186,296, 9,265,672, 9,248,054, and 9,295,590, and U.S. Patent Publication No. 2014 / 0148773(A1), all of which are incorporated herein by reference. In some configurations, the components of the waist panel 158 may be mechanically (pressure) joined in a variety of ways involving the application of pressure (and optionally heat), such as, for example, the mechanical joining devices 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. In some configurations, the components of the waist panel 158 may be mechanically (pressure) joined using ultrasonic bonding methods in various manners, such as, for example, linear or rotational type configurations, and configured as described, for example, in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and 6,645,330.

[0052] In some configurations, the elastic film 408 may be bonded together with the first substrate 402 and / or the second substrate 410, and the first substrate 402 may be directly bonded to the second substrate 410 in the area of ​​the waist panel 158. In some configurations, the first substrate 402 and the second substrate 410 may be directly bonded to one another through openings in the elastic film 408, and such openings may be formed during the bonding process. In some configurations, the elastic film 408 may participate or be involved in the bond between the first substrate 402 and the second substrate 410, where "involved" may mean that the elastic film 408 may be in intimate contact with, and possibly partially interlocked with, one or both of the first substrate 402 and the second substrate 410 to some extent. This involvement may be due to actual melt bonding around the bond site, or may be due to mechanical interaction, such as by entanglement of the fibrous elastic layer between the fibrous nonwoven layers around the bond site as well. It should be appreciated that the lumbar panel 158 may be formed using a variety of joining configurations, such as those disclosed in, for example, U.S. Patent Nos. 6,572,595, 6,830,800, 7,087,287, and 7,803,244, and U.S. Patent Application Publication Nos. 2018 / 0042778(A1), 2018 / 0042787(A1), 2018 / 0042779(A1), and 2018 / 0042780(A1), all of which are incorporated herein by reference.

[0053] In some configurations, the waist panel 158 may be formed as a zero strain stretch laminate that may be connected to the chassis 102 in a stretched state. In some configurations, the zero strain stretch laminate may include at least a layer of nonwoven material and an elastomeric element. While in a relaxed or substantially relaxed state, the elastomeric element may be attached to the layer of nonwoven material, and the resulting laminate may be made stretchable (or more broadly more stretchable) by subjecting it to an activation process that permanently elongates the nonwoven layer and temporarily elongates the elastomeric element. In some configurations, the nonwoven layer may be a separate component, in which case an elastomeric element is attached to the nonwoven layer to form a laminate, which is then connected to the chassis 102. In some configurations, the nonwoven layer may be integral with at least a portion of the chassis 102, in which case an elastomeric element may be attached to the nonwoven layer, and the nonwoven / elastomeric element laminate is then activated. In some configurations, the lumbar panel may be an extrusion bonded laminate. If one or more layers of the lumbar panel 158 are provided separately, the lumbar panel 158 may be activated either before or after attachment to the chassis 102. Examples of zero strain activation processes are disclosed in U.S. Patent Nos. 5,167,897 and 5,156,793, which are incorporated herein by reference.

[0054] It should be understood that the waist panel 158 may be located in various positions relative to the garment-facing surface 132 and the wearer-facing surface 134 of the various absorbent article components. In some configurations, the waist panel element 158 ​​may be positioned on the wearer-facing surface 132 of the topsheet 138. In some configurations, the waist panel element 158 ​​may be positioned on the wearer-facing surface 132 of the topsheet 138 and on the leg gasket element 156. In some configurations, the waist panel element 158 ​​may be positioned on the wearer-facing surface 132 of the topsheet 138, and laterally opposed end regions of the waistband 158 may be positioned between the leg gasket element 156 and the topsheet 138. In some configurations, the waist panel 158 may be positioned between the garment-facing surface 132 of the topsheet 138 and the wearer-facing surface 132 of the backsheet 136. Also, in some configurations, the waist panel 158 may be positioned on the garment-facing surface 134 of the backsheet 136.

[0055] 2 and 3, the first and second waist panels 158a, 158b herein may each include a first lateral edge 170 and a second lateral edge 172 positioned longitudinally inwardly relative to the first lateral edge 170. Additionally, the first and second waist panels 158a, 158b may include a first longitudinal end region 174 adjacent the first lateral edge 170 and a second longitudinal end region 176 adjacent the second lateral edge 172, the first longitudinal end region 174 and the second longitudinal end region 176 being separated by a central region 178. The first lateral edge 170 and the second lateral edge 172 may be connected or separated from the first longitudinal edge 180 and the second longitudinal edge 182. Thus, the first waist panel 158a and the second waist panel 158b may also include a first longitudinal end region 184 adjacent the first lateral edge 180 and a second longitudinal end region 186 adjacent the second lateral edge 182, the first lateral end region 184 and the second lateral end region 186 being separated by the central region 178. In some configurations, the first lateral edge 170, the second lateral edge 172, the first longitudinal edge 180, and / or the second longitudinal edge 182 may be defined by folds, and one or more layers of the waist panel 158 may be folded onto itself or another layer during assembly. In some configurations, the first lateral edge 170, the second lateral edge 172, the first longitudinal edge 180, and / or the second longitudinal edge 182 may be defined by unfolded edges or cut lines, and one or more layers of the waist panel 158 may be cut or trimmed during assembly.

[0056] It should be understood that the waist panels 158 herein may be configured in a variety of shapes and / or sizes. For example, as shown in FIG. 2 and FIG. 3, the first waist panel 158a may include a first width PW1 extending between the first longitudinal edge 180 and the second longitudinal edge 182, and the second waist panel 158b may include a second width PW2 extending between the first longitudinal edge 180 and the second longitudinal edge 182. It should be understood that the first width PW1 and the second width PW2 may be equal or different. In some configurations, the first width PW1 and / or the second width PW2 may be from about 80 mm to about 250 mm, specifically all 1 mm increments within the above ranges and any ranges therein or formed thereby are recited. The first waist panel 158a can include a first length PL1 extending between the first longitudinal edge 170 and the second longitudinal edge 172, and the second waist panel 158b can include a second length PL2 extending between the first longitudinal edge 170 and the second longitudinal edge 172. It should be understood that the first length PL1 and the second length PL2 can be equal or different. In some configurations, the first length PL1 and / or the second length PL2 can be from about 5 mm to about 80 mm, and specifically, all 1 mm increments within the above ranges and any ranges therein or formed thereby are recited.

[0057] It should be appreciated that the waist panel 158 may be located at various lateral and longitudinal positions relative to the various absorbent article components. In some configurations, the waist panel 158 may be positioned such that the first and second longitudinal edges 180, 182 of the waist panel 158 are laterally inboard of the leg gasket element 156. In some configurations, the waist panel 158 may be positioned such that the first and second longitudinal edges 180, 182 and the first and second longitudinal end regions 174, 176 of the waist panel 158 overlap the leg gasket element 156. In some configurations, the first waist panel 158a may be positioned longitudinally inward from the first waist edge 120 of the absorbent article 100 and / or toward or overlapping the first lateral edge 148 of the absorbent core 142, and the second waist panel 158b may be positioned longitudinally inward from the second waist edge 122 of the absorbent article 100 and / or toward or overlapping the second lateral edge 150 of the absorbent core 142. In some configurations, the first lateral edge 170 of the first waist panel 158a may be positioned longitudinally inward from the first waist edge 120 by an offset distance OD1 greater than zero. In some configurations, the first lateral edge 170 of the second waist panel 158b may be positioned longitudinally inward from the second waist edge 122 by an offset distance OD2 greater than zero. In some configurations, the offset distance OD1 and / or the offset distance OD2 may be at least 5 mm. In some configurations, the first lateral edge 170 of the first waist panel 158a may abut the first waist edge 120 such that the offset distance OD1 is zero. In some configurations, the first lateral edge 170 of the second waist panel 158b may abut the second waist edge 122 such that the offset distance OD2 is zero.

[0058] It should be appreciated that the first lumbar panel 158a and / or the second lumbar panel 158b may be joined to the chassis 102 and / or the leg gasket element 156 in various manners, such as, for example, by adhesive bonding, ultrasonic bonding, pressure bonding, heat bonding, or combinations thereof. It should be appreciated that the first lumbar panel 158a and / or the second lumbar panel 158b may be joined to the chassis 102 and / or the leg gasket element 156 using adhesive applied in various manners, such as, for example, by a spray nozzle and / or a slot coating device. In some configurations, the first lumbar panel 158a and / or the second lumbar panel 158b may be continuously bonded to the chassis 102 and / or the leg gasket element 156 by adhesive or may be continuously bonded with a patterned adhesive. In some configurations, the adhesive may be applied according to the apparatus and / or methods described in U.S. Pat. Nos. 8,186,296, 9,265,672, 9,248,054, and 9,295,590, and U.S. Patent Publication No. 2014 / 0148773(A1), all of which are incorporated herein by reference. In some configurations, the first lumbar panel 158a and / or the second lumbar panel 158b may be mechanically (pressure) joined to the chassis 102 and / or the leg gasket element 156 with the application of pressure (and optionally heat) in a variety of ways, such as, for example, the mechanical joining devices 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. In some configurations, the first lumbar panel 158a and / or the second lumbar panel 158b may be mechanically (pressure) bonded to the chassis 102 and / or the leg gasket element 156 in various manners, such as, for example, linear or rotational type configurations, and using ultrasonic bonding methods configured as described in, for example, U.S. Patent Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and 6,645,330.

[0059] As previously mentioned, it should be understood that the waist panels 158 herein may be joined to the chassis 102 and / or leg gasket elements 156 with a combination of adhesive and pressure bonds. For example, as shown in FIG. 2A, the first longitudinal end region 174 of the first waist panel 158a may be joined to the chassis 102 and / or leg gasket elements 156 by an adhesive bond 188, generally indicated by the shaded area. In addition, the first lateral end region 184 and the second lateral end region 186 of the first waist panel 158a may be joined to the chassis 102 and / or leg gasket elements 156 by a pressure bond 190. In some configurations, the first lateral end region 184 and the second lateral end region 186 of the first waist panel 158a may be joined to the inner cuff and / or the outer cuff of the leg gasket elements 156. As shown in FIG. 3A, the first longitudinal end region 174 of the second waist panel 158b may be attached to the chassis 102 and / or the leg gasket element 156 by adhesive joints 188, generally indicated by the shaded areas. In addition, the first lateral end region 184 and the second lateral end region 186 of the second waist panel 158b may be joined to the chassis 102 and / or the leg gasket element 156 by pressure joints 190. In some configurations, the first lateral end region 184 and the second lateral end region 186 of the second waist panel 158b may be joined to the inner cuff and / or the outer cuff of the leg gasket element 156. In some configurations, the pressure joints 190 may be a discontinuous pattern of separate bond sites. It should be understood that the separate bond sites may define various sizes and shapes and may be separated from one another by various distances. For example, in some configurations, the separate bond sites may be separated from one another by at least 0.2 mm. It should also be appreciated that the separate bond sites may cover a variety of different sized areas of the lumbar panel. For example, in some configurations, the multiple separate bond sites may comprise about 5% to about 50% of the area of ​​the waist panel. In some configurations, the first lateral end region 184 and the second lateral end region 186 extending along the first longitudinal edge 180 and the second longitudinal edge 182 may be joined to the chassis 102 and / or the leg gasket element 156 by a continuous bond that defines a sealed edge.

[0060] In some configurations, one or more areas of the waist panel 158 (referred to herein as bonded areas) may be bonded to the chassis 102 and / or the leg gasket element 156, and one or more areas of the waist panel 158 (referred to as non-bonded areas 192) may not be bonded (attached) to the chassis 102 and / or the leg gasket element 156, thereby forming a pocket 194 between the waist panel 158 and the chassis 102. For example, as shown in FIG. 2A , the first waist panel 158a may have bonded regions where the first longitudinal end region 174, the first lateral end region 184, and the second lateral end region 186 of the first waist panel 158a are bonded to the chassis 102 and / or the leg gasket element 156, and the first waist panel 158a may include at least one non-bonded region 192a (generally indicated by a rectangle with a dashed border) in which a portion of the second longitudinal end region 176 and at least a portion of the second lateral edge 172 may not be attached to the chassis 102 and / or the leg gasket element 156. Continuing to refer to FIG. 3A, the second waist panel 158b may have bonded regions where the first longitudinal end region 174, the first lateral end region 184, and the second lateral end region 186 of the second waist panel 158b are bonded to the chassis 102 and / or the leg gasket element 156, and the second waist panel 158b may include at least one non-bonded region 192b (generally indicated by a rectangle with a dashed border) in which a portion of the second longitudinal end region 176 and at least a portion of the second lateral edge 172 may not be attached to the chassis 102 and / or the leg gasket element 156.

[0061] It should be understood that the waist panels 158 herein may be configured with one or more non-bonded regions having various shapes and / or sizes. For example, as shown in Figures 2A and 3A, the first waist panel 158a may include a first non-bonded region 192a and / or the second waist panel 158b may include a second non-bonded region 192b. Thus, the first non-bonded region 192a may include a first laterally extending width UW1 and a first longitudinally extending length UL1, and the second non-bonded region 192b may include a second laterally extending width UW2 and a second longitudinally extending length UL2. It should be understood that the first width UW1 and the second width UW2 may be equal or different. In some configurations, the first width UW1 and / or the second width UW2 may be between about 40 mm and about 200 mm, specifically all 1 mm increments within the ranges described above and any ranges formed therein or thereby. It should also be understood that the first length UL1 and the second length UL2 may be equal or different. In some configurations, the first length UL1 and / or the second length UL2 may be between about 10 mm and about 50 mm, specifically all 1 mm increments within the ranges described above and any ranges formed therein or thereby. In some configurations, the first non-bonded region 192a may include a first area A1 and / or the second non-bonded region 192b may include a second area A2, and the first area A1 and the second area may be equal or different. In some configurations, the first area A1 and / or the second area A2 may be between about 400 mm and / or about 500 mm. 2 ~about 10000mm 2 Specifically, every 1 mm within the above ranges and any ranges therein or formed thereby. 2 The increments are enumerated.

[0062] It should also be appreciated that in some configurations, one or more regions of the waist panel 158 may be relatively completely laterally and / or longitudinally joined to the chassis 102 and / or leg gasket element 156 such that a pocket 194 is not formed between the waist panel 158 and the chassis 102.

[0063] As discussed above, the waist panel 158 herein may be elastic and may include at least one stretch direction. In some configurations, the stretch direction may be oriented laterally between the first longitudinal edge 180 and the second longitudinal edge 182. In some configurations, the first waist panel 158a and / or the second waist panel 158b may be configured to stretch at least about 10 mm with an applied force of 0 to about 3 N. It should also be appreciated that the first waist panel 158a may have stretch characteristics that are the same or different from the stretch characteristics of the second waist panel 158b. Such stretch characteristics may include a contraction rate or an elongation rate. In some configurations, the stretch characteristics of the first waist panel 158a may be the same or different between the first lateral edge 170 and the second lateral edge 172 and / or between the first longitudinal edge 180 and the second longitudinal edge 182. Also, in some configurations, the stretch characteristics of the second waist panel 158b may be the same or different between the first lateral edge 170 and the second lateral edge 172 and / or between the first longitudinal edge 180 and the second longitudinal edge 182.

[0064] It should be appreciated that the desired stretch characteristics of the lumbar panel 158 herein may be imparted to the lumbar panel 158 in a variety of ways, such as before, during, or after the lumbar panel 158 is combined with the chassis 102 and / or the leg gasket element 156. For example, structural features may be imparted to one or more individual components of the lumbar panel 158 before, during, and / or after assembly of the lumbar panel 158 to provide the desired stretch characteristics of the lumbar panel 158. In some configurations, structural features may be imparted to the lumbar panel 158, the chassis 102, and / or the combined lumbar panel 158 and chassis 102 to provide the desired stretch characteristics of the lumbar panel 158. In some configurations, the same structural features may be imparted to the first and / or second lumbar panels 158a, 158b to help ensure that the first and second lumbar panels 158a, 158b have similar stretch characteristics. In some configurations, different structural features may be imparted to the first and / or second lumbar panels 158a, 158b to help ensure that the first and second lumbar panels 158a, 158b have different stretch characteristics.

[0065] 2B and 3B show an exemplary absorbent article configuration in which a first waist panel 158a includes a first structural feature 196a and a second waist panel 158b includes a second structural feature 196b. The first structural feature 196a and the second structural feature 196b are collectively referred to as a rectangle with patterned fill. Thus, it should be understood that the first structural feature 196a of the first waist panel 158a may be different from the second structural feature 196b of the second waist panel 158b, and the first structural feature 196a and the second structural feature 196b may provide different stretch characteristics between the first waist panel 158a and the second waist panel 158b. In another example, the first lumbar panel 158a may include a first structural feature 196a that is not included in the second lumbar panel 158b, and / or the second lumbar panel 158b may include a second structural feature 196b that is not included in the first lumbar panel 158a.

[0066] It should be appreciated that the first structural feature 196a and / or the second structural feature 196b may include a variety of forms, such as, for example, embossing, openings, slits, melted material, compressed material, plastic deformation, folding, adhesive bonding, and / or pressure bonding, and may be formed in a variety of ways, such as, for example, applied ultrasonic energy, laser energy, pressure, heat, adhesives, folding, and / or cutting. In some configurations, the first structural feature 196a and / or the second structural feature 196b may be formed by cutting and removing a separate piece from the first waist panel 158a and / or the second waist panel 158b. In some configurations, the first structural feature 196a and / or the second structural feature 196b include the amount the first waist panel 158a and / or the second waist panel 158b are stretched when joined with the chassis 102 and / or the leg gasket element 156. For example, the first and second lumbar panels 158a, 158b may be joined to the chassis 102 in a stretched state, with the first lumbar panel 158a being stretched less than or more than the second lumbar panel 158b when joined to the chassis 102. In some configurations, a reinforcing element may be used to provide different stretch characteristics between the first and second lumbar panels 158a, 158b. For example, the reinforcing element may be disposed on the first and / or second lumbar panels 158a, 158b. In some configurations, the reinforcing element may include a substrate, such as, for example, a discrete patch of nonwoven fabric.

[0067] In some configurations, the first waist panel 158a and the second waist panel 158b may include the same structural feature 196 in different areas and / or regions to impart different stretch characteristics. For example, the first waist panel 158a may include a first structural feature 196a adjacent the first lateral edge 170 and the second waist panel 158b may include the same first structural feature 196a adjacent the first lateral edge 170, and the first structural feature 196a may extend across different longitudinal lengths and / or lateral widths on the first waist panel 158a and the second waist panel 158b.

[0068] 2C and 3C show exemplary illustrations where a first waist panel 158a includes a structural feature 196 in the form of a pressure joint 190 and a second waist panel 158b includes the same structural feature 196 in the form of a pressure joint 190. A first region of the pressure joint 190 may extend longitudinally inward a first distance D1 from the first lateral edge 170 of the first waist panel 158a, and a second region of the pressure joint 190 may extend longitudinally inward a second distance D2 from the first lateral edge 170 of the second waist panel 158b. In some configurations, the first distance D1 may be greater than or less than the second distance D2, such that the pressure joint 190 may impart different stretch characteristics to the first waist panel 158a and the second waist panel 158b. It should be understood that the first distance D1 and the second distance D2 may extend over a variety of lengths. In some configurations, the first distance D1 and / or the second distance D2 may extend over the entire length PL1 of the first waist panel 158a and / or the length PL2 of the second waist panel 158b, respectively. In some configurations, the first distance D1 may extend longitudinally inward of the first lateral edge 170 of the first waist panel 158a over a distance of 10 mm or less, and / or the second distance D2 may extend longitudinally inward of the first lateral edge 170 of the second waist panel 158b over a distance of 10 mm or less.

[0069] It should be understood that the absorbent article 100 may be assembled with the various components, including the waist panel 158, described herein in a variety of ways. Thus, in the context of the previous discussion, various apparatus and methods may be adapted to assemble the absorbent article 100 with a first waist panel 158a and a second waist panel 158b having structural features that impart different stretch characteristics to the first waist panel 158a and the second waist panel 158b. For example, Figure 4 shows a schematic diagram of a conversion process including an apparatus or system 300 that joins separate elastic portions 200 under tension with an advancing carrier substrate 202 to form a laminate 204 during assembly of the absorbent article 100. Various aspects of the apparatus 300 and related assemblies shown in FIG. 4 are disclosed in U.S. patent application Ser. Nos. 16 / 864,267, 16 / 864,292, 62 / 855,001, 62 / 930,181, 62 / 930,198, and 62 / 930,808, all of which are incorporated herein by reference.

[0070] 4 and 5, the carrier substrate 202 may advance in a machine direction MD at a first speed S1. The carrier substrate has a first longitudinal edge 206 and a width W CS and a second longitudinal edge 208 separated in the transverse direction CD from the first longitudinal edge 206 to define a first longitudinal edge 208. The carrier substrate 202 also includes a first surface 210 and an opposing second surface 212. As discussed in more detail below, the separate elastic portion 200 is joined to the first surface 210 of the carrier substrate 202.

[0071] In the context of the components of the absorbent article 100 and its assembly process described above, the elastic portion 200 may be configured as a waist panel 158. In some configurations, each separate elastic portion 200 may be configured as a first waist panel 158a, a second waist panel 158b, or may be a portion that is subsequently cut together with the carrier substrate 202 to be formed into the first waist panel 158a and the second waist panel 158b. The carrier substrate 202 may be configured as a continuous laminate of a combined topsheet 138 and backsheet 136 that may be a portion of a continuous topsheet 138, backsheet 136, or a continuous length of the chassis 102. The laminate 204 may be configured as a continuous length of the absorbent article 100. In some configurations, the first surface 210 of the carrier substrate 202 may correspond to the wearer-facing surface 132 or the garment-facing surface 134 of the topsheet 138 or backsheet 136. In some configurations, the elastic portion 200 may be joined between the topsheet 138 and the backsheet 136. For example, the elastic portion 200 may be joined with the wearer-facing surface 132 of the backsheet 136 which is then joined with the topsheet 138. In another example, the elastic portion 200 may be joined with the garment-facing surface 134 of the topsheet 138 which is then joined with the backsheet 136. In yet another example, the elastic portion 200 may be joined with the garment-facing surface 134 of the backsheet 136, and the wearer-facing surface 132 of the backsheet 136 may be pre-joined with the topsheet 138 or may be subsequently joined with the topsheet 138. In another example, the elastic portion 200 may be joined with the wearer-facing surface 132 of the backsheet 136, and the garment-facing surface 134 of the topsheet 138 may be pre-joined with the backsheet 136 or may be subsequently joined with the backsheet 136.

[0072] As shown in FIG. 5A, the carrier substrate 202 may also include a leg gasket element 156 positioned on the first surface 210 adjacent the first longitudinal edge 206 and the second longitudinal edge 208. Thus, each portion of the separate elastic portion 200 may also be joined with the leg gasket element 156. In some configurations, the separate elastic portion 200 may be joined with the carrier substrate 202, and the leg gasket element 156 may be subsequently joined with the carrier substrate 202. The leg gasket element 156 may be positioned relative to the elastic portion 200 such that the leg gasket element 156 may partially overlap or not overlap the opposing end portions of the elastic portion 200. In some configurations, the leg gasket element 156 may be sandwiched between the elastic portion 200 and the carrier substrate 202. Also, in some configurations, the elastic portion 200 may be sandwiched between the leg gasket element 156 and the carrier substrate 202.

[0073] 4 and 6, the continuous elastic substrate 200a is advanced in the machine direction MD at a second speed S2, which is slower than the first speed S1. The continuous elastic substrate 200a has a first longitudinal edge 214 and a width W ES and a second longitudinal edge 216 separated in the transverse direction CD from the first longitudinal edge 214 to define a The continuous elastic substrate 200a also includes a first surface 218 and an opposing second surface 220. The continuous elastic substrate 200a is extensible in at least one direction and is oriented such that the continuous elastic substrate 200a is extensible in the cross direction CD. Thus, the width W of the continuous elastic substrate is ES may be the unstretched width. In some configurations, the width W of the continuous elastic substrate 200a ES may be the width at partial stretching.

[0074] 4, 6, and 7, the system 300 may include an adhesive applicator device 302 that deposits the adhesive 222 onto the second surface 220 of the continuous elastic substrate 200a. It will be appreciated that the adhesive applicator device 302 may be configured in a variety of ways, such as, for example, a spray nozzle and / or a slot coating device. In some configurations, the adhesive applicator device 302 may be configured in accordance with the apparatus and / or methods described in, for example, U.S. Patent Nos. 8,186,296, 9,265,672, 9,248,054, and 9,295,590, and U.S. Patent Publication No. 2014 / 0148773(A1), all of which are incorporated herein by reference.

[0075] It will be appreciated that the adhesive 222 may be applied to the continuous elastic substrate 200a to define areas of adhesive 222 on the second surface 220 having various shapes and sizes relative to the continuous elastic substrate 200a. For example, as shown in FIG. 7, the adhesive 222 may be applied to the second surface 220 of the continuous elastic substrate 200a to define areas 224 of adhesive 222 that extend continuously in the machine direction MD and the cross direction CD. The adhesive 222 may extend over a width W ADH In some configurations, the adhesive 222 may extend in a transverse direction CD to define a width W ADH is the width W of the continuous elastic substrate 200a ES It can be shorter than In some configurations, the width W ADH is the width W of the continuous elastic substrate 200a ES may be equal to

[0076] 4, 7, and 8, the continuous elastic substrate 200a may be advanced in the machine direction MD from an adhesive applicator device 302 to a cutting device 304 that cuts and separates the separate elastic portions 200 from the continuous elastic substrate 200a. Thus, the separate elastic portions 200 each include a leading edge 230 and a trailing edge 232, and have a length L extending in the machine direction MD from the leading edge 230 to the trailing edge 232. EPThe elastic portion 200 also includes a first longitudinal edge 214 and a second longitudinal edge 216 that correspond to the longitudinal edges 214, 216 of the continuous elastic substrate 200a that extend between the leading edge 230 and the trailing edge 232. Additionally, the elastic portion 200 includes a first surface 218 and a second surface 220 that correspond to the first surface 218 and second surface 220 of the continuous elastic substrate 200a.

[0077] As shown in FIG. 8, the separate elastic portion 200 also includes a first end region 234 adjacent the first longitudinal edge 214 and a second end region 236 adjacent the second longitudinal edge 216, the second end region 236 being separated from the first end region 234 in the transverse direction CD by a central region 238. As described above, an adhesive 222 may be applied to the second surface 220 of the continuous elastic substrate 200a. Thus, the separate elastic portion 200 may include a zone 240 of adhesive 222 on the second surface 220. It should be understood that the adhesive zone 240 of adhesive 222 may define various sizes and shapes for the elastic portion 200. For example, as shown in FIG. 8, the zone 240 of adhesive may extend in the transverse direction CD across less than the entire width W1 of the separate elastic portion 200. In some configurations, the zone 240 of adhesive 222 may be positioned only on a central region 238 of the separate elastic portion 200 such that the first end region 234 and the second end region 236 of the second surface 220 of the separate elastic portion 200 may not include any adhesive 222.

[0078] As shown in Figures 4 and 9, the cutting device 304 may include a knife roll 306 positioned adjacent to an anvil roll 308 to define a nip 310 therebetween. The knife roll 306 may include a peripheral surface 312 and one or more blades 314 adapted to rotate in a first direction Dir1 about an axis 316. The anvil roll 308 may include a peripheral surface 318 adapted to rotate in a second direction Dir2 opposite the first direction Dir1 about an axis 320 such that the peripheral surface 318 advances at a third speed S3, the third speed S3 being faster than the second speed S2. With continued reference to FIG. 4, as the continuous elastic substrate 200a advances through the nip 310 between the knife roll 306 and the anvil roll 310, the blades 314 operate to cut separate elastic portions 200 from the continuous elastic substrate 200a. As the outer circumferential surface 318 of the anvil roll 308 advances at the third speed S3, the cut separate elastic portions 200 may then accelerate from the second speed S2 to a third speed S3 on the outer circumferential surface 318 of the anvil roll 308. It should also be appreciated that one or more components of the cutting device 304 may be configured to operate at constant and / or variable speeds. For example, the knife roll 306 and / or the anvil roll 308 may be connected with various types of motors, such as, for example, servo motors, that may rotate the knife roll 306 and / or the anvil roll 308 at constant and / or variable angular velocities.

[0079] In some configurations, the third speed S3 may be equal to the first speed S1 of the advancing carrier substrate 202. In some configurations, the third speed S3 may be less than or greater than the first speed S1 of the advancing carrier substrate 202, and thus the separate elastic portions may be accelerated or decelerated downstream of the anvil roll 308 from the third speed S3 to the first speed S1 before being combined with the carrier substrate 202. Because the first speed S1 of the carrier substrate is greater than the second speed S2, the separate elastic portions 200 are accelerated from the second speed S2 to the first speed S1 before being combined with the carrier substrate 202. By accelerating the separate elastic portions 200 from the second speed S2 to the first speed S1, the trailing edges 232 (or leading edges 230) of the successively cut separate elastic portions 200 may be separated from one another in the machine direction MD by a pitch distance PD as shown in Figure 14, which may correspond to the pitch length PL described above with reference to Figures 1A and 1B. The anvil roll 308 may also be configured to apply a vacuum pressure to the separate elastic portions 200 to help retain the separate elastic portions 200 on the peripheral surface 318 as the anvil roll 308 rotates.

[0080] It should be understood that the cutting device 304 can be configured in a variety of ways. For example, in some configurations, the blade 314 can be configured such that the resulting cut line and corresponding leading edge 230 and trailing edge 232 of the separate elastic portion 200 can be straight and / or curved. Also, the cutting device 304 can be adapted to cut the separate elastic portion 200 such that the material along the cut line adjacent the leading edge 230 and trailing edge 232 is fused and / or pressure bonded to one another. It should also be understood that the positions of the knife roll 306 and the anvil roll 308 can be reversed from that shown in FIG. 4 such that the separate elastic portion 200 can remain on the circumferential surface 312 of the knife roll 306 as opposed to the anvil roll 308. It should also be understood that the cutting device 304 can be configured to transfer and / or cut the separate elastic portion 200 in different ways.

[0081] 4, the apparatus 300 may include a rotatable transfer device 322 that transfers the separate elastic portions 200 from the cutting device 304 to a joining device 324, whereby the elastic portions 200 are combined with the carrier substrate 202. The transfer device 322 may also be configured to stretch the separate elastic portions 200 in the cross direction CD. As such, the transfer device 322 may be configured as a spreader mechanism 326 as shown in FIGS. 9 and 10. With continued reference to FIGS. 4, 9, and 10, the transfer device 322 may be positioned adjacent to the anvil roll 308 to define a nip 328 therebetween. As discussed in more detail below, the separate elastic portions 200 are received from the anvil roll 308, and the spreader mechanism 326 operates to stretch the separate elastic portions 200 in the cross direction CD. The stretched discrete elastic portions 200 are then advanced from the spreader mechanism 326 onto a rotating component of a bonding device 324 which then bonds the stretched discrete elastic portions 200 onto the carrier substrate 202 .

[0082] 9 and 10, the spreader mechanism 326 may include a first disk 330 and a second disk 332, where the first disk 330 is displaced from the second disk 332 in a transverse direction CD. The first disk 330 is adapted to rotate about a rotation axis 330a, and the second disk 332 is adapted to rotate about a rotation axis 332a, where the first disk 330 and the second disk 332 may rotate in a third direction Dir3 opposite the second direction Dir2. As shown in FIG. 11, the first disk 330 includes an outer rim 330b extending axially between an inner edge 330c and an outer edge 330d, and the second disk 332 includes an outer rim 332b extending axially between an inner edge 332c and an outer edge 332d.

[0083] 9-11, the first disk 330 and the second disk 332 are inclined relative to each other such that the outer rims 330b, 332b are separated from each other by a distance D that increases from a minimum distance Dmin at a first location to a maximum distance Dmax at a second location. As discussed below, the separate elastic portions 200 are transferred from the cutting device 304 onto the outer rims 330b, 332b during operation. Because the first disk 330 and the second disk 332 are inclined, rotation of the disks 330, 332 causes the rims 330b, 332b to pull on the first and second end regions 234, 236 of the separate elastic portions 200, stretching the central region 238 of the separate elastic portions 200 in the transverse direction CD before the separate elastic portions 200 are transferred to the joining device 324. As shown in Figures 4, 8, and 12, the spreader mechanism 326 can operate to transversely stretch the separate elastic portions 200 from a first width W1 to a second width W2 that is greater than the first width W1.

[0084] 4, 9, and 10, the disks 330, 332 may also be configured to help grip the opposing first and second end regions 234, 236 of the separate elastic portion 200 during operation. For example, the first and second disks 330, 332 may each be fluidly connected to a vacuum pressure source 334. Thus, vacuum pressure may be used to help hold the separate elastic portion 200 on the rims 330b, 332b during operation. As shown in FIGS. 11 and 11A, the disks 330, 332 may also include nubs 336 that protrude radially outward from the rims 330b, 332b. Thus, the nubs 336 may also help prevent the first and second end regions 234, 236 of the separate elastic portion 200 from sliding along the rims 330b, 332b while stretching the central region 238 of the separate elastic portion 200. It should also be noted that because the first end region 234 and the second end region 236 of the separate elastic portion 200 are held on the rims 330b, 332b during the stretching operation, the central region 238 of the separate elastic portion 200 is stretched, but the first end region 234 and the second end region 236 may not be stretched or may be stretched to a much lesser extent than the central region 238.

[0085] As previously described with reference to Figure 8, the elastic portion 200 may include a zone 240 of adhesive 222 positioned on a central region 238 of the separate elastic portion 200, and some or all of the first end region 234 and second end region 236 of the second surface 220 of the separate elastic portion 200 may be free of any adhesive 222. As shown in Figures 4, 9, and 10, upon transfer to the transfer device 322, the elastic portion 200 may be oriented such that the first surface 218 may face radially outward and the second surface 220 and zone 240 of adhesive 222 may face radially inward. Thus, the configuration of the disks 330, 322 of the spreader mechanism 326 provides the ability to rotatably transport the elastic portion 200 from the cutting device 304 to the joining device 324 with the zone 240 of adhesive 222 facing radially inward without the need for the adhesive 222 to contact the disks 330, 332.

[0086] As described above, the cut separate elastic portions 200 accelerate on the outer peripheral surface 318 of the anvil roll 308 from the second speed S2 to a third speed S3, which in some configurations may be less than or greater than the first speed S1 of the advancing carrier substrate 202. Accordingly, the transfer device 322 may be configured to rotate at a variable angular velocity to accelerate or decelerate the separate elastic portions 200 to the first speed S1. For example, when the third speed S3 is less than the first speed S1, the transfer device 322 may be configured to receive the separate elastic portions 200 from the anvil roll 308 while the rims 330b, 332b of the first and second disks 330, 332 move through the nip 328 at the third speed S3. The angular velocity of the disks 330, 332 may then be changed to accelerate the separate elastic portions 200 to the first velocity S1 before transferring the separate elastic portions 200 to the joining device 324. In another example, if the third velocity S3 is greater than the first velocity S1, the angular velocity of the disks 330, 332 may be changed to decelerate the separate elastic portions 200 to the first velocity S1 before transferring the separate elastic portions 200 to the joining device 324. In a situation where the third velocity S3 is equal to the first velocity S1, the disks 330, 332 may rotate at a constant angular velocity. It should be understood that the spreader mechanism 326 may be configured in various ways to address the need to rotate at variable angular velocities, for example, as disclosed in European Patent Publication No. EP 2 260 813 B1, which is incorporated herein by reference. The ability to rotate in the transport device 326 at variable angular speeds can help reduce the need to replace components of the apparatus 300 when assembling smaller or larger sized absorbent articles 100, although this may require a reduction or increase in the pitch distance between successively cut separate elastic portions 200.

[0087] As previously mentioned, the rotatable transfer device 322 may be configured to transfer the separate elastic portions 200 from the cutting device 304 to the joining device 324. As shown in Figures 4, 9, and 10, the joining device 324 may be positioned adjacent to the first disk 330 and the second disk 332 of the spreader device 326 to define a nip 338 therebetween. In some configurations, the first disk 330 and the second disk 332 may be configured to apply positive air pressure, sometimes referred to as blow-off air, to the separate elastic portions 200 adjacent the nip 338 to aid in detaching the separate elastic portions 200 from the disks 330, 332 during transfer to the joining device 324. As discussed in more detail below, the separate elastic portions 200 are received from the spreader mechanism 326 with the central region 238 stretched in the cross direction CD, and the bonding device 324 transfers and bonds the separate elastic portions 200 in a stretched state to the advancing carrier substrate 202.

[0088] It will be appreciated that the bonding device 324 may be configured in various ways. For example, as shown in Figures 4, 9, and 10, the bonding device 324 may be configured with a pattern roll 340 and a pressing surface 342 adjacent to the pattern roll 340 to define a nip 344 therebetween. The pattern roll 340 includes an outer peripheral surface 346 and may rotate about a rotation axis 348, and the pattern roll 340 may rotate in a fourth direction Dir4 opposite the third direction Dir3. In addition, the pattern roll 340 may rotate such that the outer peripheral surface 346 advances at or about a first speed S1. In operation, the separate elastic portions 200 in a stretched state are transferred from the first disk 330 and the second disk 332 to the outer peripheral surface 346 of the pattern roll 340. The pattern roll 340 rotates to advance the stretched elastic portions 200 between the outer peripheral surface 346 of the pattern roll and the advancing carrier substrate 202. Specifically, the first surfaces 218 of the discrete elastic portions 200 may be positioned in facing relationship and direct contact with the outer circumferential surface 346 of the pattern roll 340. Thus, the zones 240 of adhesive 222 and the second surfaces of the discrete elastic portions 200 may face radially outward from the axis of rotation 348. The carrier substrate 202 advances toward the pattern roll 340 such that the first surface 210 of the carrier substrate 200 is in direct contact and facing relationship with the outer circumferential surface 346 of the pattern roll 340. As the pattern roll 340 rotates, the second surfaces 220 of the discrete elastic portions 200 are positioned in direct contact and facing relationship with the first surface 210 of the carrier substrate 200. The combined discrete elastic portions 200 and carrier substrate 202 advance through a nip 344 between a pattern roll 340 and a pressing surface 342 to mechanically bond the discrete elastic portions 200 and the carrier substrate 202 together.

[0089] As shown in FIG. 4, the bonding device 324 may be configured as a mechanical bonding device including an anvil roll 350. The anvil roll 350 includes an outer peripheral surface 352 and rotates about an axis of rotation 354, where the anvil roll 350 may rotate in a fifth direction Dir5 opposite the fourth direction Dir4. The outer peripheral surface 352 of the anvil roll 350 may define a pressing surface 342 that operates with the pattern roll 340. As shown in FIGS. 13 and 13A, the outer peripheral surface 346 of the pattern roll 340 may also include one or more bonding surfaces 356 defined by bonding elements 358 extending radially outward. As the pattern roll 340 rotates, the separate elastic portions 200 and the carrier substrate 200 are advanced between the bonding surface 356 and the pressing surface 342 to mechanically bond or weld the elastic portions 200 and the carrier substrate 202 together to create a bond 242 between the elastic portions 200 and the carrier substrate 202. Heat and / or pressure between the pressing surface 342 and the pattern roll 340 may melt and bond the carrier substrate 202 and the elastic portion 200 together in areas supported by a bonding surface 356 on the pattern roll 340. As shown in FIG. 14 , the mechanical bonds and / or bond regions 242 may have a shape that corresponds to and may mirror the shape of the bonding surface 356.

[0090] Thus, as the laminate 204 advances through the nip 344, the carrier substrate 202 and the separate elastic portions 200 are mechanically bonded or welded together. It should be understood that the bonding device 324 herein may be configured in a variety of ways with various features described herein for bonding the separate elastic portions 200 to the carrier substrate 202. Thus, the pattern roll 340 and / or the anvil roll 350 may be configured to apply heat and pressure in a variety of manners to effect the mechanical bonding, such as, for example, the mechanical bonding devices and methods disclosed in U.S. Patent Nos. 4,854,984; 6,248,195; 8,778,127; 9,005,392; 9,962,297; and 10,052,237. 4, such that the separate elastic portions 200 may be transferred from the transfer device 322 to the outer circumferential surface 352 of the anvil roll 350 as opposed to the pattern roll 340. It should also be understood that one or more components of the bonding device 324 may be configured to operate at constant and / or variable speeds. For example, the pattern roll 340 and / or the anvil roll 350 may be connected to various types of motors, such as, for example, servo motors, that may rotate the pattern roll 340 and / or the anvil roll 350 at constant and / or variable angular velocities.

[0091] In some configurations, the carrier substrate 202 may be partially wrapped around the outer peripheral surface 346 of the pattern roll 340. Thus, the bonding device 324 may include one or more rolls that help guide the carrier substrate 202 to and / or from the pattern roll 340. For example, as shown in FIG. 4, the bonding device may include a guide roll 360 that helps guide the carrier substrate 202 onto the outer peripheral surface 346 of the pattern roll 340 downstream of the nip 338 where the elastic portion 202 is received from the transfer device 322 and upstream of the nip 344 between the pattern roll 340 and the pressing surface 342. The guide roll 360 may also be configured to apply pressure against the carrier substrate 202 and the elastic portion 200 to help enhance bonding between the adhesive 222 of the bonding zone 240 and the carrier substrate 202.

[0092] It should be understood that the bonding device 324 may be configured in a variety of ways, such as a heated or unheated pattern roll, an anvil roll, and / or an ultrasonic bonding device. For example, the bonding device 324 shown generally in FIG. 4A may include a pattern roll 340 and a pressing surface 342 that includes an energy transfer surface 362 of an ultrasonic bonding device 364. The bonding device 364 may thus include a horn 366 and may be configured to apply ultrasonic energy to the combined elastic portion 200 and carrier substrate 202 on the pattern roll 340.

[0093] It should be appreciated that the embodiments of the ultrasonic bonding device 364 may be configured in a variety of ways, such as, for example, linear or rotary type configurations, and as disclosed, for example, in U.S. Patent Nos. 3,113,225, 3,562,041, 3,733,238, 5,110,403, 6,036,796, 6,508,641, and 6,645,330. In some configurations, the ultrasonic bonding device 364 may be configured as a linear vibrating sonotrode, such as available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode may include multiple sonotrodes nested together in the transverse direction CD. It should also be appreciated that the rotating horn may be configured to rotate at a constant and / or variable angular velocity.

[0094] As described above, the pattern roll 340 includes bonding elements 358 extending radially outward to define a bonding surface 356. The bonds and / or bonding regions 242 between the separate elastic portions 200 and the carrier substrate 202 can then have a shape that corresponds to and can mirror the shape of the bonding surfaces 356. It should be understood that the pattern roll 340 can have a variety of amounts and / or shapes of bonding surfaces 356, and such bonding surfaces 356 can be positioned at a variety of locations on the pattern roll 340. For example, as shown in FIGS. 13, 13A, 14, and 15, the bonding elements 358 and bonding surfaces 356 can be positioned to correspond to the first and second end regions 234, 236 of the separate elastic portions 200. Thus, the bonding device 340 can operate to mechanically bond the first and second end regions 234, 236 of the elastic portions 200 without mechanically bonding the stretched central region 238. In some configurations, the joining elements 358 and joining surfaces 356 may be positioned such that a mechanical bond 242 is also applied to join the central regions 238 of the separate elastic portions 200 and the carrier substrate 202 together.

[0095] The pattern roll 340 may also be configured to apply vacuum pressure to the separate elastic portions 200 to help hold them on the outer peripheral surface 346 as the pattern roll 340 rotates. The vacuum pressure may also help hold the separate elastic portions 200 in an extended state while positioned on the pattern roll 340. In addition, the interface elements 358 and interface surfaces 356 may also help grip the elastic portions 200 and help hold the elastic portions 200 in an extended state. In addition, the pattern roll 340 may also be configured to apply vacuum pressure through the interface surfaces 356 of the interface elements 358. Furthermore, the pattern roll 340 may be configured to interface with the first disk 330 and the second disk 332 of the spreader mechanism 326 to help maintain the extended state of the separate elastic portions 200 during transfer to the pattern roll 340 at the nip 338. For example, as described above, the disks 330, 332 of the spreader mechanism 326 may include various amounts of nubs 336 that protrude radially outward from the rims 330b, 332b, which may help prevent the first and second end regions 234, 236 of the elastic portions 200 from sliding toward one another along the rims 330b, 332b during stretching of the separate elastic portions 200. It should be understood that the nubs 336 may be configured in various shapes and sizes, spacing, and may be constructed from various types of materials. In some configurations, the interface elements 358 on the pattern roll 340 may be configured to mate with the nubs 336 that protrude from the rims 330b, 332b of the first and second disks 330, 332. The interlocking between the nubs 336 and the joining elements 358 can help maintain the extension of the separate elastic portions 200 as the apparatus 300 is transferred from the delivery device 322 to the joining device 324 .

[0096] As shown in FIG. 4, after the discrete elastic portions 200 are joined with the carrier substrate 202 to create the laminate 204, the laminate 204 can continue to advance in the machine direction MD from the joining device 324 and can be subjected to additional converting operations, such as cutting, folding, and / or packaging operations. In some configurations, the laminate 204 may define a continuous length of absorbent article, or may be combined with additional substrates and / or components to define a continuous length of absorbent article. The continuous length of absorbent article can then be subjected to a final knife cut that separates the discrete absorbent articles from the continuous length of absorbent article. As previously mentioned, the discrete elastic portions 200 can correspond to waist panels 158 on the absorbent article 100, and the carrier substrate 202 can correspond to the topsheet substrate 138 or the backsheet substrate 136. In some configurations, the apparatus and methods herein can be configured to apply the discrete elastic portions 200 as discrete front and / or back waist panels 158. In some configurations, the separate elastic portions 200 may be applied to a carrier substrate 202, after which the separate elastic portions 200 are cut during a final knife cut into a front waist panel 158a positioned in the front waist region 116 and a back waist panel 158b positioned in the back waist region 118. It should be understood that such a final knife cut operation may be configured to apply straight and / or curved cut lines through the carrier substrate 202 and the separate elastic portions 200. For example, FIG. 14A shows a view of a laminate 204 showing the elastic portions 200 and carrier substrate 202 after being subjected to a final knife cut operation that applies a cut line 231 through the carrier substrate 202 and the separate elastic portions 200. Thus, the separate elastic portions 200 may be cut into a first elastic portion 200b and a second elastic portion 200c. In some configurations, the first elastic portion 200b may correspond to a first waist panel 158 positioned in the panel first waist region 116, and the second elastic portion 200c may correspond to a second waist panel 158 positioned in the second waist region 118.In some configurations, the curved cut line 231 may be adapted to create an umbilical notch 233a as disclosed in U.S. Patent No. 8,608,720 and U.S. Patent Publication No. 2017 / 0246052(A1), both of which are incorporated herein by reference.

[0097] It should also be understood that the carrier substrate 202 may include portions, such as, for example, laterally extending side panels, attached upstream of the bonding device 324. Accordingly, the system 300 may also include rails and / or conveyors to help guide and control the carrier substrate 202, particularly such laterally extending features, within the bonding device 324 to help prevent unintentional bonding of such features.

[0098] As discussed above, the separate elastic portions may be combined with a carrier substrate adhesive and / or mechanical joints. It will be appreciated that the adhesive and mechanical joints may be configured in a variety of ways. It will also be appreciated that the zones 240 of adhesive 222 may be applied to define a variety of different shapes and sizes relative to the separate elastic portions 200 and / or the carrier substrate 202. For example, as shown in FIG. 14, the zones 240 of adhesive 222 may be applied to the separate elastic portions 200 and / or the carrier substrate 202 over a length L in the machine direction MD. AZ In some configurations, the length L of the zone 240 of the adhesive 222 may be defined as AZ is the total length L of the separate elastic portion 200 EP In some configurations, the zone 240 of adhesive 222 may extend in the transverse direction CD to the leading edge of the elastic portion 200. In some configurations, the length L of the zone 240 of adhesive 222 may be abutted by one or both of the edge 230 and the trailing edge 232. AZ is the total length L of the separate elastic portion 200 extending from the leading edge 230 to the trailing edge 232. EP The length of the slit may extend over a range of 100 mm to 150 mm.

[0099] 4, the system 300 may include an adhesive applicator device 302 that may be configured to apply adhesive 222 to the continuous elastic substrate 200a upstream of a nip 310 between the knife roll 306 and the anvil roll 308. The discrete elastic portions 200, in turn, separated from the continuous elastic substrate 200a may include zones 240 of adhesive 222 adapted to adhesively bond the elastic portions 200 to the carrier substrate 202. It should be understood that the zone 240 of adhesive 222 may comprise the adhesive 222 applied to the continuous elastic substrate 200a, the elastic portions 200, and / or the carrier substrate 202 in various configurations and / or locations in the assembly process. For example, as shown in FIG. 4, the system 300 may include an adhesive applicator device 302a that may be configured to apply adhesive 222 to the discrete elastic portions 200 at a location downstream of a nip 310 between the knife roll 306 and the anvil roll 308. In another example, as shown in FIG. 4, the apparatus 300 may include an adhesive applicator device 302b that deposits adhesive 222 on the first surface 210 of the carrier substrate 202 to define a zone 240 of adhesive 222 that bonds the elastic portions 200 with the carrier substrate 202. It should be understood that the adhesive applicator device 302a may be configured to operate in addition to or in place of the adhesive applicators 302, 302b, and the adhesive applicator device 302b may be configured to operate in addition to or in place of the adhesive applicators 302, 302a. It should also be understood that the adhesive applicator devices 302a, 302b may be configured in a variety of ways, such as the adhesive applicator 302 described above, for example, as a spray nozzle and / or a slot coating device, etc. It should also be understood that in some configurations, the separate elastic portion 200 may be coupled to the carrier substrate 202 using only mechanical bonding without the use of adhesives.

[0100] In accordance with the above discussion of various shapes and sizes of the zones 240 of adhesive 222, it should be understood that the adhesive 222 may be applied to the continuous elastic substrate 200a and / or the carrier substrate 202 in various ways to define the zones 240 of adhesive 222. For example, as described above with reference to Figures 4 and 7, the adhesive 222 may be applied to define areas 224 of adhesive 222 in separate patches 226 on the continuous elastic substrate 200a in the machine direction MD. In another example, the adhesive 222 may be applied to the second surface 220 of the continuous elastic substrate 200a to extend continuously in the machine direction MD and / or the cross direction CD. In another example, as shown in Figure 16, the adhesive 222 may be applied to the first surface 210 of the carrier substrate 202 in separate patches 226 on the carrier substrate 202 in the machine direction MD. It should be understood that the adhesive 222 may be applied to the continuous elastic substrate 200a, the elastic portion 200, and / or the carrier substrate 202 in a shape and size that defines zones 240 of adhesive 222 that bond the elastic portion 200 and the carrier substrate 202 together. The separate patches 226 of adhesive 222 may be separated from one another in the machine direction MD on the carrier substrate 202 by a pitch distance PD.

[0101] The lumbar panel 158 herein may also be constructed as described in, for example, U.S. Pat. Nos. 6,572,595, 6,830,800, 7,087,287, and 7,803,244, and U.S. Patent Application Publication Nos. 2018 / 0042778(A1), 2018 / 0042787(A1), 2018 / 0042779(A1), all of which are incorporated herein by reference. 2018 / 0042780(A1), and U.S. Patent Application Nos. 16 / 864,267, 16 / 864,292, 62 / 855,001, 62 / 930,181, 62 / 930,198, and 62 / 930,808. For example, Figures 17A-17D show various schematic diagrams of an apparatus 500 operative to assemble a continuous elastic substrate 200a from which separate elastic portions 200 may be cut, as described above.

[0102] It should be understood that the continuous elastic substrate 200a and the separate elastic portions 200 herein may be configured in a variety of ways and may include one or more elastic materials, such as elastic films and / or strands. For example, the continuous elastic substrate 200a and the separate elastic portions 200 may be configured as a single layer of elastic film. For example, the continuous elastic substrate 200a and the separate elastic portions 200 may be configured as a laminate of two or more substrates. For example, the continuous elastic substrate 200a and the separate elastic portions 200 may be configured as an elastic film bonded between two or more nonwoven substrates and / or bonded to one or more nonwoven substrates. For example, the continuous elastic substrate 200a and the separate elastic portions 200 may be configured as a bi-layer laminate with an elastic film bonded to a single nonwoven substrate. In another example, the continuous elastic substrate 200a and the separate elastic portions 200 may be configured as an elastic film bonded between two or more substrates, which may include nonwovens. It should be understood that the nonwoven substrates of the elastic substrate 200a and the separate elastic portions 200 may be of the same material and / or basis weight or of different materials and / or basis weights. In some configurations, the nonwoven substrates of the elastic substrate 200a and the separate elastic portions 200 may be of the same material and / or basis weight or of different materials and / or basis weights as the nonwoven substrates of the carrier substrate 202.

[0103] It should also be understood that the continuous elastic substrate 200a and the separate elastic portions 200 may be assembled in a variety of manners, such as those disclosed in U.S. Patent Nos. 6,572,595, 6,830,800, 7,087,287, and 7,803,244, and U.S. Patent Application Publication Nos. 2018 / 0042778(A1), 2018 / 0042787(A1), 2018 / 0042779(A1), and 2018 / 0042780(A1), all of which are incorporated herein by reference. For example, Figures 17A-17D show various schematic views of an apparatus 500 operative to assemble a continuous elastic substrate 200a from which separate elastic portions 200 may be cut, as described above.

[0104] As shown in FIGS. 17A-17C, a first substrate 402 advances in a machine direction MD onto a rotating anvil 502. More specifically, the first substrate 402 includes a first surface 404 and an opposing second surface 406, and the first substrate 402 advances to wrap the first surface 404 onto the circumferential surface 504 of the rotating anvil 502. During the assembly process, a spreader mechanism 512 stretches the elastic film 408 by stretching the elastic film 408 in a cross direction CD to a first extension. And, the stretched elastic film 408 is positioned in contact with the second surface 406 of the first substrate 402. The elastic substrate 200a can then be formed by ultrasonically bonding the first substrate 402 and the elastic film 408 together with a second substrate 410 on the anvil 502. More specifically, the second substrate 410 includes a first surface 412 and an opposing second surface 414, and the second substrate 410 advances to bring the first surface 412 into contact with the elastic film 408 and the second surface 406 of the first substrate 402.

[0105] 17-17C, as the anvil 502 rotates, the first substrate 402, the elastic film 408, and the second substrate 410 are advanced between the peripheral surface 504 of the anvil 502 and one or more ultrasonic devices 530 adjacent the anvil 502. It should be appreciated that the ultrasonic devices 530 may include a horn 532 and may be configured to apply ultrasonic energy to the combined substrates and elastic film on the anvil 502. It should be appreciated that the aspects of the ultrasonic bonding device 530 may be configured in a variety of ways, such as, for example, linear or rotational type configurations, and as disclosed, for example, in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and 6,645,330. In some configurations, the ultrasonic bonding device 530 may be configured as a linear vibrating sonotrode, for example, available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode may include multiple sonotrodes nested together in the transverse direction CD. The ultrasonic horn 532 then bonds the first substrate 404, the elastic film 408, and the second substrate 410 together to form the elastic substrate 200a.

[0106] As shown in Figs. 17A and 18, the elastic substrate 200 can be advanced from the anvil 502 and accumulated, such as by being wound onto a roll 200R or tied into a container. It will be appreciated that the elastic substrate 200a can be wound onto the roll 200R in a fully stretched state, a partially stretched state, or a fully relaxed state. The accumulated elastic substrate 200a can be stored and / or moved to a location for incorporation into an absorbent article assembly process, where the elastic substrate 200a can be converted into an absorbent article component as described above. It will also be appreciated that the elastic substrate 200a can be advanced from the anvil 502 directly into the absorbent article assembly process. Fig. 19 also shows the elastic substrate 200a in a relaxed state, with the central region 408c of the elastic film 408 contracted in the cross direction CD. It should be appreciated that the apparatus 500 may be configured to assemble the elastic substrate 200a with a single lane of elastic film 408, or may be configured to assemble the elastic substrate 200a with multiple lanes of elastic film 408 that are separated from one another in the transverse direction. The elastic substrate 200a may then be cut along the machine direction MD between such lanes of elastic film 408 to create a plurality of individual elastic substrates 200a.

[0107] It should be appreciated that during the ultrasonic bonding process, the bond imparted from the ultrasonic horn 532 to the elastic substrate 200a may correspond to a pattern and / or shape defined by a plurality of pattern elements extending radially outward from the outer peripheral surface 504 of the anvil 502. It should be appreciated that the elastic substrate 200a may include various portions of components bonded together in various ways and with different or identical bond patterns. For example, the elastic film 408 may be bonded together with the first substrate 402 and / or the second substrate 410, and the first substrate 402 may be bonded directly to the second substrate 410 in the area of ​​the elastic substrate 200a. In some configurations, the first substrate 402 and the second substrate 410 may be bonded directly to one another through openings in the elastic film, and such openings may be formed during the bonding process. In some configurations, the elastic film 408 may participate or be involved in the bond between the first substrate 402 and the second substrate 410, where "involved" may mean that the elastic film may be in intimate contact with, and perhaps even partially interlocked with, to some degree with one or both of the first substrate 402 and the second substrate 410. This involvement may be due to actual melt bonding around the bond site, or may be due to mechanical interaction, such as by entanglement of fibrous elastic layers between fibrous nonwoven layers, also around the bond site. It should be understood that the apparatus 500 can be adapted to produce various types of bond configurations, such as those disclosed in U.S. Pat. Nos. 6,572,595, 6,830,800, 7,087,287, and 7,803,244, and U.S. Patent Application Publication Nos. 2018 / 0042778(A1), 2018 / 0042787(A1), 2018 / 0042779(A1), and 2018 / 0042780(A1), all of which are incorporated herein by reference.

[0108] As previously described, the spreader mechanism 512 stretches the elastic film 408 to a first extension E1 in the transverse direction CD. With particular reference to Figures 17A and 17D, the elastic film 408 includes a first edge 416a and a second edge 416b separated from the first edge 416a in the transverse direction CD. In addition, the elastic film 408 includes a first edge region 408a adjacent to the first edge 416a and a second edge region 408b adjacent to the second edge 416b. The first edge region 408a is separated from the second edge region 408b in the transverse direction CD by a central region 408c. 17A and 17B, the elastic film 408 can define an initial width Wi in the cross direction CD between a first edge 416a and a second edge 416b upstream of the spreader mechanism 512. The elastic film 512 advances in the machine direction MD onto the spreader mechanism 512 at a first position 520. It should be appreciated that the elastic film 408 can define an initial width Wi in the cross direction CD while advancing onto the spreader mechanism 512. It should also be appreciated that the elastic film 408 can be in a relaxed state upstream of the spreader mechanism 512.

[0109] As shown in Figures 17B and 17D, the first edge region 408a of the elastic film 408 advances onto the outer rim 516b of the first disk 516 of the spreader mechanism 512, and the second edge region 408b advances onto the outer rim 518b of the second disk 518. In addition, the outer rim 516b of the first disk 516 may extend axially between an inner edge 516c and an outer edge 516d, and the outer rim 518b of the second disk 518 may extend axially between an inner edge 518c and an outer edge 518d. The outer rims 516b, 518b of the first disk 516 and the second disk 518 of the spreader mechanism 512 may include channels 524 fluidly connected to a vacuum pressure source and may include radially protruding nubs 528. Thus, as shown in FIG. 17D, the first edge region 408a of the elastic film 408 may be held in place on the outer rims 516b by the vacuum air pressure in the channels 524 and the radially protruding nubs 528. Similarly, the second edge region 408b of the elastic film 408 may be held in place on the outer rim 518b by the vacuum air pressure in the channels 524 and the radially protruding nubs 528.

[0110] 17B and 17D, the first disk 516 and the second disk 518 are inclined. Thus, as the first disk 516 and the second disk 518 of the spreader mechanism 512 rotate, the elastic film 408 is stretched in the transverse direction CD while advancing from the first location 520 or downstream of the first location 520 toward the second location 522. Thus, as shown in FIGS. 17A, 17B, and 17D, the spreader mechanism 512 can stretch the elastic film 408 in the transverse direction CD from an initial width Wi (and a first elongation Ei) to a first width W1 (and an initial elongation E1), where W1 is greater than Wi and E1 is greater than Ei. In some configurations, the elastic film 408 can be consolidated to a second width W2 (and a second elongation E2), where W2 is less than W1 and E2 is less than E1. It is understood that the elastic film 408 remains stretched to a second width W2 (and second elongation E2). It is also understood that the elastic film 408 may be in a relaxed state at an initial width Wi (and initial elongation Ei), and thus the second width W2 may be greater than the initial width Wi and the second elongation E2 may be greater than the initial elongation Ei. In an unconsolidated configuration of the elastic film, W2 may be equal to W1 and E2 may be equal to E1.

[0111] In some configurations, when the spreader mechanism includes an inclined disk, the first edge region 408a and the second edge region 408b of the elastic film 408 may be held in place on the outer rims 516b, 518b of the disks 516, 518. Thus, some portions of the first edge region 408a and the second edge region 408b may still be unstretched in the cross direction CD when the first disk 516 and the second disk 518 rotate. Thus, when the first disk 516 and the second disk 518 of the first spreader mechanism 512 rotate, the central region 408c of the elastic film 408 is stretched in the cross direction CD.

[0112] 17A-17D, the elastic film 408 advances from the spreader mechanism 512 downstream of the second location 522 onto the anvil 502 and onto the anvil 502 onto the second surface 406 of the first substrate 402. And as the anvil 502 rotates, the second substrate 410 advances over the anvil 502 and positions the first surface 412 in contact with the elastic film 408 and the second surface 406 of the first substrate 402 to form the elastic substrate 200a, and the first substrate 402, elastic film 408, and second substrate 410 are bonded together.

[0113] 17A and 17B, the outer peripheral surface 504 of the anvil 502 may be fluidly connected to a vacuum source 505 such that vacuum air pressure may be applied to the first substrate 402 on the anvil 502. For example, the outer peripheral surface 504 of the anvil roll 502 may include a plurality of apertures fluidly connected to a vacuum pressure source. If the first substrate 402 is configured as a porous substrate such as a nonwoven, the vacuum air pressure may also be applied to the elastic film 408 on the anvil 502 and thus help maintain the elastic film 408 in an extended state while on the anvil 502. In some configurations, an adhesive on the nonwoven may also help reduce the porosity of the nonwoven, which in turn may increase the ability of the vacuum air pressure to help maintain the component in an extended state.

[0114] As mentioned above, the elastic substrate 200a and the elastic portion 200 may comprise a nonwoven substrate, which may be of the same material and / or basis weight or different materials and / or basis weights. For example, the first substrate 402 and the second substrate 410 described above with reference to Figs. 17A-19 may be configured as a nonwoven substrate. Thus, the first substrate 402 and the second substrate 410 of the elastic substrate 200a and the elastic portion 200 may be the same type of nonwoven or different types of nonwoven and / or have the same or different basis weights. In addition, the carrier substrate 202 may comprise one or more nonwoven substrates. Thus, the first substrate 402 and / or the second substrate 410 of the elastic substrate 200a and the elastic portion 200 may be the same or different types of nonwoven and / or have the same or different basis weights as the nonwoven substrate of the carrier substrate 202. In addition to the substrates, the nonwoven substrates of the elastic substrate 200a and the elastic portion 200, such as the first 402 and / or second substrate 410, for example, may comprise a nonwoven substrate having the same or a different fiber orientation as the nonwoven substrate of the carrier substrate 202. In turn, the elastic portion 200 configured as a lumbar panel 158 and the carrier substrate 202 configured as a topsheet or backsheet within an absorbent article may each comprise a nonwoven substrate that is the same or a different type of nonwoven, and / or may have the same or a different basis weight, and / or may have the same or a different fiber orientation.

[0115] As described above, the apparatus and methods for assembling waist panels and / or joining waist panels to other absorbent article components may be adapted to assemble an absorbent article 100 having a first waist panel 158a and a second waist panel 158b that include structural or morphological features that impart different stretch characteristics to the first waist panel 158a and the second waist panel 158b.

[0116] For example, referring to FIG. 4, the apparatus 300 may include one or more transforming devices 600 that may be adapted to modify the elastic substrate 200a, the elastic portions 200, the carrier substrate 202, and / or the laminate 204 to create a morphological difference resulting in a morphological difference between the first waist panel 158a and the second waist panel 158b. The transforming devices 600 are generally represented in FIG. 4 as a dashed rectangle. It should be understood that the transforming devices 600 may be adapted to form various types of morphological features, such as embossing, apertures, slits, melted material, compressed material, plastic deformation, folding, adhesive bonding, and / or pressure bonding, in various ways, such as, for example, applied ultrasonic energy, laser energy, pressure, heat, adhesives, folding, and cutting. It should be understood that the morphological features may also include size differences between the separate elastic portions 200, such as, for example, different machine direction MD lengths. As shown in FIG. 4, the apparatus 300 may include a converting device 600a upstream of the nip 310 that may be adapted to impart a morphological feature to the elastic substrate 200a. In some configurations, the converting device may be downstream of the nip 310 that may be adapted to impart a morphological feature to the elastic portion 200. The converting device 600b may be positioned upstream of the nip 344 that may be adapted to impart a morphological feature to the carrier substrate 202. The converting device 600c may be positioned downstream of the nip 344 that may be adapted to impart a morphological feature to the laminate 204. With continued reference to FIG. 4, the bonding device 324 may also be configured as a converting device 600d that may be adapted to impart a morphological feature to the elastic portion 200 and / or the carrier substrate 202 during bonding at the nip 344.

[0117] In another example, referring to FIG. 17A, the apparatus 500 may include one or more transforming devices 600 that may be adapted to modify the first substrate 402, the second substrate 410, the elastic film 408, and / or the assembled elastic substrate 200a. The transforming devices 600 are generally depicted as dashed rectangles in FIG. 17A. As mentioned above, it should be understood that the transforming devices 600 may be adapted to form various types of morphological features, such as embossing, apertures, slits, melted material, compressed material, plastic deformation, folding, adhesive bonding, and / or pressure bonding, in various ways, such as, for example, by applying ultrasonic energy, laser energy, pressure, heat, adhesive, folding, and cutting. As shown in FIG. 17A, the apparatus 500 may include a transforming device 600f upstream of the spreader mechanism 512 that may be adapted to impart a morphological feature to the elastic film 408. In some configurations, the converting device may be downstream of the spreader mechanism 512, which may be adapted to impart a morphological feature to the stretched elastic film 408. With continued reference to FIGURE 17A, the anvil 502 and / or horn 530 may also be configured as a converting device 600f, which may be adapted to impart a morphological feature to the elastic film 408, the first substrate 406, and / or the second substrate 410 during the bonding operation. A converting device 600g may be positioned downstream of the horn 530, which may be adapted to impart a morphological feature to the elastic laminate 200a.

[0118] It should also be appreciated that the processes and / or apparatus herein may be configured with additional features, such as a splicing operation, to help avoid the need to stop assembly process operations to replenish material supplies. In some configurations, the apparatus 300 discussed herein may be configured to operate with an apparatus configured to provide an uninterrupted supply of continuous elastic substrate 200a. For example, during operation, a replacement supply of continuous elastic substrate 200a may be spliced ​​into a current supply of continuous elastic substrate 200a used in an assembly operation before the current supply is completely depleted.

[0119] It should be understood that various types of splicing operations may be used to replenish the supply of continuous elastic substrate 200a. For example, some splicing operations may be configured to apply a strip of splicing tape to connect a replacement continuous elastic substrate 200a to a nearly exhausted elastic substrate 200a to avoid interruptions in the supply. As described above, the continuous elastic substrate 200a may advance through a cutting device 304 that separates the continuous elastic substrate 200a into separate elastic portions 200. In addition, the transport device 322 and / or the joining device 324 may further subject the separate elastic portions 200 to a transverse stretching and / or joining operation. However, some splicing tape materials may not be stretchable and / or may not contribute to the joining operation. The separate elastic portions 200 connected to the splicing tape may then undesirably disrupt the operation of the stretching and / or joining process. Accordingly, some apparatus 300 may be configured to remove the separate elastic portions 200 with the splicing tape attached from the assembly operation before such undesirable process disruptions can occur. In some examples, the splicing operation may be configured to utilize an extensible splicing tape and / or other material that is more conducive to the various assembly operations to prevent unintended assembly process disruptions and / or to eliminate the need to apply the splicing tape and remove the elastic portions 200.

[0120] Some splicing operations may be configured to weld or otherwise join a replacement supply of continuous elastic substrate 200a to a current supply of continuous elastic substrate 200a used in an assembly operation without the need to use a splicing tape. Such welding operations may utilize a hot wire or ultrasonic device to create a thermal splice. The thermal splice process may cut and weld materials together. In some configurations, a thermal splice may be applied to maintain some stretch properties, which may allow separate elastic portions 200 with such a thermal splice to advance through a transverse stretching operation and / or joining operation without disrupting such operation.

[0121] As mentioned above, it should be understood that the continuous elastic substrate 200a and the separate elastic portions 200 herein may be configured in various ways and may include one or more elastic materials, such as elastic films and / or strands. In some configurations, the continuous elastic substrate 200a and the separate elastic portions 200 may comprise a single layer of elastic film. In some configurations, the continuous elastic substrate 200a and the separate elastic portions 200 may comprise a laminate of two more substrates, such as an elastic film joined with one or more nonwoven substrates. When the continuous elastic substrate 200a is configured to include an elastic film joined with one or more consolidated nonwovens, the thermal splice may be configured to melt both the film and nonwoven layers to create a weld that traps the consolidation of the nonwoven material. A transverse stretching process may then stretch the elastic portions 200 so that the weld may extend in the transverse direction as well, by partially breaking the portion of the weld that trapped the consolidated nonwoven, sometimes referred to as "popping the weld." Depending on various splicing process parameters, such as, for example, weld time, dwell time, and quench time, and various material properties, such as, for example, basis weight, fiber type, and plastic properties, the transverse force required to pop and stretch the weld may vary. In some examples, an ultrasonic splicing device including a relatively sharp cutting anvil may be configured to produce a weld with a relatively low transverse force required for popping and stretching. In particular, a relatively small overall weld may be produced when the sharp angle of the anvil can rupture through the fibers in the material without causing a relatively large melt zone, while at the same time allowing the films to be welded together, resulting in a splice that may require reduced popping and / or be relatively easier to stretch in the transverse direction CD without the need for popping.

[0122] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0123] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest or disclose such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document 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 document shall govern.

[0124] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. Absorbent articles, A first lumbar region (116), a second lumbar region (118), and a groin region (119) disposed between the first lumbar region (116) and the second lumbar region (118), A first lumbar edge (120), a second lumbar edge (122), a first longitudinal side edge (128), a second longitudinal edge (130), A chassis (102) including a top sheet (138), a back sheet (136), and an absorbent core (140) positioned between the top sheet (138) and the back sheet (136), A leg gasket element (156) extending from the first lumbar region (116) to the second lumbar region (118), A first waist panel (158a) comprising an inner lateral edge (172), an outer lateral edge (170), and two longitudinal edges (180, 182), wherein the first waist panel (158a) includes a first elastic film bonded to a first nonwoven fabric in a stretched state, and the first waist panel (158a) is connected to the chassis (102) and positioned within the first waist region (116), A second waist panel (158b) comprising an inner lateral edge (172), an outer lateral edge (170), and two longitudinal edges (180, 182), wherein the second waist panel (158b) includes a second elastic film bonded to a second nonwoven fabric in a stretched state, and the second waist panel (158b) is connected to the chassis (102) and positioned within the second waist region (118), The first waist panel is joined to the chassis by a first region of the first pressure joint, the first region of the first pressure joint extends longitudinally inward by a first distance D1 from the outer lateral edge of the first waist panel, The second waist panel is joined to the chassis by a second region of the second pressure joint, the second region of the second pressure joint extends longitudinally inward by a second distance D2 from the outer lateral edge of the second waist panel, and D1 is greater than D2. The first pressure joint and the second pressure joint provide different stretch characteristics between the first waist panel (158a) and the second waist panel (158b) in an absorbent article.

2. The area of ​​the first waist panel (158a) adjacent to the outer lateral edge (170) and the longitudinal edges (180, 182) is joined to the chassis (102), and at least a portion of the inner lateral edge (172) of the first waist panel (158a) is not attached to the chassis (102). The absorbent article according to claim 1, wherein the region of the second waist panel (158b) adjacent to the outer lateral edge (170) and the longitudinal edges (180, 182) is joined to the chassis (102), and at least a portion of the inner lateral edge (172) of the second waist panel (158b) is not attached to the chassis (102).

3. The absorbent article according to claim 1 or 2, wherein the region of the second waist panel (158b) adjacent to the outer lateral edge (170) is adhesively bonded to the chassis (102), and the region of the second waist panel (158b) adjacent to the longitudinal edges (180, 182) is pressure-bonded to the leg gasket element (156).

4. The absorbent article according to claim 3, wherein the leg gasket element (156) comprises an inner cuff and an outer cuff.

5. The absorbent article according to claim 4, wherein the region adjacent to the longitudinal edge portions (180, 182) of the second waist panel (158b) is pressure-bonded to the inner cuff of the leg gasket element (156).

6. The area of ​​the second waist panel (158b) that is not attached to the chassis (102) is approximately 400 mm ２ ~Approx. 10000mm ２ An absorbent article according to any one of claims 1 to 5, having the area of ​​the above.

7. The absorbent article according to any one of claims 1 to 6, wherein the first lumbar region (116) includes an anterior lumbar region, and the second lumbar region (118) includes a posterior lumbar region.

8. The absorbent article according to any one of claims 1 to 7, wherein the outer lateral edge (170) of the second lumbar panel (158b) is in contact with the second lumbar edge (122), and the outer lateral edge (170) of the first lumbar panel (158a) is in contact with the first lumbar edge (120).

9. The absorbent article according to any one of claims 1 to 5, wherein the outer lateral edge of the second waist panel is positioned longitudinally inward of the second waist edge (122).

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