Method of applying adhesive to an edge of moving web

The invention relates to methods of applying adhesive to a lateral edge of a first web. The method includes transporting the first web along a first path and transporting a second web along a second path generally in surface-to-surface relationship with the first web at the lateral edge, with the second web extending outwardly from the first web. When adhesive is applied such as by spraying to the first web at the lateral edge, at least some adhesive passes outwardly of the lateral edge as overspray and is received by the second web. Thus, adhesive applied to the edge of the first web is received in combination by both of the first and second webs. Both of the first and second webs can be utilized in manufacturing articles. In some embodiments, adhesive is applied at both first and second lateral edges of the first web. In some embodiments, spaced leg cutouts are formed in lateral edges of the web. In this context, second and optionally third webs can receive adhesive overspray directed toward the first web including at locations of the leg cut-outs. The second web can have a width greater than the first web and can thus extend outwardly beyond at least both leg cut-outs of the first web, and preferably beyond the entire lengths of the lateral edges of the first web.

FIELD OF THE INVENTION 
This invention relates to a method of applying adhesive to the edge of a 
moving first web of material. A second web of material underlies the first 
web and receives excess adhesive placed beyond the edge of the first web. 
The method allows placement of adhesive to the edge of the first web 
without forming angel hairs or having the adhesive otherwise string out. 
The method prevents contamination of equipment. 
BACKGROUND OF THE INVENTION 
One method of applying adhesive to the edge of a moving web is to simply 
spray adhesive onto the edge of the web. Any adhesive not received and 
retained by the web, namely the overspray, can contaminate equipment. 
Further, adhesive disposed at the distal edge of the web can string out 
and form angel hairs. Where the so-treated web is used in manufacturing an 
absorbent article such as a diaper, the angel hairs can have an 
uncomfortable tackiness for the body of the wearer of such an absorbent 
article. The strung out adhesive can also cause problems elsewhere in the 
manufacturing process. 
Another method of applying adhesive simply sprays adhesive onto a moving 
web close to, but without quite reaching a lateral edge of the web. This 
method generally avoids adhesive going beyond the lateral edge, but also 
prevents applying adhesive at the distal edge, such that bonding of the 
distal edge of the web to another web or workpiece is frustrated. 
Other methods of applying adhesive require complex registration systems. 
These registration systems can use printed, intermittent or oscillating, 
or other applicators to apply adhesive to a web. 
Prior methods of applying chemicals to a web of material include utilizing 
a stencil between a chemical applicator and the web. In this manner, a 
defined surface area of the web of interest is covered by the chemicals. 
U.S. Pat. No. 5,415,717 to Pemeborn shows an example of a stencil belt 
controlling the placement of particles onto an underlying web. There is no 
disclosure of applying adhesives or applying the particles at the lateral 
edge of the underlying web. 
U.S. Pat. Nos. 5,094,886 and 4,968,534 to Bogardy disclose methods and 
apparatus for impregnating the surface of a web with a liquid in the form 
of a pattern. Stencil pattern belt 211 is located between the web and the 
liquid applicator. This device would not work with hot melt adhesives 
because the adhesives would build up on the stencil belt and make the 
device inoperative over a short period of time. Further, there is no 
disclosure of applying adhesives at the lateral edge of the underlying 
web. 
U.S. Pat. No. 5,501,149 to Schleinz et al disclose a dual substrate 
printing system. A printed substrate is located between an ink printing 
station and a backing substrate. The backing substrate receives ink that 
strikes through the printed substrate. Thus two ink patterns are formed. 
Column 4, lines 31-42 disclose registration of ink patterns. Registration 
is not needed or desired for the invention described herein. Further, 
there is no disclosure of applying adhesives in Schleinz et al, including 
not at the lateral edges of the printed substrate. 
None of the art discloses having a second web in surface-to-surface 
relationship with a first web and extending outwardly from a lateral edge 
of the first web, and then applying adhesive at the lateral edge of the 
first web, some adhesive being received on the second web outwardly of the 
lateral edge of the first web. 
SUMMARY OF THE DISCLOSURE 
The invention comprises methods of applying adhesive to an edge of a web of 
material. One method comprises the steps of transporting, along a first 
path, a first web of material having a lateral edge extending along the 
first path, transporting a second web of material along a second path, the 
second web facing the first web in surface-to-surface relationship with 
the first web at the lateral edge, and extending outwardly beyond the 
lateral edge. The method further includes applying adhesive to the first 
web at the lateral edge, at least some adhesive passing outwardly of the 
lateral edge, adhesive passing outwardly of the lateral edge, and thus 
outwardly of the first web, being received on the second web adjacent the 
lateral edge of the first web. The first and second webs are separated 
after adhesive is applied to the first web. 
The method can include having a third web facing the first web in 
surface-to-surface relationship with the first web at the second lateral 
edge, and extending outwardly beyond the second lateral edge of the first 
web. The method can include the steps of transporting the third web along 
a third path, and separating the third web from the first web. The first, 
second and third webs can comprise respective substrates. 
In some methods, the step of applying adhesive to the first web includes 
applying adhesive to the first web at the second lateral edge, at least an 
outer portion of the adhesive passing outwardly of the second lateral 
edge, and thus outwardly of the first web, the outer portion of the 
adhesive being received on a third web adjacent the second lateral edge. 
In some embodiments, the adhesive comprises a composition which at least 
partially solidifies after the adhesive is applied to the first web, the 
separating of the second web from the first web occurring before 
significant solidification of the adhesive. To that end, the separating 
step may occur less than about 3 seconds after adhesive is applied to a 
respective portion of the first web. The separation of the second web from 
the first web thus forms a clean distal edge at the lateral edge of the 
first web. 
In preferred methods, a hot melt adhesive is sprayed onto the webs. Prompt 
separation of the second web from the first web effectively avoids 
formation of angel hairs extending from the lateral edge of the first web. 
Other methods of the invention are similar, except for periodic spaced 
cut-outs at a lateral edge of a first web. Adhesive is then applied to the 
first web at the lateral edge, including at spaced locations corresponding 
to the spaced cut-outs. 
In some methods, such as those having no third web, the first and second 
webs have respective first and second widths, the second width being 
greater than the first width. Thus, the second web can concurrently extend 
outwardly beyond both respective lateral edges of the first web, at least 
at the spaced cut-outs. 
In some methods, the lateral edge comprises a first lateral edge, the 
spaced cut-outs comprise first spaced cut-outs, the first web has a second 
opposing lateral edge, and the second lateral edge has second spaced 
cut-outs. A third web faces the first web in surface-to-surface 
relationship with the first web at the second lateral edge, and extends 
outwardly from the second lateral edge at least at the second spaced 
cut-outs. The third web receives adhesive passing outwardly of the second 
lateral edge. 
In some methods, the first and second webs are transported and adhesive 
applied without ongoing longitudinal registration of the second web with 
respect to the first web. 
In another embodiment of the invention, the method includes the steps of 
transporting a first web of material along a first path, periodically 
cutting leg cut-outs at spaced locations along opposing first and second 
lateral edges of the first web, transporting a second web of material 
along a second path, the second web facing the first web in 
surface-to-surface relationship with the first web at least at one of the 
first and second lateral edges, applying adhesive to the first web, at 
least some of the adhesive passing outwardly of at least one of the first 
and second lateral edges, adhesive passing outwardly of a lateral edge of 
the first web being received on the second web adjacent the respective one 
of the first and second lateral edges, separating the first and second 
webs, and securing the first web to a product forming web to form the 
product substrate. 
The manufacture of an article utilizing elements from the first web having 
adhesive thereon, and elements from the second web having adhesive thereon 
is a further part of the invention. For instance, the first web can be 
utilized to manufacture a product substrate. The product substrate, in 
combination with elements from the second web having adhesive thereon, can 
be used to manufacture an article.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
The present invention is directed toward methods for applying adhesive to a 
lateral edge of a first web of material. A second web of material is 
placed adjacent and in surface-to-surface relationship with the first web 
of material at the lateral edge. An adhesive applicator then applies 
adhesive to the lateral edge of the first web. The second web receives and 
retains adhesive which passes outwardly of the lateral edge of the first 
web. The second web is then turned away from the first web so that the 
clean distal edge of the first web retains adhesive without development of 
angel hairs at the distal edge. 
FIG. 1 shows an assembly for applying adhesive to a first web 10 of 
material, comprising a first substrate, and supplied from supply roll 12. 
First web 10 has first lateral edge 14 and second opposing lateral edge 16 
extending along the length of web 10. First web 10 moves along a first 
path in the direction shown by arrow 18. 
Second web 20 of material comprising a second substrate from second supply 
roll 22 turns about first and second turning rolls 24, 26, and travels in 
a substantially straight second path between turning rolls 24, 26 in 
substantially the same direction as first web 10. Between first and second 
turning rolls 24, 26, second web 20 faces first web 10 in 
surface-to-surface relationship with the first web, and extends outwardly 
beyond first lateral edge 14 as shown in FIG. 1. From turning roll 26, 
second web 20 moves downwardly in the direction of arrow 28 after turning 
about second turning roll 26. 
A third web 30 of material comprising a third substrate from third supply 
roll 32 is disposed at substantially the same angles and positions as 
second web 20, as applied at second lateral edge 16 of first web 10. Thus 
third web 30 turns about third and fourth turning rolls 34, 36 and travels 
in a substantially straight third path between turning rolls 34, 36. 
Between third and fourth turning rolls 34, 36, third web 30 faces first 
web 10 in surface-to-surface relationship with the first web, and extends 
outwardly beyond second lateral edge 16. From such face-to-face 
relationship, turning roll 36 guides third web 30 downwardly in the 
direction of arrow 38. Adhesive 40 is applied by adhesive applicators 42, 
44, for example, in a swirling pattern as shown in FIG. 1. Since the 
purpose of the operation illustrated in FIG. 1 is to apply adhesive at and 
adjacent lateral edges 14, 16 of web 10, some, and preferably most, of 
adhesive 40 is received at and adjacent lateral edges 14, 16, and remains 
at such locations on first web 10, while an outer portion of the adhesive 
comprising overspray from applicators 42, 44 passes outwardly of lateral 
edges 14, 16 and is received and retained on webs 20, 30. 
Web 10 of material may be a web which can be used to make outer covers for 
absorbent articles for receiving human exudates, such as diapers. Thus web 
10 is typically substantially impermeable to liquids. Such web 10 can be 
formed from a single layer, or from multiple components, layers, or 
partial layers, of material. 
Web 10 may be manufactured from a wide selection of web materials, such as 
polyolefin films, porous foams, reticulated foams, apertured plastic 
films, or one or more layers made with natural fibers. A typical web 10 
may be manufactured from a thin plastic film or other flexible 
liquid-impermeable material. For example, first web 10 can be formed from 
a polyethylene film having a thickness of from about 0.012 millimeters to 
about 0.051 millimeters. 
When it is desirable that first web 10 have a more clothlike feeling, the 
web may comprise a polyethylene film laminated to a nonwoven web, such as 
a spunbonded web of polyolefin fibers. For example, a polyethylene film 
having a thickness of about 0.015 millimeters may have thermally or 
otherwise laminated thereto a spunbonded web of polyolefin fibers having a 
thickness from 1.5 to 2.5 denier per filament, which nonwoven web has a 
basis weight of about 24 grams per square meter. 
Various woven and nonwoven fabrics can be used for web 10. For example, web 
10 may be composed of a meltblown or spunbonded web of polyolefin fibers. 
Web 10 may also comprise a carded and/or bonded web composed of natural 
and/or synthetic fibers. Further, web 10 can be formed of a woven or 
nonwoven fibrous web which has been constructed or treated, in whole or in 
part, to impart a desired level of liquid impermeability to selected 
regions of the web. 
Web 10 may be composed of a substantially hydrophobic material wherein the 
hydrophobic material is treated with a surfactant or otherwise processed 
to impart a desired level of wettability and hydrophilicity. Still 
further, first web 10 may optionally be composed of a micro-porous 
material which permits vapors to escape through the web while preventing 
human liquid exudates from passing through the web. 
Web 10 can also comprise a bodyside liner for the above described absorbent 
article. For example, first web 10 may comprise wood or cotton fibers. 
Other possible materials are synthetic fibers, such as polyester or 
polypropylene fibers, or a combination of natural and synthetic fibers. 
Web 10 may be formed from a single layer, or may comprise a multiplicity of 
components, layers, or partial layers, which correspond to any of the 
materials disclosed herein, as well as others known in the art. 
In a particular embodiment of the present invention, web 10 may comprise a 
spunbonded polypropylene fabric composed of about 2.8-3.2 denier fibers 
formed into a web having a basis weight of about 22 grams per square meter 
and a density of about 0.06 grams per cubic centimeter. A preferred fabric 
is treated with about 0.3 weight percent of a surfactant. 
Second web 20 can comprise any of the materials described above as 
potentially comprising first web. Furthermore, second web 20 can comprise, 
for example, a laminate including first and second outer nonwoven facing 
layers on opposing sides of an elastomeric core layer, the elastomeric 
core layer comprising a thermoplastic elastomeric composition such as a 
styrene ethylene butylene styrene terpolymer. 
Second web 20 can also comprise a plurality of elastomeric elements 
comprising strands, ribbons or the like secured in a stretched condition 
to a nonelastomeric substrate, the elastomeric elements extending along 
the length of the nonelastomeric substrate. 
Examples of other materials of which second web 20 may be comprised 
include, without limitation, spandex, nonwoven laminated webs, extruded 
elastomeric webs or meltblown webs, cross-machine direction stretchable 
web materials made with stretchable nonwovens, stretchable foam webs, and 
the like. 
Turning rolls 24 and 26, in combination, guide second web 20 in 
surface-to-surface relationship with first web 10 between the respective 
turning rolls. Surface-to-surface relationship is defined as being in 
close proximity to, and preferably in physical contact with, a portion of 
the surface of another web. A portion of the width of second web 20 
extends outwardly from first lateral edge 14 of first web 10 as shown in 
FIGS. 1 and 2. First and second webs 10, 20 are in substantially the same 
plane, except first web 10 is positioned above second web 20, and between 
web 20 and adhesive applicator 42. 
Turning rolls 34 and 36, in combination, guide third web 30 in 
surface-to-surface relationship with first web 10 between the respective 
turning rolls. A portion of the width of third web 30 extends outwardly 
from second lateral edge 16 of first web 10 as shown in FIGS. 1 and 2. 
First and third webs 10, 30 are in substantially the same plane, except 
first web 10 is positioned above third web 30 and between web 30 and 
adhesive applicator 44. Spacing between webs 10 and 20, and between webs 
10 and 30, is acceptable so long as the spacing is limited such that the 
adhesive overspray from applicators 42, 44 is effectively received and 
retained by webs 20 and 30. 
Turning rolls 24, 26, 34, 36 can comprise standard anvil rolls, idler rolls 
or other rolls well known in the art. The speed of first, second, and 
third webs 10, 20, 30 can be controlled elsewhere by driven rolls, by 
winders, or by other driven or driving devices. While second and third 
webs 20, 30 underlying first web 10 can be driven at speeds 20% greater 
than the speed of the first web, the first, second, and third webs 
preferably are driven at substantially the same speeds along the 
respective first, second and third paths in substantially the same 
direction between the respective turning rolls. 
Adhesive applicator 42 applies an exemplary swirling pattern of adhesive 40 
toward first and second webs 10, 20. While only a single applicator 42 
having a single nozzle to form the swirling pattern is shown in FIG. 1, 
any number of applicators having any number of nozzles can be utilized to 
apply adhesive 40. For example, an adhesive applicator 42 with three 
nozzles can be utilized to provide the adhesive pattern shown in FIG. 4. 
Three adhesive applicators can also be used instead of one applicator with 
three nozzles. One example of an adhesive applicator is set forth in U.S. 
Pat. No. 4,949,668 to Heindel et al, the disclosure of which is hereby 
incorporated by reference in its entirety. Heindel et al disclose 
apparatus for applying hot melt adhesive to a web in making an absorbent 
article. 
Adhesive applicator 44 preferably sprays patterns of adhesive 40 toward 
first and third webs 10, 30. Adhesive applicator 44 can be the same as 
adhesive applicator 42 and as described in Heindel et al. A wide variety 
of other applicators, such as other spray applicators, printing or other 
patterned rolls or the like, and applying cold as well as hot adhesives 
are contemplated as being within the scope of the invention. 
Adhesive 40 can comprise a composition which at least partially solidifies 
after the adhesive is applied to the respective web. In that regard, 
adhesive 40 preferably comprises a hot melt adhesive. Suitable adhesives 
include, for example, 34-5522 or 34-5510 adhesive supplied by National 
Starch and Chemical Corp., or other hot-melt adhesives or adhesive 
compositions having similar properties. Furthermore, water soluble 
ethylene vinyl acetate adhesives, or other adhesives with appropriate 
characteristics can be utilized. 
While FIG. 1 shows a generally continuous, semi-cycloidal swirl pattern for 
adhesive 40, other patterns can be utilized. For instance, zig-zag 
patterns, straight line patterns, an overall pattern, and other continuous 
or discontinuous patterns can be used so long as requisite amounts of 
adhesive are applied in acceptable patterns. 
In operation, first web 10 is drawn from supply roll 12 by any of a wide 
variety of conventional driven devices (not shown) such as a driven roll. 
Similarly, second and third webs 20 and 30 are drawn from second and third 
supply rolls 22, 32 by any of a wide variety of conventional driven 
devices (not shown) such as driven rolls. 
Turning roll 24 turns second web 20 at a location adjacent and extending 
outwardly from first lateral edge 14 of first web 10. Turning rolls 24 and 
26, in combination, position second web 20 in surface-to-surface 
relationship with first web 10, and guide web 20 in substantially the same 
direction as first web 10 and along a second path closely adjacent the 
first path traversed by web 10. Turning roll 26 then turns second web 20 
downwardly in direction 28 for further usage in the manufacturing process. 
While second web 20 is between first and second turning rolls 24, 26, 
adhesive 40 is applied by adhesive applicator 42. Adhesive 40 is generally 
projected toward and received on web 10 at and adjacent lateral edge 14. 
With the spray pattern being specifically directed at the lateral edge, 
some of the adhesive passes outwardly of lateral edge 14, and is received 
on and adheres to second web 20. Thus, second web 20 receives the 
overspray that is inherent in projecting a spray pattern at lateral edge 
14. Second web 20 thus protects and shields web handling machinery 
underlying web 20 from adhesive 40. 
As illustrated in FIGS. 1-3, adhesive is applied to at least one of the 
webs 10, 20 and 30 over less than the entirety of the respective surface 
thereof. 
In terms of applying adhesive, if the overspray is being minimized, zones 
along the edge of second and third webs 20, 30, comprise the entire area 
where adhesive 40 overspray is received on webs 20, 30 from applicators 
42, 44. These overspray zones can have a width of about two centimeters, 
but preferably within about 1 centimeter. 
Intentional overspray of adhesive 40 is contemplated, when necessary, to 
secure second and/or third web 20, 30 elsewhere in the process. 
Furthermore, other nozzles (not shown) can be utilized to completely cover 
first web 10 with adhesive 40 for securement to another web, substrate or 
the like. 
While FIGS. 1 and 2 show second web 20 underlying a portion of first web 10 
and adhesive applicator 42 above first and second webs 10, 20, all of 
their positions can be reversed such that adhesive applicator 42 is below 
the webs pointing upwardly, and second web 20 is above first web 10. The 
relative three dimensional ordering of first and second webs 10, 20 and 
adhesive applicator 42 relative to each other is critical, but their three 
dimensional spatial arrangement with respect to a reference surface such 
as a horizontal surface is not critical since properly oriented adhesive 
applicators can direct a spray in any desired direction, at any angle 
without limitation. 
Referring again to FIGS. 1 and 2, after adhesive 40 is sprayed onto webs 
10, 20, second turning roll 26 turns second web 20 downwardly and away 
from first web 10. This turning operation separates second web 20 from 
first web 10. The turning operation or separating step occurs before 
significant solidification of the adhesive. Since the preferred adhesive 
is a hot melt adhesive, and since hot melt adhesives may cool rapidly upon 
application to web 10, the turning of web 20 away from web 10 as at roll 
26 generally occurs less than about 3 seconds after adhesive 40 is applied 
to the respective portion of first web 10, namely before the hot melt 
adhesive solidifies significantly. Since second web 20 separates from web 
10 before the hot melt adhesive solidifies, namely while the hot melt 
adhesive is quite liquidous, any adhesive bridging webs 10, 20 at lateral 
edge 14 separates into respective elements thereof on the respective webs 
while still in liquid form. Thus, the separation occurs cleanly, without 
creation of strings, or angel hairs, between the two webs as the webs 
separate. Such clean separation leaves distal edge 14 similarly clean and 
free from such angel hairs. 
Clean distal edge is defined as a lateral edge having no, or substantially 
no, angel hairs formed by the adhesive. If, on the other hand, the hot 
melt adhesive is allowed to cool and thus become more viscous before 
separation of web 20, angel hairs may be formed by the hot melt adhesive 
stringing outwardly along the lateral edge of a web as the webs are 
separated. These angel hairs generally are too viscous to break clean from 
the web. Angel hairs generally are very fine and can be up to about two 
feet in length. A final product, such as an absorbent article having angel 
hairs is aesthetically unattractive, and functionally less desirable 
because of the angel hairs. 
Turning roll 34 turns third web 30 at a location adjacent and extending 
outwardly from second lateral edge 16 of first web 10. Turning rolls 34 
and 36, in combination, position third web 30 in surface-to-surface 
relationship with first web 10, and guide web 30, in substantially the 
same direction as first web 10 and along a third path closely adjacent the 
first path traversed by web 10. Turning roll 36 then turns third web 30 
downwardly in direction 38 for further usage in the manufacturing process. 
Third web 30, turning rolls 34, 36 and second adhesive applicator 44 
operate in essentially the same way as second web 20, turning rolls 24, 
26, and adhesive applicator 42 to apply adhesive to second lateral edge 16 
of first web 10. 
An important operating feature of the invention is the lack of any need for 
longitudinal registration. Therefore, there is no need for any particular 
longitudinal positioning between first, second, and third webs 10, 20, 30. 
While FIGS. 1 and 2 show second and third webs 20, 30 at respective lateral 
edges of first web 10, the invention broadly contemplates applying 
adhesive 40 to only one lateral edge in some embodiments. In such 
instance, third web 30 and second adhesive applicator 44 are not required. 
The adhesive applied to first web 10 can be used to secure other webs or 
other elements to web 10 in a manufacturing process. An article can be 
formed utilizing elements e.g. severed from first web 10, the severed 
elements having adhesive 40 thereon. Such article can include elements 
from second web 20 having adhesive 40 thereon as well as third web 30 in 
some instances. One class of products desirably made with the 
adhesive-coated webs made with the methods of the invention is absorbent 
articles for receiving and retaining body exudates, for example diapers. 
While the method of applying adhesive to lateral edge 14 of first web 10 is 
generally disclosed for use in manufacturing absorbent articles, the 
method can be used to adhere pieces of apparel, sheets, and any other 
substrate materials to one another. 
The embodiment shown in FIGS. 1 and 2 can be modified so that a single 
second web 20 extends both beyond first lateral edge 14 and beyond second 
lateral edge 16. In this embodiment, second web 20 has a greater width 
than first web 10, thus obviating the need for web 30. This arrangement is 
similar to the embodiment of FIGS. 3 and 4 described in more detail 
hereinafter, except for the leg cut-outs. 
While FIG. 1 shows supply roll 12 feeding first web 10 toward adhesive 
applicators 42, 44 and second and third webs 20, 30 similarly being fed 
toward adhesive applicators 42, 44, other manufacturing steps can operate 
on any or all of such webs before the respective webs reach the adhesive 
applicators. For example, attachment ears or other elements can be secured 
to first web 10 before web 10 reaches second and third webs 20, 30. Thus, 
the invention is not limited in the order or amount of steps taking place 
in the manufacturing process, either before, during, or after application 
of adhesive 40. 
FIGS. 3 and 4 show a second embodiment of the invention. In this 
embodiment, first web 10 from supply roll 12 passes through die cutter 46 
before reaching turning roll 24. Die cutter 46 comprises an anvil roll 48 
and a knife roll 50. Die cutter 46 forms periodic, opposing spaced leg 
cut-outs 52, 54 in first web 10 as shown in FIG. 3. First web 10 having 
opposing leg cut-outs 52, 54 then advances along the first path to a locus 
adjacent turning rolls 24, 26. 
In this embodiment, turning rolls 24, 26 extend across the width of first 
web 10, and outwardly of lateral edges 14, 16 of web 10 at least at 
cut-outs 52, 54. Turning rolls 24 and 26, in combination, guide second web 
20 of material in surface-to-surface relationship with first web 10, as 
defined earlier. The relationship wherein web 20 receives and retains 
overspray of adhesive 40 at edges 14, 16 occurs between turning rolls 24, 
26. Turning roll 26 then turns second web 20 away from first web 10. In 
this embodiment, second web 20 has a greater width than first web 10 and 
extends outwardly therefrom at least at leg cut-outs 52, 54, and may 
extend outwardly of web 10 at the greatest widths of web 10 as shown in 
FIG. 3. 
As in the earlier embodiments, turning rolls 24, 26 can comprise standard 
anvil rolls, idler rolls, or other rolls well known in the art. Similarly, 
the speed of first and second webs 10, 20 can be controlled elsewhere by 
driven rolls, by winders, or by other driven or driving devices. First and 
second webs 10, 20 preferably are driven at substantially the same speeds 
along the respective first and second paths in substantially the same 
direction between the respective turning rolls. 
First web 10 and second web 20 can comprise the materials disclosed in the 
first embodiment. First web 10 preferably comprises outer cover material 
for an absorbent article such as a diaper, feminine napkin, training pants 
or the like. Second web 20 can comprise any of the materials disclosed 
earlier with respect to the first embodiment of the invention. 
Instead of having a single nozzle as shown in the embodiment of FIGS. 1 and 
2, adhesive applicator 42 can comprise an applicator having multiple 
nozzles or multiple applicators. A swirl pattern of adhesive 40 as shown 
in FIG. 3 or other adhesive patterns can be directed toward first and 
second webs 10, 20. 
Die cutter 46 is shown as a combination of anvil roll 48 and knife roll 50. 
A variety of known cutter devices are acceptable for cutting leg cut-outs 
52, 54. In all such cutter devices, the cutting loci effectively move 
inwardly and outwardly while first web 10 passes through the respective 
cut-out device to form the shaped leg cut-outs 52, 54. 
In operation, the embodiment of FIGS. 3 and 4 receives first web 10 at die 
cutter 46. Knife roll 50, in combination with anvil roll 48, cuts out leg 
cut-outs 52, 54 at spaced distances or intervals as shown in FIG. 3. 
Second web 20 leaves second supply roll 22 and advances to first turning 
roll 24. First turning roll 24 directs second web 20 toward second turning 
roll 26 facing the first web in surface-to-surface relationship with, and 
preferably in physical contact with, first web 10. Second web 20 extends 
outwardly of the first web at lateral edges 14, 16 at least at leg 
cut-outs 52, 54 and can extend outwardly beyond lateral edges 14, 16 at 
the widest portions of first web 10, such as between leg cut-outs 52 or 
between leg cut-outs 54, or both. 
Lateral edges 14, 16 of first web 10 have adhesive 40 applied by adhesive 
applicators 42, 44. In terms of applying adhesive 40, each lateral edge 
defines a zone along the edge including at cut-outs 52, 54 of web 10. This 
zone can comprise the entire area where adhesive 40 is applied in FIGS. 3 
and 4. This zone extends inwardly from the innermost edge 14 or 16 at leg 
cut-outs 52, 54 and can extend outwardly beyond lateral edges 14, 16 in 
areas away from leg cut-outs 52. 
Adhesive 40 can be applied continuously at one or more locations between 
first turning roll 24 and second turning roll 26. 
Some of adhesive 40 reaches second web 20 along leg cut-outs 52, 54. Much 
of the adhesive remains on first web 10 at the edge of leg cut-outs 52, 54 
as well as along the entireties of lateral edges 14, 16. However, adhesive 
40 could be applied intermittently only in the regions of leg cut-outs 52, 
54 if desired. Intermittent application of adhesive 40, however, would 
require registration of leg cut-outs 52, 54 with operation of adhesive 
applicators 42, 44. Therefore, intermittent operation is not preferred. 
After application of adhesive 40, turning roll 26 then directs second web 
20 downwardly away from first web 10. This step separates second web 20 
from first web 10 while the adhesive is still highly liquidous. Thus, the 
turning or separating step occurs before significant solidification of the 
adhesive. Thus, the turning step preferably occurs less than about 3 
seconds after adhesive 40 is applied to a respective portion of first web 
10. 
Due to the quick removal of second web 20, opposing leg cut-outs 52, 54 of 
first web 10 have clean distal edges with no angel hairs or adhesive 40 
extending outwardly from the edge of the respective leg cut-out, as 
described for the previous embodiment. In use, second web 20 receives the 
overspray adhesive 40 at lateral edges 14, 16, thus protecting and 
shielding underlying machinery from the adhesive. 
The adhesive on first web 10 can be used to secure the first web to a 
product forming web in a manufacturing process (not shown) to form a 
product substrate (not shown). A product forming web can, for example, 
comprise leg cuff material, an absorbent core, a bodyside liner or the 
like. 
The product forming web can also comprise a substrate that can be arranged 
to pass under, in surface-to-surface relationship with a first web 
comprising an outer cover such that overspray of adhesive sprayed at leg 
cut-outs, for instance, is received by the substrate. The substrate can 
then be used to form part of the chassis of an absorbent article. Thus, 
the substrate can be used to prevent contamination of absorbent article 
fabrication machinery and can then be used as a base structure for the 
chassis. The substrate can be directed as needed by turning rolls to 
travel to other areas of an apparatus. In such an apparatus, first web 10 
comprises an outer cover including attachment ears and second web 20 
comprises the substrate. 
Referring, now to the instant invention, other arrangements are also 
contemplated. For instance, first web 10 can comprise a bodyside liner, 
absorbent core, or the like. First web 10 can also be used as a substrate 
for other products such as apparel, blankets, or the like, or as a layer 
to be applied to substrates of such products. 
FIG. 5 is a further embodiment, combining the leg cut-outs shown in FIGS. 3 
and 4 with the two underlying webs 20, 30 shown in FIGS. 1 and 2. 
In operation, the assembly of FIG. 5 operates essentially the same way as 
the embodiment of FIGS. 3 and 4. The main difference is that third web 30 
replaces the function of second web 20 at second lateral edge 16 and leg 
cut-outs 54. 
Second web 20 and/or third web 30 can be combined or utilized as described 
earlier to create a substrate, absorbent article chassis or the like. 
While the above invention is used mainly to form absorbent articles or the 
like, other applications are contemplated. For instance, the invention can 
be utilized to form disposable garments, clothes, or other products. 
Therefore, the invention is not limited to absorbent articles or the 
health care field. 
Those skilled in the art will now see that certain modifications can be 
made to the invention herein disclosed with respect to the illustrated 
embodiments, without departing from the spirit of the instant invention. 
And while the invention has been described above with respect to the 
preferred embodiments, it will be understood that the invention is adapted 
to numerous rearrangements, modifications, and alterations, all such 
arrangements, modifications, and alterations are intended to be within the 
scope of the appended claims.