Apparatuses and methods for making absorbent articles

The present disclosure relates to methods and apparatuses for controlling the relative placement of advancing substrates and discrete components in diaper converting lines. The diapers may each include a chassis connected with front and back elastic belts. In controlling the relative placement of these elements during the assembly process, a controller may change the machine direction speed and/or position of certain elements and cross direction speed and/or position of other elements such as the advancing substrates and components in order to help achieve proper placement and orientation. During the assembly process, the registration features are detected, and a controller may change the machine direction speeds of the advancing elastic laminates and/or chassis and/or may change the cross directional and/or machine direction position of the advancing elastic laminates and/or chassis.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbent articles, and more particularly, to apparatuses and methods for controlling the registration of advancing substrates and discrete components in diaper converting lines.

BACKGROUND OF THE INVENTION

Along an assembly line, adding components to and/or otherwise modifying an advancing, continuous web of material may enable the assembly of various types of articles, such as for example, diapers and other absorbent articles. For example, in some processes, advancing webs of material are combined with other advancing webs of material. In other examples, individual components created from advancing webs of material are combined with advancing webs of material, which in turn, are then combined with other advancing webs of material. In some cases, individual components created from advancing web or webs are combined with other individual components created from other advancing web or webs. Webs of material and component parts used to manufacture diapers may include: backsheets, topsheets, leg cuffs, waist bands, absorbent core components, front and/or back belts or ears, fastening components, and various types of elastic webs and components such as leg elastics, barrier leg cuff elastics, stretch side panels, belts, and waist elastics. Once the desired component parts are assembled, the advancing web(s) and component parts are subjected to a final knife cut to separate the web(s) into discrete diapers or other absorbent articles.

Some diaper pant embodiments are configured with a chassis connected with front and back elastic belts, wherein laterally opposing end regions of the front and back belts are connected with each other at side seams. In some process configurations adapted to assemble such diaper pants, stretched elastic strands are glued between two continuous nonwoven webs to form a continuous elastic laminate. The continuous elastic laminate may be subsequently cut along the machine direction to form two separate continuous elastic laminates, which are adapted to form the front and back elastic belts. Next, discrete chassis may be bonded with the continuous elastic laminates; the chassis may be folded; and the elastic laminates may be bonded to each other and subjected to a final knife cut.

However, in some converting operations, the discrete chassis may be cut from an advancing continuous laminate; subsequently turned 90 degrees; and accelerated or decelerated before being combined with the advancing elastic laminates. Such manufacturing processes require control of the placement and combination of the chassis with the advancing elastic laminates in both machine and cross directions in order to control the relative positions of these components in a desired manner Consequently, it would be beneficial to provide methods and apparatuses that are configured to provide relatively precise registration processes and web handling systems to combine the chassis with the advancing elastic laminates in such a way to maximize the aesthetic appearances of assembled products.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for controlling the relative placement of advancing substrates and discrete components in diaper converting lines. The diapers may each include a chassis connected with front and back elastic belts. In controlling the relative placement of these elements during the assembly process, a controller may change the machine direction speed and/or position of certain elements and cross direction speed and/or position of other elements such as the advancing substrates and components in order to help achieve proper placement and orientation. During the assembly process, the registration features are detected, and a controller may change the machine direction speeds of the advancing elastic laminates and/or chassis and/or may change the cross directional and/or machine direction position of the advancing elastic laminates and/or chassis.

In one embodiment, a method for assembling disposable pant diapers, wherein each pant diaper includes a chassis having a first end region and an opposing second end region separated from each other by a central region, and having a longitudinal axis and a lateral axis, the chassis comprising: a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, includes the steps of: advancing a first continuous substrate in a first machine direction at a first speed, the first continuous substrate defining a width in a first cross direction, wherein the first continuous substrate includes first registration features arranged along the first machine direction; advancing a second continuous substrate in a second machine direction at a second speed, the second continuous substrate defining a width in a second cross direction, wherein the second continuous substrate includes second registration features arranged along the second machine direction; cutting the second continuous substrate into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the second machine direction; turning each chassis such that the lateral axis is parallel with the first machine direction; bonding the first end regions of each chassis with the first continuous substrate; detecting positions of first and second registration features relative to each other along the first machine direction and along the first cross direction; changing placement of first and second registration features relative to each other along the first machine direction for each chassis subsequently bonded to the first continuous substrate based on detections of first and second registration features relative to each other on chassis previously bonded to the first continuous substrate by at least one of: adjusting the first speed of the first continuous substrate and shifting the second continuous substrate in the second cross direction; and changing the placement of first and second registration features relative to each other along the first cross direction for each chassis subsequently bonded to the first continuous substrate based on detections of first and second registration features relative to each other on chassis previously bonded to the first continuous substrate by at least one of: shifting the first continuous substrate in the first cross direction and adjusting the second speed of the second continuous substrate in the second machine direction.

In another embodiment, a method for assembling disposable pant diapers, wherein each pant diaper comprising a chassis having a first end region and an opposing second end region separated from each other by a central region, and having a longitudinal axis and a lateral axis, the chassis comprising: a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, includes the steps of: advancing a first continuous elastic laminate in a first machine direction at a first speed, the first continuous elastic laminate defining a width in a first cross direction, wherein the first continuous elastic laminate includes first registration features arranged along the first machine direction; advancing a second continuous elastic laminate in a second machine direction at a second speed, the second continuous elastic laminate defining a width in a second cross direction, wherein the second continuous elastic laminate includes second registration features arranged along the second machine direction; cutting the second continuous elastic laminate into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the second machine direction; turning each chassis such that the lateral axis is parallel with the first machine direction; bonding the first end regions of each chassis with the first continuous elastic laminate; advancing a third continuous elastic laminate in the first machine direction, the third continuous elastic laminate defining a width in the first cross direction, wherein the third continuous elastic laminate includes third registration features arranged along the first machine direction; and bonding the second end regions of each chassis with the third continuous elastic laminate; changing positions of the first, second, and third registration features relative to each other along the first machine direction; and changing the positions of the first, second, and third registration features relative to each other along the first cross direction.

In yet another embodiment, a method for assembling disposable pant diapers, wherein each pant diaper includes a chassis having a first end region and an opposing second end region separated from each other by a central region, and having a longitudinal axis and a lateral axis, the chassis comprising: a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, includes the steps of: advancing a first continuous substrate in a first machine direction at a first speed, the first continuous substrate having an outer longitudinal edge and an inner longitudinal edge defining a width in a first cross direction, wherein the first continuous substrate includes first registration features arranged along the first machine direction; advancing a second continuous substrate in a second machine direction at a second speed, the second continuous substrate defining a width in a second cross direction, wherein the second continuous substrate includes second registration features arranged along the second machine direction; cutting the second continuous substrate into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the second machine direction; turning each chassis such that the lateral axis is parallel with the first machine direction; bonding the first end regions of each chassis with the first continuous substrate; advancing a third continuous substrate in the first machine direction, the third continuous substrate having an outer longitudinal edge and an inner longitudinal edge defining a width in the first cross direction; and bonding the second end regions of each chassis with the third continuous substrate; folding each chassis along the lateral axis to position the first continuous substrate into a facing relationship with the third continuous substrate and defining uncovered regions of the first continuous substrate intermittently spaced between the chassis along the first machine direction and having a width extending in the first cross direction defined by a distance extending between the inner longitudinal edge of the first continuous elastic laminate and the inner longitudinal edge of the third continuous elastic laminate; and removing at least portions of the first registration features by cutting discrete pieces of trim material from the uncovered regions of the first continuous substrate.

In still another embodiment, a method for assembling disposable pant diapers, wherein each pant diaper includes a chassis having a first end region and an opposing second end region separated from each other by a central region, and having a longitudinal axis and a lateral axis, the chassis comprising: a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, includes the steps of: advancing a first continuous substrate in a first machine direction at a first speed, the first continuous substrate defining a width in a first cross direction, wherein the first continuous substrate includes first registration features arranged along the first machine direction; advancing a second continuous substrate in a second machine direction at a second speed, the second continuous substrate defining a width in a second cross direction, wherein the second continuous substrate includes second registration features arranged along the second machine direction; cutting the second continuous substrate into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the second machine direction; turning each chassis such that the lateral axis is parallel with the first machine direction; detecting positions of first and second registration features relative to each other along the first machine direction and along the first cross direction; changing placement of first and second registration features relative to each other along the first machine direction for each chassis based on detections of first and second registration features relative to each other by at least one of: adjusting the first speed of the first continuous substrate and shifting the second continuous substrate in the second cross direction; changing placement of first and second registration features relative to each other along the first cross direction for each chassis based on detections of first and second registration features relative to each other by at least one of: shifting the first continuous substrate in the first cross direction and adjusting the second speed of the second continuous substrate in the second machine direction; and subsequently bonding the first end regions of each chassis with the first continuous substrate.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding the present disclosure:

“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. “Diaper” is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso. The term “disposable” is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than 10% greater than its initial length and will substantially recover back to about its initial length upon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

As used herein, the term “graphic” refers to images or designs that are constituted by a figure (e.g., a line(s)), a symbol or character, a color difference or transition of at least two colors, or the like. A graphic may include an aesthetic image or design that can provide certain benefit(s) when viewed. A graphic may be in the form of a photographic image. A graphic may also be in the form of a 1-dimensional (1-D) or 2-dimensional (2-D) bar code or a quick response (QR) bar code. A graphic design is determined by, for example, the color(s) used in the graphic (individual pure ink or spot colors as well as built process colors), the sizes of the entire graphic (or components of the graphic), the positions of the graphic (or components of the graphic), the movements of the graphic (or components of the graphic), the geometrical shapes of the graphic (or components of the graphics), the number of colors in the graphic, the variations of the color combinations in the graphic, the number of graphics printed, the disappearance of color(s) in the graphic, and the contents of text messages in the graphic.

“Longitudinal” means a direction running substantially perpendicular from a waist edge to a longitudinally opposing waist edge of an absorbent article when the article is in a flat out, uncontracted state, or from a waist edge to the bottom of the crotch, i.e. the fold line, in a bi-folded article. Directions within 45 degrees of the longitudinal direction are considered to be “longitudinal.” “Lateral” refers to a direction running from a longitudinally extending side edge to a laterally opposing longitudinally extending side edge of an article and generally at a right angle to the longitudinal direction. Directions within 45 degrees of the lateral direction are considered to be “lateral.”

“Radial” means a direction running from the center of a drum toward a drum outer circumferential surface.

The term “substrate” is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. 1/10 or less) in comparison to its length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers or fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may comprise two or more layers laminated together. As such, a web is a substrate.

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

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

The term “cross direction” (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closed diaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can be configured with a continuous or closed waist opening and at least one continuous, closed, leg opening prior to the article being applied to the wearer. A pant can be preformed by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be preformed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed).

The present disclosure relates to methods and apparatuses for assembling absorbent articles, and in particular, to methods and apparatuses for controlling the relative placement of advancing substrates and discrete components in diaper converting lines. The diapers may each include a chassis connected with front and back elastic belts. The chassis may include a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The chassis may also have a first end region and an opposing second end region separated from each other by a central region. During the assembly process, opposing end regions of the chassis are connected with the elastic belts in the form of first and second continuous elastic laminates. The chassis are then folded to place the elastic laminates into a facing relationship. Once the chassis are folded, the first and second continuous elastic laminates are cut in the cross direction to form discrete pant diapers. In controlling the relative placement of these elements during the assembly process, a controller may change the machine direction speed and/or position of certain elements and cross direction speed and/or position of other elements such as the advancing substrates and components in order to help achieve proper placement and orientation. The controller may affect such changes in speeds and positions based on the detection of registration features. In some configurations, the first and/or second elastic laminates and chassis may include registration features. During the assembly process, the registration features are detected, and a controller may change the machine direction speeds of the advancing elastic laminates and/or chassis and/or may change the cross directional and/or machine direction position of the advancing elastic laminates and/or chassis. It is to be appreciated that the speed changes discussed herein may be transient changes or steady step changes. With a transient change, an object or substrate advancing at a first speed may be temporarily accelerated or decelerated to a second speed, and then decelerated or accelerated back to the first speed. With steady step change, an object or substrate advancing at a first speed may be accelerated or decelerated to a second speed.

For example, as discussed below, a first continuous substrate, such as an elastic belt laminate, may advance in a first machine direction at a first speed, wherein the first continuous substrate defines a width in a first cross direction. The first continuous substrate includes first registration features arranged along the first machine direction. In addition, a second continuous substrate, such as a continuous length of chassis assemblies, may advance in a second machine direction at a second speed, wherein the second continuous substrate defines a width in a second cross direction. The second continuous substrate includes second registration features arranged along the second machine direction. The advancing second continuous substrate may then be cut into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the second machine direction. Each chassis may be turned such that the lateral axis is parallel with the first machine direction. While turning, the second speed of each chassis may also be altered to the first speed. Once turned, the first end regions of each chassis may be bonded with the first continuous substrate. Based on detections of the first and second registration features, a controller may then adjust the first speed of the first continuous substrate and/or the cross direction position of the first continuous substrate and a controller may adjust the speed of the second continuous substrate and/or shift the second continuous substrate in the second cross direction to change the relative positions of the first and second registration features along the first machine direction. In addition, a controller may alter the speed and/or shift the position of the discrete chassis relative to the first continuous substrate in the first cross direction and/or adjust the second speed of the second continuous substrate in the second machine direction to change the relative positions of the first and second registration features along the first cross direction, and thus, to bring the discrete chassis and the first continuous substrate into proper alignment.

Further to the above discussion, a third continuous substrate, such as an elastic belt laminate, may also advance in the first machine direction at a third speed, wherein the third continuous substrate defines a width in the first cross direction. And the second end regions of each chassis are bonded with the third continuous substrate. The third continuous substrate may also include third registration features arranged along the first machine direction. Thus, based on detections of the first, second, and third registration features, the controller may adjust the first speed of the first continuous substrate, the third speed of the third continuous substrate, and/or shift the second continuous substrate in the second cross direction to change the relative positions of the first, second, and third registration features along the first machine direction. In addition, the controller may shift the first and/or third continuous substrates in the first cross direction and/or adjust the second speed of the second continuous substrate in the second machine direction to change the relative positions of the first, second, and third registration features along the first cross direction. Further, each chassis may be folded along the lateral axis to position the first continuous substrate into a facing relationship with the third continuous substrate. And the first continuous substrate may be bonded with the third continuous substrate at discrete bond regions. The first and third continuous substrates may then be cut along the first cross direction to form discrete pant diapers.

It is to be appreciated that either first or third continuous substrates may be used to form either the front or back elastic belts. In some configurations, the first continuous substrate may include registration features, and the third continuous substrate may not include registration features. In addition, the first continuous substrate may be used to form the back elastic belt, and the third continuous substrate may be used to form the front elastic belt. And the registration features may be subsequently removed from the first continuous substrate. In some configurations, the registration features may be simultaneously removed from the first continuous substrate while the first and third continuous elastic laminates are cut along the first cross direction to form discrete pant diapers.

As discussed in more detail below, graphics or portions of graphics on various substrates may be relatively consistently positioned relative to the registration features. Thus, adjustments of the relative positions of the registration features during the assembly process may be used to combine the chassis with the advancing elastic laminates in such a way to maximize the aesthetic appearances of the graphics on assembled products. For example, the front and/or back elastic belts as well as the chassis may include graphics. And some graphics may be configured to appear as a design that appears to extend contiguously across combined diaper components, such as the front elastic belt, chassis, and/or back elastic belt. Thus, in some converting configurations, continuous nonwoven webs used to form the elastic laminates may include portions of such graphics. And some chassis components, such as a backsheet or topsheet, may include portions of such graphics. Therefore, during the assembly process, the chassis and elastic laminates may be assembled such that the graphic portions are combined to provide the appearance of contiguous designs that extend across more than one component, such as the elastic laminates and/or chassis.

As previously mentioned, the processes and apparatuses discussed herein may be used in the manufacture of different types of absorbent articles. To help provide additional context to the subsequent discussion of the process embodiments, the following provides a general description of absorbent articles in the form of diaper pants that include belt substrates that may be cut in accordance with the methods and apparatuses disclosed herein.

FIGS. 1A, 1B, 2A, and 2Bshow an example of a diaper pant100that may be assembled and folded in accordance with the apparatuses and methods disclosed herein. In particular,FIGS. 1A and 1Bshow perspective views of a diaper pant100in a pre-fastened configuration, andFIGS. 2A and 2Bshow plan views of the diaper pant100with the portion of the diaper that faces away from a wearer oriented toward the viewer. The diaper pant100includes a chassis102and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt106and a second elastic belt108are bonded together to form the ring-like elastic belt104. Although only the second elastic belt108is shown with a contoured or shaped edge, it is to be appreciated that either or both the first elastic belt106and second elastic belt108may include shaped edges made in accordance with the apparatuses and processes herein.

With continued reference toFIGS. 2A and 2B, the chassis102includes a first waist region116, a second waist region118, and a crotch region119disposed intermediate the first and second waist regions. The first waist region116may be configured as a front waist region, and the second waist region118may be configured as back waist region. In some embodiments, the length of each of the front waist region, back waist region, and crotch region may be ⅓ of the length of the absorbent article100. The diaper100may also include a laterally extending front waist edge121in the front waist region116and a longitudinally opposing and laterally extending back waist edge122in the back waist region118. To provide a frame of reference for the present discussion, the diaper100and chassis102ofFIGS. 2A and 2Bare shown with a longitudinal axis124and a lateral axis126. In some embodiments, the longitudinal axis124may extend through the front waist edge121and through the back waist edge122. And the lateral axis126may extend through a first longitudinal or right side edge128and through a midpoint of a second longitudinal or left side edge130of the chassis102.

As shown inFIGS. 1A, 1B, 2A, and 2B, the diaper pant100may include an inner, body facing surface132, and an outer, garment facing surface134. The chassis102may include a backsheet136and a topsheet138. The chassis102may also include an absorbent assembly140, including an absorbent core142, disposed between a portion of the topsheet138and the backsheet136. As discussed in more detail below, the diaper100may also include other features, such as leg elastics and/or leg cuffs to enhance the fit around the legs of the wearer.

As shown inFIGS. 2A and 2B, the periphery of the chassis102may be defined by the first longitudinal side edge128, a second longitudinal side edge130, a first laterally extending end edge144disposed in the first waist region116, and a second laterally extending end edge146disposed in the second waist region118. Both side edges128and130extend longitudinally between the first end edge144and the second end edge146. As shown inFIG. 2A, the laterally extending end edges144and146are located longitudinally inward from the laterally extending front waist edge121in the front waist region116and the laterally extending back waist edge122in the back waist region118. When the diaper pant100is worn on the lower torso of a wearer, the front waist edge121and the back waist edge122of the chassis102may encircle a portion of the waist of the wearer. At the same time, the chassis side edges128and130may encircle at least a portion of the legs of the wearer. And the crotch region119may be generally positioned between the legs of the wearer with the absorbent core142extending from the front waist region116through the crotch region119to the back waist region118.

It is to also be appreciated that a portion or the whole of the diaper100may also be made laterally extensible. The additional extensibility may help allow the diaper100to conform to the body of a wearer during movement by the wearer. The additional extensibility may also help, for example, the user of the diaper100, including a chassis102having a particular size before extension, to extend the front waist region116, the back waist region118, or both waist regions of the diaper100and/or chassis102to provide additional body coverage for wearers of differing size, i.e., to tailor the diaper to an individual wearer. Such extension of the waist region or regions may give the absorbent article a generally hourglass shape, so long as the crotch region is extended to a relatively lesser degree than the waist region or regions, and may impart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper pant100may include a backsheet136. The backsheet136may also define the outer surface134of the chassis102. The backsheet136may be impervious to fluids (e.g., menses, urine, and/or runny feces) and may be manufactured in part from a thin plastic film, although other flexible liquid impervious materials may also be used. The backsheet136may prevent the exudates absorbed and contained in the absorbent core from wetting articles which contact the diaper100, such as bedsheets, pajamas and undergarments. The backsheet136may also comprise a woven or nonwoven material, polymeric films such as thermoplastic films of polyethylene or polypropylene, and/or a multi-layer or composite materials comprising a film and a nonwoven material (e.g., having an inner film layer and an outer nonwoven layer). The backsheet may also comprise an elastomeric film. An example backsheet136may be a polyethylene film having a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplary polyethylene films are manufactured by Clopay Corporation of Cincinnati, Ohio, under the designation BR-120 and BR-121 and by Tredegar Film Products of Terre Haute, Ind., under the designation XP-39385. The backsheet136may also be embossed and/or matte-finished to provide a more clothlike appearance. Further, the backsheet136may permit vapors to escape from the absorbent core (i.e., the backsheet is breathable) while still preventing exudates from passing through the backsheet136. The size of the backsheet136may be dictated by the size of the absorbent core142and/or particular configuration or size of the diaper100.

Also described above, the diaper pant100may include a topsheet138. The topsheet138may also define all or part of the inner surface132of the chassis102. The topsheet138may be compliant, soft feeling, and non-irritating to the wearer's skin. It may be elastically stretchable in one or two directions. Further, the topsheet138may be liquid pervious, permitting liquids (e.g., menses, urine, and/or runny feces) to penetrate through its thickness. A topsheet138may be manufactured from a wide range of materials such as woven and nonwoven materials; apertured or hydroformed thermoplastic films; apertured nonwovens, porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Woven and nonwoven materials may comprise natural fibers such as wood or cotton fibers; synthetic fibers such as polyester, polypropylene, or polyethylene fibers; or combinations thereof. If the topsheet138includes fibers, the fibers may be spunbond, carded, wet-laid, meltblown, hydroentangled, or otherwise processed as is known in the art.

Topsheets138may be selected from high loft nonwoven topsheets, apertured film topsheets and apertured nonwoven topsheets. Apertured film topsheets may be pervious to bodily exudates, yet substantially non-absorbent, and have a reduced tendency to allow fluids to pass back through and rewet the wearer's skin. Exemplary apertured films may include those described in U.S. Pat. Nos. 5,628,097; 5,916,661; 6,545,197; and 6,107,539.

As mentioned above, the diaper pant100may also include an absorbent assembly140that is joined to the chassis102. As shown inFIG. 2A, the absorbent assembly140may have a laterally extending front edge148in the front waist region116and may have a longitudinally opposing and laterally extending back edge150in the back waist region118. The absorbent assembly may have a longitudinally extending right side edge152and may have a laterally opposing and longitudinally extending left side edge154, both absorbent assembly side edges152and154may extend longitudinally between the front edge148and the back edge150. The absorbent assembly140may additionally include one or more absorbent cores142or absorbent core layers. The absorbent core142may be at least partially disposed between the topsheet138and the backsheet136and may be formed in various sizes and shapes that are compatible with the diaper. Exemplary absorbent structures for use as the absorbent core of the present disclosure are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores that contain reduced amounts of cellulosic airfelt material. For instance, such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even 1% of cellulosic airfelt material. Such a core may comprises primarily absorbent gelling material in amounts of at least about 60%, 70%, 80%, 85%, 90%, 95%, or even about 100%, where the remainder of the core comprises a microfiber glue (if applicable). Such cores, microfiber glues, and absorbent gelling materials are described in U.S. Pat. Nos. 5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. Patent Publication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diaper100may also include elasticized leg cuffs156. It is to be appreciated that the leg cuffs156can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. The elasticized leg cuffs156may be configured in various ways to help reduce the leakage of body exudates in the leg regions. Example leg cuffs156may include those described in U.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115; 4,909,803; and U.S. Patent Publication No. 2009/0312730A1.

As mentioned above, diaper pants may be manufactured with a ring-like elastic belt104and provided to consumers in a configuration wherein the front waist region116and the back waist region118are connected to each other as packaged, prior to being applied to the wearer. As such, diaper pants may have a continuous perimeter waist opening110and continuous perimeter leg openings112such as shown inFIGS. 1A and 1B. The ring-like elastic belt may be formed by joining the first elastic belt to a second elastic belt with a permanent side seam or with an openable and reclosable fastening system disposed at or adjacent the laterally opposing sides of the belts.

As previously mentioned, the ring-like elastic belt104is defined by a first elastic belt106connected with a second elastic belt108. As shown inFIG. 2A, the first elastic belt106defines first and second opposing end regions106a,106band a central region106c,and the second elastic108belt defines first and second opposing end regions108a,108band a central region108c.The central region106cof the first elastic belt is connected with the first waist region116of the chassis102, and the central region108cof the second elastic belt108is connected with the second waist region116of the chassis102. As shown inFIGS. 1A and 1B, the first end region106aof the first elastic belt106is connected with the first end region108aof the second elastic belt108at first side seam178, and the second end region106bof the first elastic belt106is connected with the second end region108bof the second elastic belt108at second side seam180to define the ring-like elastic belt104as well as the waist opening110and leg openings112.

As shown inFIGS. 2A, 3A, and 3B, the first elastic belt106also defines an outer laterally extending edge107aand an inner laterally extending edge107b,and the second elastic belt108defines an outer laterally extending edge109aand an inner laterally extending edge109b.The outer laterally extending edges107a,109amay also define the front waist edge121and the laterally extending back waist edge122. The first elastic belt and the second elastic belt may also each include an outer, garment facing layer162and an inner, wearer facing layer164. It is to be appreciated that the first elastic belt106and the second elastic belt108may comprise the same materials and/or may have the same structure. In some embodiments, the first elastic belt106and the second elastic belt may comprise different materials and/or may have different structures. It should also be appreciated that the first elastic belt106and the second elastic belt108may be constructed from various materials. For example, the first and second belts may be manufactured from materials such as plastic films; apertured plastic films; woven or nonwoven webs of natural materials (e.g., wood or cotton fibers), synthetic fibers (e.g., polyolefins, polyamides, polyester, polyethylene, or polypropylene fibers) or a combination of natural and/or synthetic fibers; or coated woven or nonwoven webs. In some embodiments, the first and second elastic belts include a nonwoven web of synthetic fibers, and may include a stretchable nonwoven. In other embodiments, the first and second elastic belts include an inner hydrophobic, non-stretchable nonwoven material and an outer hydrophobic, non-stretchable nonwoven material.

The first and second elastic belts106,108may also each include belt elastic material interposed between the outer layer162and the inner layer164. The belt elastic material may include one or more elastic elements such as strands, ribbons, films, or panels extending along the lengths of the elastic belts. As shown inFIGS. 2A, 3A, and 3B, the belt elastic material may include a plurality of elastic strands168which may be referred to herein as outer, waist elastics170and inner, waist elastics172. Elastic strands168, such as the outer waist elastics170, may continuously extend laterally between the first and second opposing end regions106a,106bof the first elastic belt106and between the first and second opposing end regions108a,108bof the second elastic belt108. In some embodiments, some elastic strands168, such as the inner waist elastics172, may be configured with discontinuities in areas, such as for example, where the first and second elastic belts106,108overlap the absorbent assembly140. In some embodiments, the elastic strands168may be disposed at a constant interval in the longitudinal direction. In other embodiments, the elastic strands168may be disposed at different intervals in the longitudinal direction. The belt elastic material in a stretched condition may be interposed and joined between the uncontracted outer layer and the uncontracted inner layer. When the belt elastic material is relaxed, the belt elastic material returns to an unstretched condition and contracts the outer layer and the inner layer. The belt elastic material may provide a desired variation of contraction force in the area of the ring-like elastic belt. It is to be appreciated that the chassis102and elastic belts106,108may be configured in different ways other than as depicted inFIG. 2A. The belt elastic material may be joined to the outer and/or inner layers continuously or intermittently along the interface between the belt elastic material and the inner and/or outer belt layers.

In some configurations, the first elastic belt106and/or second elastic belt108may define curved contours. For example, as shown inFIG. 2A, the inner lateral edge109bof the second elastic belt108may include non-linear or curved portions109cin the first and second opposing end regions108a,108b.Such curved contours may help define desired shapes to leg opening112, such as for example, relatively rounded leg openings. Although the inner lateral edge107bof the first elastic belt is depicted as being a straight line, it is to be appreciated that the inner lateral edge107bmay also include curved portions in the first and second opposing end regions106a,106b.In addition to having curved contours, the elastic belts106,108may include elastic strands168,172that extend along non-linear or curved paths that may correspond with the curved contours of the inner lateral edges107b,109b.

As previously mentioned, the diaper pant may include one or more graphics. For example, as shown inFIGS. 1A, 1B, and 2B, the diaper pant100may include graphics, G, represented by a first printed stripe G1and/or a second printed stripe G2, each extending through the first waist region116, the crotch region119, and the second waist region118. As shown inFIG. 2B, the first stripe G1and the second stripe G2each include a first portion Gp1, a second portion Gp2, and a third portion Gp3. In particular, the first portion Gp1of each stripe G1, G2may be located on the second elastic belt108; the second portion Gp2of each stripe G1, G2may be located on the chassis102; and the third portion Gp3of each stripe G1, G2may be located on the first elastic belt106. As discussed in more detail below, aspects of the diaper converting process may be controlled such that the first elastic belt106, second elastic belt108, and chassis102are combined such that the first stripe G1and/or second stripe G2appear to be contiguous although each stripe includes multiple portions printed on different diaper components.

With reference toFIG. 2B, the first portion Gp1of the first printed stripe G1extends from a first end region200at the inner lateral edge109bof the second elastic belt108to a second end region202at the first end region108aof the second elastic belt108. The second portion Gp2of the first printed stripe G1extends longitudinally through the crotch region119along the chassis102from a first end region204to a second end region206. The third portion Gp3of the first printed stripe G1extends from a first end region208at the inner lateral edge107bof the first elastic belt106to a second end region210at the first end region106aof the first elastic belt106. With continued reference toFIG. 2B, the first portion Gp1of the second printed stripe G2extends from a first end region212at the inner lateral edge109bof the second elastic belt108to a second end region214at the second end region108bof the second elastic belt108. The second portion Gp2of the second printed stripe G2extends longitudinally through the crotch region119along the chassis102from a first end region216to a second end region218. The third portion Gp3of the second printed stripe G2extends from a first end region220at the inner lateral edge107bof the first elastic belt106to a second end region222at the second end region106bof the first elastic belt106.

It is to be appreciated that the second portion Gp2of the first printed stripe G1and/or second printed stripe G2may define various lengths on the chassis102. For example, the second portion Gp2of the first and/or second printed stripes G1, G2may extend along the entire length of the chassis102from the first laterally extending end edge144to the second laterally extending end edge146. And as such, opposing end portions of the second portion Gp2of the first and/or second printed stripes G1, G2may be covered by the first and second elastic belts106,108. In other examples, the second portion Gp2of the first and/or second printed stripes G1, G2may extend less than the entire length of the chassis102.

As previously mentioned, the apparatuses and methods according to the present disclosure may be utilized to assemble various components of pre-fastened, refastenable pant diapers100. For example,FIG. 4shows a schematic view of a converting apparatus300adapted to manufacture pant diapers100. The method of operation of the converting apparatus300may be described with reference to the various components of pant diapers100described above and shown inFIGS. 1A, 1B, 2A, and 2B. Although the following methods are provided in the context of the diaper100shown inFIGS. 1A, 1B, 2A, and 2B, it is to be appreciated that various embodiments of diaper pants can be manufactured according to the methods disclosed herein, such as for example, the absorbent articles disclosed in U.S. Pat. No. 7,569,039; U.S. Patent Publication Nos. 2005/0107764A1, 2012/0061016A1, and 2012/0061015A1, which are all hereby incorporated by reference herein.

As described in more detail below, the converting apparatus300shown inFIG. 4operates to advance first and second elastic belt laminates406,408along a first machine direction MD1. In addition, a continuous length of chassis assemblies302are advanced in a second machine direction MD2and cut into discrete chassis102such that the longitudinal axis of each chassis102is parallel with the second machine direction MD2. The discrete chassis102are then turned to advance the discrete chassis102along the first machine direction MD1such that the lateral axis of each chassis102is parallel with the first machine direction MD1. The discrete chassis102are also spaced apart from each other along the first machine direction MD1. Opposing waist regions116,118of the spaced apart chassis102are then connected with continuous lengths of advancing first and second elastic belt laminates406,408. The chassis102may then be folded along the lateral axis, or parallel to the lateral axis, to bring the first and second elastic belt laminates406,408into a facing relationship, and the first and second elastic belt laminates are bonded together with laterally opposing bonds336. As discussed in more detail below, the first and second elastic belt laminates may be bonded together with adjacent bonds336a,336bintermittently spaced along the first machine direction MD1. Each bond336a,336bmay be a discrete bond site extending contiguously in a first cross direction CD1across a width of the first and second elastic belt laminates and/or may include a plurality of relatively small, discrete bond sites arranged in the cross direction. The first and second continuous elastic laminates406,408are then cut in the first cross direction CD1between adjacent bonds336a,336bto create discrete pant diapers100, such as shown inFIGS. 1A and 1B. In some configurations, discrete pieces of trim material may also be removed from regions of the first and/or second elastic belt laminates406,408extending between adjacent folded chassis.

As shown inFIG. 4, a first continuous substrate layer in the form of a continuous length of outer layer belt material162; a second continuous substrate layer in the form of a continuous length of inner layer belt material164; and elastics168are combined to form a continuous elastic laminate in the form of a belt material402. More particularly, continuous lengths of outer layer belt material162, inner layer belt material164, outer elastic strands170and inner elastic strands172are advanced in a first machine direction MD1and combined at nip rolls502to form a continuous length of belt material402. Before entering the nip rolls502, the outer elastic strands170and inner elastic strands172are stretched in the first machine direction MD1. In addition, adhesive504may applied to the elastic strands170,172as well as either or both of the continuous lengths of outer layer belt material162and inner layer belt material164before entering nip rolls502. Further, adhesive504may be applied intermittently along the lengths of the inner elastic strands172and/or intermittently along the length of either or both of the continuous lengths of outer layer belt material162and inner layer belt material164before entering nip rolls502. As such, the inner elastic strands172may be intermittently bonded to either or both of the continuous lengths of outer layer belt material162and inner layer belt material164along the first machine direction MD1. Thus, the belt material402may include non-bonded regions intermittently spaced between bonded regions along the first machine direction MD1, wherein the inner elastic strands172are not bonded to either the outer layer belt material162or inner layer belt material164in the non-bonded regions. And the inner elastic strands172are bonded to the outer layer belt material162and/or inner layer belt material164in the bonded regions. AlthoughFIG. 4shows an embodiment wherein the belt material402is formed by combining continuous lengths of outer layer belt material162and inner layer belt material164with elastic strands168, it is to be appreciated the belt material402can be formed in various ways, such as disclosed in U.S. Pat. No. 8,440,043 and U.S. Patent Publication Nos. US2013/0255861A1; US2013/0255862A1; US2013/0255863A1; US2013/0255864A1; and US2013/0255865A1.

Referring back toFIG. 4, from the nip rolls502the continuous length of belt material402advances in the first machine direction MD1to a cutter506that cuts the belt material402into two continuous belt substrates, referred to as a first belt substrate406and a second belt substrate408. The cutter506may be configured in various ways. For example, in some embodiments the cutter506may be a slitter or a die cutter that separates the belt material into two continuous belt substrates with either a straight line cut and/or a curved line cut. The cutter506may also be configured as a perforator that perforates the belt material with a line of weakness and wherein the belt material is separated along the line of weakness in a later step. From the cutter506, the first and second belt substrates406,408advance through a diverter508that separates the first and second belt substrates from each other in the first cross direction CD1, such as shown inFIG. 5C. The elastic strands170,172, and thus, the continuous length of first and second belt substrates406,408are maintained in a stretched condition while advancing along the first machine direction MD1. It is to be appreciated that the diverter508may be configured in various ways. For example, in some embodiments, the diverter508may include turn bars angled at 45 degrees or some other angle with respect to the machine direction. In some embodiments, the diverter may include cambered rollers. It is to be appreciated that the front and back belts may be formed by separate continuous lengths of belt material similar to the description above and as such would not required the slitting step or the diverting step.

In some embodiments, the diverter508may include a pivot or tracking table, such as for example, the FIFE-500 Web Guiding System, by Maxcess-FIFE Corporation, which can adjust the positions of the continuous length of first and second belt substrates406,408in the first cross direction CD1. Other suitable pivot or tracking tables are available from Erhardt & Leimer, Inc. The diverter may also include instrumentation and web edge control features that allow for precise active control of the substrate positions.

As shown inFIG. 5C, the first belt substrate406includes an outer longitudinal edge107aand an inner longitudinal edge107bdefining a substantially constant width, W1, in the first cross direction CD1. And the second belt substrate408includes an outer longitudinal edge109aand an inner longitudinal edge109bdefining a substantially constant width, W2, in the first cross direction CD1, wherein W2is greater than W1. It is to be appreciated that in some configurations, W1may be equal to or greater than W2. As previously mentioned, the first belt substrate406is separated in the first cross direction from the second belt substrate408to define a gap between the inner longitudinal edge107bof the first belt substrate406and the inner longitudinal edge109bof the second belt substrate408. As discussed in more detail below, the first and second belt substrates406,408advance from the diverter508to a nip316between the carrier apparatus308and a carrier apparatus318to be combined with discrete chassis102.

As shown inFIGS. 4 and 5A, a continuous length of chassis assemblies302are advanced in a second machine direction MD2and define a width in a second cross direction CD2. The continuous length of chassis assemblies302may include absorbent assemblies140sandwiched between topsheet material138and backsheet material136, leg elastics, barrier leg cuffs and the like. As shown inFIG. 5A, portion of the chassis assembly is cut-away to show a portion of the topsheet material138and an absorbent assembly140. The continuous length of chassis assemblies302advance to a carrier apparatus308and are cut into discrete chassis102with knife roll306, while advancing in the orientation shown in FIG.5B1, wherein the longitudinal axis124of each chassis102is generally parallel with the second machine direction MD2.

In some embodiments, the converting apparatus300may include a pivot or tracking table301, such as for example, the FIFE-500 Web Guiding System, by Maxcess-FIFE Corporation, which can adjust the positions of the continuous length of chassis assemblies302in the second cross direction CD2. Other suitable pivot or tracking tables are available from Erhardt & Leimer, Inc.

After the discrete absorbent chassis102are cut by the knife roll306, the carrier apparatus308rotates and advances the discrete chassis102in the second machine direction MD2in the orientation shown in FIG.5B1. While the chassis102shown in FIG.5B1is shown with the second laterally extending end edge146as a leading edge and the first laterally extending end edge144as the trailing edge, it is to be appreciated that in other embodiments, the chassis102may be advanced in other orientations. For example, the chassis may be oriented such that the second laterally extending end edge146is a trailing edge and the first laterally extending end edge144is a leading edge. The carrier apparatus308also rotates while at the same time changing the orientation of the advancing chassis102. In changing the chassis orientation, the carrier apparatus308may turn each chassis102such that the lateral axis126of the chassis102is parallel or generally parallel with the first machine direction MD1, such as shown in FIG.5B2. The carrier apparatus308may also change the speed at which the chassis102advances in the second machine direction MD2to a different speed in the first machine direction MD1. FIG.5B2shows the orientation of the chassis102on the carrier apparatus308while advancing in the first machine direction MD1. More particularly, FIG.5B2shows the chassis102with the lateral axis126of the chassis102generally parallel with the first machine direction MD1, and wherein the second longitudinal side edge130is the leading edge and the first longitudinal side edge128is the trailing edge. It is to be appreciated that various forms of carrier apparatuses may be used with the methods herein, such as for example, the carrier apparatuses disclosed in U.S. Pat. No. 7,587,966 and U.S. Patent Publication Nos. US2013/0270065A1; US2013/0270069A1; US20130270066A1; and US20130270067A1. As discussed below, in some embodiments, the carrier apparatus308may rotate at a variable angular velocity that may be changed or adjusted by a controller in order to change the relative placement of registration features on the chassis102and the advancing belt laminates406,408.

As discussed below with reference toFIGS. 4, 5C, 5D, 5E, and 5F, the chassis102are transferred from the carrier apparatus308and combined with advancing, continuous lengths of belt laminates406,408, which are subsequently cut to form first and second elastic belts106,108on diapers100.

With reference toFIGS. 4, 5C, and 5D, the chassis102are transferred from the carrier apparatus308to a nip316between the carrier apparatus308and a carrier apparatus318where the chassis102is combined with continuous lengths of advancing front belt406and back belt408substrate material. The front belt laminate material406and the back belt laminate material408each define a wearer facing surface312and an opposing garment facing surface314. The wearer facing surface312of the first belt laminate406may be combined with the garment facing surface134of the chassis102along the first waist region116, and the wearer facing surface312of the second belt laminate408may be combined with the garment facing surface134of the chassis102along the second waist region118. As shown inFIG. 4, adhesive320may be intermittently applied to the wearer facing surface312of the first and second belt laminates406,408before combining with the discrete chassis102at the nip316between roll318and the carrier apparatus308.

With reference toFIGS. 4 and 5D, a continuous length of absorbent articles400are defined by multiple discrete chassis102spaced from each other along the first machine direction MD1and connected with each other by the second belt laminate408and the first belt laminate406. As shown inFIG. 4, the continuous length of absorbent articles400advances from the nip316to a folding apparatus332. At the folding apparatus332, each chassis102is folded in the first cross direction CD1parallel to or along a lateral axis126to place the first waist region116, and specifically, the inner, body facing surface132into a facing, surface to surface orientation with the inner, body surface132of the second waist region118. The folding of the chassis also positions the wearer facing surface312of the second belt laminate408extending between each chassis102in a facing relationship with the wearer facing surface312of the first belt laminate406extending between each chassis102. As shown inFIGS. 4, 5D, and 5E, the folded discrete chassis102connected with the first and second belt laminates406,408are advanced from the folding apparatus332to a bonder apparatus334. The bonder apparatus334operates to bond an overlap area362, thus creating discrete bonds336a,336b.The overlap area362includes a portion of the second belt laminate408extending between each chassis102and a portion of the first belt laminate406extending between each chassis102.

As previously mentioned, the first belt laminate406may define a first width, W1, in the first cross direction CD1and the second belt laminate may define a second width, W2, in the first cross direction CD1, wherein W2is greater than W1. Thus, as shown inFIGS. 5Eand5E1, folding each chassis102and positioning the first belt laminate406into a facing relationship with the second belt laminate408may define uncovered regions410of the second belt laminate408intermittently spaced between the chassis102along the first machine direction MD1. The uncovered regions410may have a width, W3, extending in the cross direction defined by a distance extending between the inner longitudinal edge107bof the first belt laminate406and the inner longitudinal edge109bof the second belt laminate408. It is to be appreciated that folding each chassis102and positioning the first belt laminate406into a facing relationship with the second belt laminate408may also include aligning the outer longitudinal edge107aof the first belt laminate406with the outer longitudinal edge109aof the second belt laminate408.

As shown inFIGS. 4 and 5F, the continuous length of absorbent articles400are advanced from the bonder334to a cutting apparatus338where the first belt laminate406and the second belt laminate408are cut along the first cross direction CD1between adjacent bonds336a,336bto create discrete absorbent articles100. As such, bond336amay correspond with and form a first side seam178on an absorbent article100, and the bond336bmay correspond with and form a second side seam180on a subsequently advancing absorbent article.

In addition to cutting the first belt laminate406and the second belt laminate408along the first cross direction CD1between adjacent bonds336a,336b,the cutting apparatus338may also be configured to remove discrete pieces of trim material412from the uncovered regions410of the second belt laminate408, such as shown in FIGS.5E1and5F1. As shown in FIG.5E1, the cutting apparatus338may be configured to cut the first and second belt laminates406,408along a first cut line414and a second cut line416. The first cut line414may extend in the first cross direction CD1to sever the first and second belt laminates406,408. And the second cut line may extend in the first machine direction MD1and first cross direction CD1to sever the pieces of trim material412from the first belt laminate406and/or the second belt laminate408. As such, the cutting apparatus338may be configured to cut discrete absorbent articles100from the continuous length of absorbent articles400while at the same time forming contoured and/or shaped front and/or back elastic belts106,108on the absorbent articles100. As discussed below, the processes and apparatuses herein may be configured to produce absorbent articles100having a front elastic belt106with a substantially constant width and a back elastic belt108having a variable width defined by a contoured or shaped edge109b.

It is to be appreciated that that the first and second cut lines may be configured in various ways. For example, as shown in FIGS.5E1and5F1, the first cut line414may extend in a straight line in the first cross direction CD1to intersect with the second cut line416. The second cut line may extend in a curved path to define a length TL in the first machine direction MD1. As shown in FIG.5E1, the adjacent chassis102may be separated from each other in the first machine direction MD1by a distance D, and as such, the second cut line416may have a length TL that is equal to or less then the distance D such that the chassis102are not cut while removing the trim material412. However, in some embodiments, the length TL may be greater than the distance D. The second cut line416may also intersect with and extend in the first cross direction CD1from the inner longitudinal edge107band/or inner longitudinal edge109bof the first and/or second belt laminates406,408. For example, as shown in FIG.5E1, the second cut line416extends in the first cross direction CD1from the inner longitudinal edge109bof the second belt laminate408a distance TW to intersect with the first cut line414. Thus, as shown in FIG.5F1, the piece of trim material412may have a corresponding length TL and width TW.

It is to be appreciated that the first cut line414may extend along a straight and/or curved path along the first cross direction CD1. In addition, the first cut line414may be perpendicular with respect to the outer longitudinal edge107aand/or outer longitudinal edge109aof the first and/or second belt laminates406,408. In some configurations, the first cut line414may be define an angle that is less than 90° with respect to the outer longitudinal edge107aand/or outer longitudinal edge109a.In addition, it is to be appreciated that the second cut line416may extend along a path defined by straight and/or curved portions.

With continued reference to FIGS.5E1and5F1, the cutting apparatus338may be configured to remove trim material412from only the uncovered regions410of the second belt laminate408without removing material from the first belt laminate406. For example, the first cut line414may extend from the outer longitudinal edges107a,109aof the first and second belt laminates406,408to the inner longitudinal edge107bof the first belt laminate406. And the second cut line416may extend a distance TW in the cross direction from the inner longitudinal edge109bof the second belt laminate408to inner longitudinal edge107bof the first belt laminate406without crossing the inner longitudinal edge107b.As such, in some configurations, the width TW of the trim material412may be the equal to or substantially equal to the width W3of the uncovered region410. In some configurations, the second cut line416may extend a distance TW in the cross direction from the inner longitudinal edge109bof the second belt laminate408that is less than the width W3of the uncovered region410. And in some configurations, the second cut line416may extend a distance TW in the cross direction from the inner longitudinal edge109bof the second belt laminate408that is greater than the width W3of the uncovered region410. As such, the second cut line416may cross the inner longitudinal edge107bof the first belt laminate406, and thus, the trim material412may include a portion of the first belt laminate406as well as the second belt laminate408.

Although the cutting apparatus338may be configured to cut discrete absorbent articles100from the continuous length of absorbent articles400while at the same time forming contoured and/or shaped front and/or back elastic belts106,108on the absorbent articles100, it is to be appreciated that the process and apparatuses herein may be configured to perform these steps at different times. For example, the process may be configured with a separate trim removal unit that forms the contoured and/or shaped front and/or back elastic belts106,108on the absorbent articles100before cutting discrete absorbent articles100from the continuous length of absorbent articles400. In some embodiments, the separate trim removal or contouring cut may be performed after the apparatus334operates to bond an overlap area362, thus creating discrete bonds336a,336b.In other embodiments, the separate trim removal or contouring cut may be performed after the folding apparatus332folds the chassis also positions the wearer facing surface312of the second belt laminate408extending between each chassis102in a facing relationship with the wearer facing surface312of the first belt laminate406extending between each chassis102, and before the apparatus334operates to bond an overlap area362, thus creating discrete bonds336a,336b.

As discussed in more detail below, converting apparatus300may control the relative placement of first elastic belt106, second elastic belt108, and/or chassis102during the assembly process. For example, in some configurations, the relative placement of first elastic belt106, second elastic belt108, and/or chassis102may be controlled to align the portions Gp1, Gp2, Gp3of the first and/or second printed stripes G1, G2in a desired manner. For example, as shown inFIG. 4, the converting apparatus may include a controller600adapted to change the machine direction speeds and/or cross direction positions of advancing elastic laminates and/or chassis. Such changes machine direction speeds and/or cross direction positions may be based on the detection of registration features Rf. In turn, the changes in machine direction speeds and/or cross direction positions may alter the relative alignment of the portions Gp1, Gp2, Gp3of the first and/or second printed stripes G1, G2.

As shown inFIGS. 11 and 14, an inspection system600may be configured to interact with, monitor, and/or control the converting line300. As shown inFIG. 2and as described in more detail below, various sensors602and other devices may be arranged adjacent the converting line300may communicate with a controller604. Based on such communications, the controller604may monitor and affect various operations on the converting line300. For example, the controller may send various types of control commands1000to the converter line, such as speed change commands based on communications with the sensors602. In some embodiments, the control commands1000may be in the form of reject commands communicated to the reject system326. In the systems and methods described herein, the controller604may include one or more computer systems. The computer system may, for example, include one or more types of programmable logic controller (PLC) and/or personal computer (PC) running software and adapted to communicate on an EthernetIP network. Some embodiments may utilize industrial programmable controllers such as the Siemens S7 series, Rockwell ControlLogix, SLC or PLC 5 series, or Mitsubishi Q series. The aforementioned embodiments may use a personal computer or server running a control algorithm such as Rockwell SoftLogix or National Instruments Labview or may be any other device capable of receiving inputs from sensors, performing calculations based on such inputs and generating control actions through servomotor controls, electrical actuators or electro-pneumatic, electrohydraulic, and other actuators. Process and product data may be stored directly in the controller or may be located in a separate data historian. In some embodiments, the historian is a simple data table in the controller, in other embodiments, the historian may be a relational or simple database. Common historian applications include Rockwell Automation Factory Talk Historian, General Electric Proficy Historian, OSI PI, or any custom historian that may be configured from Oracle, SQL or any of a number of database applications.

As shown inFIGS. 4-6, the first and/or second elastic belt laminates406,408and/or the continuous length of chassis assemblies302may include registration features Rf. For example, the first belt laminate406may include registrations features Rf1arranged along the first machine direction MD1, and the second belt laminate408may include registrations features Rf2arranged along the first machine direction MD1. In addition, the continuous length of chassis assemblies302may include registration features Rf3arranged along the second machine direction MD2.

It is to be appreciated that registration features Rf may be configured in different ways. Registration features Rf may include any signaling mechanism that is recognizable by a machine. For example, registration features Rf may be in the form of printed graphics. In some configurations, the registration features Rf may include a physical discontinuity such as notch, a protrusion, a depression, or a hole formed in a substrate and/or components. In some configurations, the registration features Rf may include a region of magnetic discontinuity, electrical discontinuity, electromagnetic discontinuity, and/or any combination thereof. Some registration features Rf may provide an optical marker that operates on the basis of providing detectable changes in intensities of visible and/or non-visible wavelengths of light. Various examples of registration features are provided in U.S. Pat. Nos. 5,286,543; 6,444,064; and 6,955,733. Registration features Rf may be configured to operatively indicate the boundaries between virtual products, and in some configurations, the registration features Rf are regularly spaced at substantially equal intervals along machine direction of a substrate. As shown inFIGS. 5A and 5C, the registration features Rf may be positioned adjacent lateral side edges of the substrates. It is also to be appreciated that the registration features may be located in various positions on the various diaper components other than what is depicted herein. In addition, it is to be appreciated that instead of having separate graphics and registrations features, all or portions of the graphics may be composed of registration features.

The systems and methods herein may utilize various types of sensors to monitor the substrates and components traveling through the converting line300. As shown inFIG. 4, various types of inspection sensors602may be used to perform various functions. For example, inspection sensors602may be used to detect registration features Rf, the relative placement of substrates and/or components, and various types of defects. Based on the detections of the inspection sensors602, feedback signals from the inspection sensors may be communicated to the controller600. For example, a sensor602can be configured to detect a registration feature Rf on a substrate and communicate an inspection parameter corresponding with the detection of the registration feature to the controller600. The controller600receives the feedback signals from the sensors and compares the feedback signal with setpoints. Based on the comparison, the controller may change the machine direction speeds and/or cross directional positions of the substrates. It is also to be appreciated that various types of controllers and inspection sensors can be configured in various ways and with various algorithms to provide various types of data and perform various functions, for example, such as disclosed in U.S. Pat. Nos. 5,286,543; 5,359,525; 6,801,828; 6,820,022; 7,123,981; 8,145,343; 8,145,344; and 8,244,393; and European Patent No. EP 1528907B1, all of which are incorporated by reference herein.

It is to be appreciated that various different types of inspection sensors602may be used to detect registration features Rf and monitor the substrates and components while advancing through the converting line300. For example, inspection sensors602may be configured as photo-optic sensors that receive either reflected or transmitted light and serve to determine the presence or absence of a specific material; metal-proximity sensors that use electromagnetic to determine the presence or absence of a ferromagnetic material; capacitive or other proximity sensors using any of a number of varied technologies to determine the presence or absence materials. Inspection sensors602may also be configured as vision systems and other sub-processing devices to perform detection and, in some cases, logic to more accurately determine the status of an inspected product. Particular examples of inspections sensors602may include simple vision based sensors such as Cognex Checker series, integrated smart camera systems such as Cognex Insight, DVT Legend or Keyence smart cameras, component vision systems such as National Instruments CVS vision systems or PC based vision system such as Cognex VisionPro or any other vision system software which can run on a PC platform.

As shown inFIG. 4, the inspection sensors602are connected with the controller600through a communication network604, which allows the inspection sensors602to communicate inspection parameters to the controller600. It should also be appreciated that the inspection parameters may be provided from inspection sensors602in various forms. In one embodiment, inspection parameters may be in the form “results,” such as for example, provided from a sensor state change resulting in a binary input corresponding with the detected presence or absence of a registration feature. In some embodiments, inspection parameters may be provided in the form of measurements and/or numerical indications of detected positions of registration features relative to components and/or substrates; and/or numerical indications of the positions of components and/or substrates relative to other physical or virtual references. In other embodiments, inspection parameters may be in the form of images transferred via a standard protocol such as ftp (File Transfer Protocol), DDE (Dynamic Data Exchange), or OPC (Object Linking and Embedding for Process Control).

As mentioned above, the controller600may be adapted to control the relative placement of first elastic belt106, second elastic belt108, and/or chassis102during the assembly process based on detections of the registration features Rf on the first and/or second belt laminates406,408and/or continuous length of chassis assemblies302. For the purposes of the following discussion, with reference toFIGS. 4 and 6, the second belt laminate408may advance in the first machine direction MD1at a speed S1; and the continuous length of chassis assemblies302may advance in the second machine direction MD2at a speed S2; and first belt laminate406may advance in the first machine direction MD1at a speed S3.

In an example, with continued reference toFIGS. 4 and 6, the controller600may be configured to change the placement of the registration features Rf2and Rf3relative to each other along the first machine direction MD1by adjusting the speed S1of the second belt laminate408and/or shifting the continuous length of chassis assemblies302in the second cross direction CD2. In addition, the controller600may be configured to change the placement of the registration features Rf2and Rf3relative to each other along the first cross direction CD1by adjusting the speed S2of the continuous length of chassis assemblies302and/or shifting the second belt laminate408in the first cross direction CD1. In yet another example, the controller600may be configured to change the placement of the registration features Rf2and Rf3relative to each other along the first cross direction CD1by adjusting an angular velocity of the carrier apparatus308, which in turn, adjusts the speed of the discrete chassis102. As also discussed above with reference toFIGS. 4,5B1,5B2, and6, the carrier apparatus308may be configured to change the chassis orientation. Thus, in yet another example, the carrier apparatus308may turn each chassis102such that the lateral axis126of the chassis102is parallel or generally parallel with the first machine direction MD1. As such, the controller600may also be configured to change the placement of the registration features Rf2and Rf3(or Rf1) relative to each other along the first cross direction CD1and/or machine direction MD1by adjusting how much the carrier apparatus308may turn each chassis102. It is also to be appreciated that the carrier apparatus308may be configured with transfer members that turn in opposite directions, and thus operates to turn each consecutive chassis in opposite directions, such as disclosed for example, in U.S. patent application Ser. No. 14/038,821, entitled “Method and Apparatus for Changing the Orientation of an Absorbent Article,” filed on Sep. 27, 2013, which is hereby incorporated by reference. In turn, changing the relative placement of the registration features changes the relative placement of the portions of the graphics. For example, changing the relative placement of the registration features Rf2and Rf3changes the relative placement of the first portion Gp1and the second portion Gp2of the first stripe G1and the second stripe G2. Thus, the relative placement of registration features Rf2and Rf3may be controlled to align the portions Gp2and Gp3of the first and/or second printed stripes G1, G2in a desired manner.

In an additional example, the controller600may be configured to change the placement of the registration features Rf1and Rf3relative to each other along the first machine direction MD1by adjusting the speed S3of the first belt laminate406and/or shifting the continuous length of chassis assemblies302in the second cross direction CD2. In addition, the controller600may be configured to change the placement of the registration features Rf1and Rf3relative to each other along the first cross direction CD1by adjusting the speed S2of the continuous length of chassis assemblies302and/or shifting the first belt laminate406in the first cross direction CD1. In yet another example, the controller600may be configured to change the placement of the registration features Rf1and Rf3relative to each other along the first cross direction CD1by adjusting an angular velocity of the carrier apparatus308, which in turn, adjust the speed of the discrete chassis102. In turn, changing the relative placement of the registration features Rf1and Rf3changes the relative placement of the third portion Gp3and the second portion Gp2of the first stripe G1and the second stripe G2. Thus, the relative placement of registration features Rf1and Rf3may be controlled to align the portions Gp2and Gp3of the first and/or second printed stripes G1, G2in a desired manner.

It is to be appreciated that in some configurations, the second belt laminate408; the first belt laminate406; and the continuous length of chassis assemblies302may all include registration features Rf. In some configurations, the continuous length of chassis assemblies302may include registration features Rf, whereas only one of the second belt laminate408and the first belt laminate406may include registration features Rf. It is also to be appreciated that the registrations features Rf may be removed from the second belt laminate408; the second elastic belt108; the first belt laminate406; the first elastic belt106; the continuous length of chassis assemblies302; and/or the discrete chassis102at various stages of the assembly process. For example, as shown in FIGS.5E1and5F1, the registrations features Rf2are removed along with the trim material412.

It is to be appreciated that the various components discussed above may include one or more registration features. For example, although the chassis102inFIG. 6is depicted as having two laterally opposing registration features Rf3located generally in the crotch region119, the chassis102may be configured with a single registration feature Rf that may be located in various regions, such as either the waist regions116,118or the crotch region119. In another example such as shown inFIG. 7, the chassis may include one or more registration features Rf3in the crotch region and one more registration features Rf4in one or both waist regions116,118. In such a configuration, the registration features Rf3may be used to adjust placement of the chassis102along the first cross direction CD1, and the registration feature Rf4may be used to adjust placement of the chassis102along the first machine direction MD1. For example, the relative placement of registration features Rf1and Rf4in the first waist region116may be controlled to align the portions Gp2and Gp3of the first and/or second printed stripes G1, G2along the first machine direction MD1. And the relative placement of registration features Rf2and Rf4in the second waist region118may be controlled to align the portions Gp1and Gp2of the first and/or second printed stripes G1, G2in along the first machine direction MD1.