Absorbent articles and method for manufacturing same

An absorbent product comprises a seal along one or more edges. The seal may be formed using a cohesive or selective adhesive. The seal prevents contamination of the wearer-facing surface of an individual absorbent product without requiring an overwrap or other individual unit packaging. The absorbent product may also comprise one or more removable trim regions for sealing and shaping the absorbent product.

FIELD OF THE INVENTION

The present disclosure generally relates to absorbent articles and methods for manufacturing the same, and more particularly relates to absorbent articles packaged for individual sale and methods for manufacturing the same.

BACKGROUND OF THE INVENTION

Absorbent articles, such as diapers, for example, can be sold individually. Although typically sold in packages containing multiple absorbent articles, it may be desirable to purchase a single absorbent article under certain circumstances. For example, individual articles may be desirable as unplanned or “emergency” purchases from a vending machine or convenience store; when a consumer wishes to experiment with a new size, brand, or style of absorbent article; or in locales where the average income may make bulk packages price prohibitive for many consumers. In such instances, a retailer may open a package of the absorbent articles and then sell individual absorbent articles to consumers.

One common function of the packaging or overwrap for a package of multiple absorbent articles is keeping the absorbent articles clean and dry prior to purchase and use. For products such as bandages, diapers, catamenial napkins, and other absorbent articles which may be used in proximity to tender or disrupted skin, a contaminated surface may compromise product performance; introduce undesirable irritants to the skin, mucosal membranes, or wound adjacent the absorbent article during use; or present an undesirable “dirty” appearance that may deter purchase or use. For these and other reasons, absorbent articles intended to be carried for later application or to be sold individually are often packaged in individual overwraps. However, these overwraps add cost and bulk to the articles, and generate extra waste when the overwrap is removed and discarded.

It would be desirable to provide an absorbent article suitable for individual sales which has interior, skin-contacting surfaces protected from contamination without an extra wrapper or package for each individual article.

SUMMARY OF THE INVENTION

In some embodiments, the invention comprises an absorbent product comprising a chassis. The chassis comprises a topsheet having a wearer-facing surface, a backsheet having a garment-facing surface, an absorbent core disposed between the topsheet and the backsheet, a first longitudinal side edge, a second longitudinal side edge, a first lateral end edge, a second lateral end edge, and a first lateral axis. The absorbent product is folded about the first lateral axis such that the first lateral end edge and the second lateral end edge are adjacent to each other and the chassis has a first portion on one side of the first lateral axis and a second portion on the other side of the first lateral axis. The absorbent product further comprises a first seal between the first lateral end edge and the second lateral end edge; a second seal between the first longitudinal side edge in the first portion of the chassis and the first longitudinal side edge in the second portion of the chassis; and a third seal between the second longitudinal side edge in the first portion of the chassis and the second longitudinal side edge in the second portion of the chassis. The first seal forms a waist opening when at least a portion of the first seal is disrupted, and the second and third seals form leg openings when at least a portion of the second and third seals are disrupted.

DETAILED DESCRIPTION OF THE INVENTION

Various non-limiting embodiments of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the apparatuses and methods disclosed herein. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. It is to be appreciated that the apparatuses and methods specifically described herein and illustrated in the accompanying drawings are non-limiting example embodiments and that the scope of the various non-limiting embodiments of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting embodiment may be combined with the features of other non-limiting embodiments. It is also to be appreciated that such features can be combined with features of the absorbent articles and methods of manufacture disclosed in the U.S. patent application entitled “ABSORBENT ARTICLES AND METHODS FOR MANUFACTURING SAME,” filed Nov. 24, 2009, and identified as attorney docket number 11516. Such modifications and variations are intended to be included within the scope of the present disclosure.

As used herein, the terms “typical adhesive” and “traditional adhesive” are interchangeable and refer to an adherent which demonstrates adhesion when applied to another material generally (e.g. the adherend material is not specially selected). Traditional adhesive materials connect to other materials indiscriminately and may stick to a variety of materials. Traditional adhesives are tacky and/or become tacky at certain temperatures. Generally, typical adhesive materials used in disposable absorbent articles demonstrate adhesion either at certain temperatures (such as a hot melt adhesive) or under pressure (a pressure sensitive adhesive).

As used herein, the term “cohesive” refers to a material that demonstrates surface interaction (in terms of connection of one surface to another) when applied to itself or to an analog of itself (i.e., the same or essentially the same material is both the adherent and adherend) at room temperature. An A-A type cohesive material will fasten or form a connection primarily to itself. Generally, such cohesives are substantially non-tacky (such as to skin) at room temperature or while under moderate pressure (e.g., finger pinch pressure).

As used herein, the term “selective adhesive” refers to an adherent which demonstrates surface interaction (in terms of connection of one surface to another) when applied to a specially selected adherend at room temperature. An A-A′ type selective adhesive system demonstrates surface interaction where adherent A will stick to adherend A′, where A′ is a material that is chemically similar to A. An A-B type selective adhesive system demonstrates surface interaction properties where adherent A will stick to a different material, adherend B. The adherend may also be a selective adhesive or cohesive. For example, in an A-A′ type selective system, A may also attach to A, and A′ may attach to A′. In another example, an A-B type selective adhesive system could also exist where material A may attach to itself or to material B, but material B will not attach to itself. The adherent and adherend of selective adhesives can be non-tacky.

As used herein, the term “contaminant” refers to any substance or object which is not intended to be present on the wearer-facing surface of the product, and may include, but is not limited to, bacteria; insects, rodents, or their droppings; dust; dirt; chemicals; excessive moisture; and the like.

As used herein, the terms “inboard” and “outboard” refer to the position of an object relative to the longitudinal or lateral centerline of an absorbent article. A first object is inboard of a second object if the first object is nearer the longitudinal or lateral centerline than the second object. A first object is outboard of a second object if the first object is farther from the longitudinal or lateral centerline than the second object.

As used herein, the terms “absorbent product” and “absorbent article” refer to different configurations of an article for receiving and containing urine, menses, and/or other bodily exudates, such as diapers, pull-on diapers, training pants, incontinence briefs, sanitary napkins, and the like. An absorbent article is in the final shape and configuration for application to a wearer, although seals or fasteners may need to be adjusted prior to or during application. An absorbent product is an absorbent article which requires additional shaping prior to application, as, for example, by removing a removable trim region, as described below.

As used herein, the terms “sealed” and “joined” refer to different connections between components of an article. A “seal” is frangible and is broken or disrupted to enable some functionality of an article. A “joint” is a connection between parts of the article and is typically not intended to be broken or disrupted during use. For example, a seal may be broken to form a waist opening or leg opening that allows a disposable absorbent article to be fitted to a wearer. A joint may join the backsheet and topsheet of a disposable absorbent article, or join a fastening system to the waist region. A joint may be frangible, but a frangible joint will typically be disrupted or broken at the end of a product's useful life, e.g., to remove a used absorbent article.

Absorbent articles, such as diapers, training diapers, pull-up pants, incontinence briefs, and undergarments, for example, may be sold individually. A retailer may open a package of multiple absorbent articles, and sell the absorbent articles individually. To protect the individual absorbent articles from contaminants after the package is opened, individual absorbent products may be configured to maintain wearer facing surfaces of the individual absorbent articles in a sanitary condition prior to use. In one embodiment, the individual absorbent products may be sealed about at least a portion of an outer perimeter to prevent contaminants from contacting the wearer-facing surfaces of the product prior to use.

In various embodiments of the present disclosure, referring toFIGS. 1-4, absorbent article42, which can be individually sealed, may comprise chassis12, which may form a main body of absorbent article42. Chassis12may comprise an outer covering including liquid pervious topsheet14and liquid impervious backsheet16. Topsheet14may comprise a wearer facing surface15and backsheet16may comprise garment facing surface17. Chassis12may comprise absorbent core18positioned intermediate topsheet14and backsheet16. Stated another way, absorbent core18may be sandwiched intermediate topsheet14and backsheet16, as shown inFIG. 2. In some embodiments, chassis12may be folded about lateral axis19such that first portion20of chassis12may be positioned adjacent to, or substantially adjacent to, second portion22of chassis12. In such an embodiment, first and second portions20and22may form first waist region24comprising laterally opposing ends25, second waist region27comprising laterally opposing ends29, and crotch region26longitudinally intermediate first and second waist regions24and27. In some embodiments, first and second waist regions24and27may comprise elastic elements such that they gather about a waist of a wearer to provide improved fit and containment of urine and other body exudates, for example. Crotch region26is the portion of absorbent article42which is generally positioned between the wearer's legs.

The figures show a highly simplified overview of absorbent article42and its components. However, absorbent article42may comprise any materials or construction known in the art. While topsheet14, backsheet16, and absorbent core18may be assembled in a variety of configurations, some exemplary configurations are described generally in U.S. Pat. No. 5,554,145, entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature”, issued to Roe et al. on Sep. 10, 1996; U.S. Pat. No. 5,569,234, entitled “Disposable Pull-On Pant”, issued to Buell et al. on Oct. 29, 1996; and U.S. Pat. No. 6,004,306, entitled “Absorbent Article With Multi-Directional Extensible Side Panels”, issued to Robles et al. on Dec. 21, 1999.

In some embodiments, topsheet14may be fully or partially elasticized or may be foreshortened to provide a void space between topsheet14and absorbent core18. Exemplary structures including elasticized or foreshortened topsheets are described in more detail in U.S. Pat. No. 5,037,416, entitled “Disposable Absorbent Article Having Elastically Extensible Topsheet”, issued to Allen et al. on Aug. 6, 1991; and U.S. Pat. No. 5,269,775, entitled “Trisection Topsheets for Disposable Absorbent Articles and Disposable Absorbent Articles Having Such Trisection Topsheets”, issued to Freeland et al. on Dec. 14, 1993.

Absorbent core18may comprise any absorbent material that is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids, such as urine and other body exudates. Absorbent core18may comprise a wide variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles, such as comminuted wood pulp, which is generally referred to as air felt. Examples of other suitable absorbent materials include creped cellulose wadding; melt blown polymers, including co-form; chemically stiffened, modified or cross-linked cellulosic fibers; tissue, including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any other known absorbent material or combinations of materials. Absorbent core18may further comprise minor amounts (typically less than 10%) of non-liquid absorbent materials, such as adhesives, waxes, oils, and the like, for example.

Exemplary absorbent structures for use in absorbent core18are described in U.S. Pat. No. 4,610,678, entitled “High-Density Absorbent Structures”, issued to Weisman et al. on Sep. 9, 1986; U.S. Pat. No. 4,834,735, entitled “High Density Absorbent Members Having Lower Density and Lower Basis Weight Acquisition Zones”, issued to Alemany et al. on May 30, 1989; U.S. Pat. No. 4,888,231, entitled “Absorbent Core Having A Dusting Layer”, issued to Angstadt on Dec. 19, 1989; U.S. Pat. No. 5,260,345, entitled “Absorbent Foam Materials for Aqueous Body Fluids and Absorbent Articles Containing Such Materials”, issued to DesMarais et al. on Nov. 9, 1993; and U.S. Pat. No. 5,387,207, entitled “Thin-Unit-Wet Absorbent Foam Materials for Aqueous Body Fluids and Process for Making Same”, issued to Dyer et al. on Feb. 7, 1995; and U.S. Pat. No. 5,397,316, entitled “Slitted Absorbent Members for Aqueous Body Fluids Formed of Expandable Absorbent Materials”, issued to LaVon et al. on Mar. 14, 1995.

In some embodiments, backsheet16may be joined with topsheet14at least around portions of the outer perimeters of backsheet16and topsheet14, thereby sandwiching absorbent core18therebetween. Backsheet16can prevent, or at least inhibit, any exudates absorbed by absorbent core18and contained within absorbent article42from soiling other external articles that may contact absorbent product10, such as bed sheets, pants, garments, or undergarments, for example. In some embodiments, backsheet16may be substantially impervious to liquids (e.g., urine) and may comprise a laminate of a nonwoven and a thin plastic film, such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm, for example. Suitable backsheet films include those manufactured by Tredegar Industries Inc. of Terre Haute, Ind. and sold under the trade names X15306, X10962, and X10964. Other suitable backsheet materials may include breathable materials that permit vapors to escape through backsheet16while still preventing exudates from passing through backsheet16. Exemplary breathable materials may include materials such as woven webs, nonwoven webs, composite materials such as film-coated nonwoven webs, and microporous films such as manufactured by Mitsui Toatsu Co., of Japan, under the designation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex., under the designation EXXAIRE. Suitable breathable composite materials comprising polymer blends are available from Clopay Corporation, Cincinnati, Ohio under the name HYTREL blend P18-3097. Such breathable composite materials are described in greater detail in PCT Application No. WO 95/16746, published on Jun. 22, 1995, in the name of E. I. DuPont. Other breathable backsheets including nonwoven webs and apertured formed films are described in U.S. Pat. No. 5,571,096, entitled “Absorbent Article Having Breathable Side Panels”, issued to Dobrin et al. on Nov. 5, 1996.

Absorbent article42may also comprise other features as are known in the art, such as front and rear ear panels, waist cap features, elastic, and other suitable components, for example, to provide better fit, better containment, and more pleasant aesthetic characteristics. Various additional features are described in further detail in U.S. Pat. No. 3,860,003, entitled “Contractable Side Portions for Disposable Diaper”, issued to Buell on Jan. 14, 1975; and U.S. Pat. No. 5,151,092, entitled “Absorbent Article With Dynamic Elastic Waist Feature Having a Predisposed Resilient Flexural Hinge”, issued to Buell et al. on Sep. 29, 1992.

In some embodiments, referring toFIGS. 1-4, backsheet16may comprise first laterally extending end edge28, second laterally extending end edge30longitudinally opposed to first laterally extending edge28, first longitudinally extending side edge32, and second longitudinally extending side edge34laterally opposed to first longitudinally extending side edge32. Backsheet16may have lateral axis19and longitudinal centerline54. First lateral end edge28may oppose second lateral end edge30such that when first portion20of absorbent product10is folded about lateral axis19over second portion22of absorbent product10, first lateral end edge28can be positioned adjacent to, or substantially adjacent to, second lateral end edge30. In some embodiments, first longitudinal side edge32can oppose second longitudinal side edge34. When first portion20of absorbent product10is folded over second portion22of absorbent product10about lateral axis19, first longitudinal side edge32can be folded over itself such that a first portion of the first longitudinal side edge32is positioned adjacent to, or substantially adjacent to, a second portion of the first longitudinal side edge32. Likewise, second longitudinal side edge34can be folded over itself such that a first portion of the second longitudinal side edge34is positioned adjacent to, or substantially adjacent to, a second portion of second longitudinal side edge34.

A portion of laterally opposing ends25of first waist region24may be permanently or refastenably attached to laterally opposing ends29of second waist region27to form a circular waist opening. Alternately, a fastening system may be provided such that laterally opposing ends25and29can be operatively joined to one another when absorbent article42is applied to a wearer. In some embodiments, absorbent article42may include ear panels or side panels, which extend laterally opposing ends25and29laterally. If ear or side panels are present, the fastening system may be disposed on the ear or side panels rather than, or in addition to, the laterally opposing ends.

Further to the above, referring toFIG. 5, seal38can be formed partially about outer perimeter40, or inboard of outer perimeter40, of absorbent article42to seal first portion20to second portion22and maintain absorbent article42in a sanitary condition prior to being positioned on a wearer. To fit absorbent article42to a wearer, seal38is opened to position the wearer's waist and legs in absorbent article42. In some embodiments, seal38may not extend through crotch region26of absorbent article42, as the wearer-facing surface of crotch region26will already be enclosed owing to the folding of first portion20over second portion22about lateral axis19. Seal38can be formed by applying an adhesive or cohesive near or on the outer perimeter of first portion20and/or second portion22and then applying pressure to absorbent article42to cause the adhesive or cohesive to seal first portion20to second portion22.

If seal38comprises an adhesive, the adhesive used may be a selective adhesive or an “A-B” adhesive that adheres preferentially to specific surfaces. In such an embodiment, when the product is opened, it is less likely that the adhesive residue will adhere to the wearer; will adhere to the wearer's undergarments, garments, or bedsheets; will adhere to other parts of the product; or will collect dust and dirt from the wearer's environment. Selective adhesives are described, for example, in U.S. Patent Application Publication No. 2008/0107861, filed Nov. 2, 2007 in the name of Dalal, et al. Exemplary selective adhesive combinations include a styrene block copolymer adherent (such as styrene-isoprene-styrene, styrene-butadiene-styrene, or styrene-isoprene-styrene) with a polypropylene or polyethylene adherend.

Seal38may also comprise a cohesive. A cohesive, like a selective adhesive or A-B adhesive, may be selected such that it will not adhere significantly to equipment used during manufacture, or to unintended parts of the product being assembled, and may provide similar benefits in terms of not adhering to the wearer, other surfaces, or dust or dirt from the wearer's environment. Cohesives are described, for example, in U.S. Pat. No. 6,156,424 to Taylor; U.S. Patent Application Publication No. 2008/0107861, filed Nov. 2, 2007 in the name of Dalal, et al; and U.S. Patent Application Publication No. 2005/0177127, filed Jan. 28, 2005 in the name of Ashton, et al. Exemplary cohesive compounds include water-based polychloroprene emulsions, water-based polyurethanes inherently capable of crystallization (such as polyester polyurethane and polycaprolactone polyurethane), latex, polyisoprene, polystyrene-polyisoprene-polystyrene or polystyrene-polybutadiene-polystyrene elastomers, budadiene-acrylonitrile-iosoprene, butadiene-acrylonitrile polymers, poly(ethylene terephthalate), polyamide, polypropylene, polyethylene, and combinations thereof.

To prevent damage to chassis12when opening seal38, the selective adhesive or cohesive used may be selected to exhibit peel forces between about 0.5N to about 15N. In some embodiments, the selective adhesive or cohesive will exhibit a peel force of less than about 10N. It should be understood that the magnitude of the strength of the bond created by the selective adhesive or cohesive along seal38may vary with the materials and construction of chassis12, as different chassis designs will be more or less sensitive to damage from opening seal38at various peel forces. “Damage” refers to pinholes, tears, cuts, necking, or other unintended modifications of chassis12resulting from the force applied to open seal38which can or do degrade the performance of chassis12. For example, some kinds of damage may permit leakage of urine or other exudates from chassis12when absorbent article42is used, or may interfere with proper fit of absorbent article42with undesirable effects on wearer comfort or aesthetics.

In some embodiments, seal38can be formed by melting at least a segment of the outer perimeters, or at least a segment proximate to the outer perimeters, of first and second portions20and22together using a suitable heating or melting device. Other suitable seals and/or methods of sealing are within the scope of the present disclosure, including, but not limited to ultrasonic seals and static charges. Such bonds may be constructed to permit opening seal38without damaging the product. For example, the bonds may be placed as discrete spot bonds, or may use a minimal amount of energy to tack the surfaces together without forming a bond of sufficient strength to damage chassis12. A separate waist seal36may be used to join opposing lateral end portions25of first waist region24and opposing lateral end portions29of second waist region27to form a waist within absorbent article42.

In some embodiments, seals36(if present) and38may both be disrupted and separated and the absorbent article laid flat, thereby forming open chassis74which can be applied to a wearer in a taped diaper configuration. A taped diaper configuration may have a fastening system comprising, for example, fastening tab72and landing zone70. Fastening tab72includes fastener76. Fastener76may attach directly to backsheet16, as, for example, if fastener76was an adhesive. Fastener76may also attach preferentially or exclusively to landing zone70. For example, fastener76may comprise hooks and landing zone70may comprise loops, forming a hook-and-loop fastening system. Fastener76and, if present, landing zone70, may be any fastener known in the art, including, but not limited to, adhesives, selective adhesives, cohesives, hook-and-loop, snaps, tab-and-slot, and the like. The fastening system may initially be engaged or unengaged. If the fastening system is engaged, once seal38is disrupted, the fastening system will hold the absorbent article in a pull-on configuration, as shown inFIG. 12. If the fastening system is unengaged, once seal38is disrupted, open chassis74is formed and can be applied to a wearer in a taped diaper configuration, as shown inFIGS. 11A and 11B. Alternatively, seal38may extend only partially along the perimeter at or adjacent to lateral end edge30and longitudinal side edges32and34, such that when seal38is disrupted separate seal36remains intact, such that waist opening68and leg openings66are formed, thereby providing a pull-on style absorbent article (i.e. the product has a closed waist circumference and closed leg circumferences). A pull-on style absorbent article may also comprise a fastening system, to supplement or strengthen seal36, or to provide a refastenable waist joint if seal36is disrupted. Seal36might be disrupted accidentally during application, or intentionally after absorbent article42has been applied to a wearer to remove absorbent article42to allow the wearer to use the toilet, or to check whether absorbent article42has been soiled, for example.

Absorbent article42may have a grip or loose edge such that a caregiver or wearer can easily grasp and pull apart the sides of absorbent article42when the caregiver or wearer is ready to use absorbent article42. There are a variety of ways to construct absorbent article42to facilitate opening seal38, as shown inFIG. 6. For example, seal38may be placed such that corner56is not sealed, so that an edge of front waist portion and rear waist portion may be separately gripped and pulled apart to dislodge seal38. In some embodiments, seal38may not extend fully to lateral axis19in crotch region26, such that a finger or object may be inserted into opening58between seal38and lateral axis19and used to pull apart seal38. In some embodiments, separate tab or grip60may be attached to facilitate opening seal38.

In some embodiments, longitudinal side edges32and34may be folded inboard, creating fold lines62, as shown inFIG. 7A. Fold lines62may be the outboard-most edges of crotch region26of absorbent article42once the article is folded. Folding may be mechanically guided during manufacture. In embodiments including leg cuffs and leg elastics or similar structures, folding may occur with or without mechanical guidance, as the article may tend to fold in on itself when the elastic elements in the article are released from tension and allowed to contract. Seal38may be somewhat laterally inboard of fold lines62, such that fold lines62are themselves grips that can be used to open seal38. In some embodiments, multiple grips or openings may be available to facilitate opening seal38.

Seal38may provide different functionality in different embodiments. For example, in some embodiments, seal38may have intermittent or discrete bonding points. In such embodiments, seal38would prevent some contamination, but would not present a water-tight seal. In some embodiments, seal38may be a continuous seal, to provide greater protection against contamination by solid contaminants and some vapor-phase contaminants. Seal38may also be a continuous, water-tight seal. Where seal38presents a water-tight seal, and backsheet16is liquid impervious, absorbent article42would be protected from vapor and liquid contaminants as well as particulates and pests. A watertight seal may be particularly helpful in wet climates or environments, where absorbent article42would be exposed to more than typical humidity (“typical” humidity is approximately 40-60% relative humidity). Examples of wet climates or environments may include, but are not limited to, tropical climates, rainy or wet seasons, water parks, boats, and the like.

Absorbent article42may be derived from absorbent product10by manipulating absorbent product10before applying absorbent article42to a wearer. For example, as shown inFIG. 10, removable trim region44may be used to shape absorbent article42from absorbent product10. For example, absorbent product10may be substantially rectangular, and absorbent article42may have a generally hourglass shape. An hourglass shape may be used to provide a trimmer fit through crotch region26of absorbent article42, which may improve or create an impression of improved wearer comfort or mobility or both.

In various embodiments, longitudinal lines of weakness46and48and lateral lines of weakness50and52may be formed in absorbent product10such that removable trim region44can be separated from absorbent article42formed within absorbent product10, as shown inFIGS. 8-10. Removable trim region44can comprise seal38thereon. Alternately, seal38may be inboard of removable trim region44. Removable trim regions and methods of making them are disclosed in detail in a co-pending U.S. patent application, filed Nov. 24, 2009, entitled “ABSORBENT ARTICLES AND METHODS FOR MANUFACTURING THE SAME” and identified as attorney docket number 11516.

Removable trim region44may have an area formed between an outer perimeter of absorbent article42, first and second longitudinal side edges32and34, and first and second lateral end edges28and30. Removable trim region44can be configured to be separated from absorbent article42about lines of weakness formed in absorbent product10. After removable trim region44is separated from absorbent article42, removable trim region44can be discarded and absorbent article42can be positioned on the wearer. In some embodiments, removable trim region44may comprise a portion of backsheet16. In some embodiments, removable trim region44may comprise a portion of top sheet14, a portion of backsheet16, and/or a portion of absorbent core18. Removable trim region44may have lines of weakness defined therein such that it can be readily separated from absorbent article42in portions or sections. AlthoughFIG. 10shows lines of weakness that are substantially symmetrical about lateral axis19, lines of weakness may be constructed to shape first portion of chassis20and second portion of chassis22differently. For example, lines of weakness may be constructed asymmetrically about lateral axis19to provide greater coverage in the rear of absorbent article42and wider leg holes in crotch region26of absorbent article42, to improve wearer comfort and exudate containment, as shown inFIGS. 8-9.

In one embodiment, a method for manufacturing absorbent product10may comprise the steps of advancing a continuous substrate through a converting line and combining the substrate with topsheet14and absorbent core18. In such an embodiment, absorbent core18may be disposed between topsheet14and the substrate. In some embodiments, the substrate may then be cut to form backsheet16having first lateral end edge28, second lateral end edge30, first longitudinal side edge32, and second longitudinal side edge34. Backsheet16, absorbent core18, and topsheet14may then be folded about lateral axis19to position first lateral end edge28adjacent to, or substantially adjacent to, second lateral end edge30, to position first portion20of first longitudinal side edge32adjacent to, or substantially adjacent to, second portion22of first longitudinal side edge32, and to position first portion20of second longitudinal side edge34adjacent to, or substantially adjacent to, second portion22of second longitudinal side edge34.

After such positioning, first lateral end edge28may be connected to second lateral end edge30, first portion20of first longitudinal side edge32may be connected to second portion22of first longitudinal side edge32, and first portion20of second longitudinal side edge34may be connected to second portion22of second longitudinal side edge34. The connection between the various portions may comprise a seal, such as a selective adhesive or cohesive seal, for example.

First longitudinal line of weakness46, if present, may be created laterally inboard of first longitudinal end edge32, second longitudinal line of weakness48may be created laterally inboard of second longitudinal end edge34, first lateral line of weakness50may be created longitudinally inboard of first lateral end edge28, and second lateral line of weakness52may be created longitudinally inboard of second lateral end edge30. In some embodiments, the various lines of weakness may define outer perimeter40of absorbent article42comprising absorbent core18disposed between backsheet16and topsheet14. Removable trim region44may be defined by an area of backsheet16between outer perimeter40of absorbent article42and first and second longitudinal side edges32,34and first and second lateral end edges28,30.

In some embodiments, absorbent article42may comprise a diaper having wearer facing surface15defined by topsheet14and garment facing surface17defined by backsheet16. Absorbent article42may have longitudinally opposing first and second waist regions24,27adjacent to, or substantially adjacent to, first and second lateral lines of weakness50,52, and crotch region26longitudinally intermediate of first and second waist regions27,27. Opposing lateral end portions25of first waist region24may be connected with opposing lateral end portions29of second waist region27to form waist opening68. In some embodiments, the connection between first and second waist regions24,27may comprise overlap seams or butt seams, for example. In some embodiments, first and second longitudinal lines of weakness46,48may define leg openings66in absorbent article42. In an embodiment where absorbent article42comprises ears, first and second ears may be connected to first waist region24. The first and second ears may be configured to releasably connect to second waist region27, or ears formed thereon, to form waist opening68in absorbent article42.

In some embodiments, the various lines of weakness may be formed in backsheet16, topsheet14, and/or absorbent core18by perforating backsheet16, topsheet14, and/or absorbent core18using a perforating device or a cutting member, for example. In other embodiments, the various lines of weakness may be formed in backsheet16, topsheet14, and/or absorbent core18by scoring backsheet16, topsheet14, and/or absorbent core18using a scoring device, for example. In one embodiment, first and second lateral lines of weakness50,52may be connected to or can intersect with first and second longitudinal lines of weakness46,48.

In some embodiments, first portion20of absorbent product10and second portion22of absorbent product10may be sealed to each other within the area of removable trim region44, or, in other embodiments, may be sealed to each other outside the areas of removable trim regions44. In some embodiments, portions of seal38are within area of removable trim44and other portions of seal38are outside areas of removable trim44. In some embodiments, an entire length of first lateral end edge28may be sealed with an entire length of second lateral end edge30; an entire length of first portion20may be sealed with an entire length of second portion22of first longitudinal side edge32; and an entire length of first portion20may be sealed with an entire length of second portion22of second longitudinal side edge34. In other embodiments, seal38may be intermittent along various portions of perimeter40of absorbent article42. In such an embodiment, intermittent seal38can join first portion20of absorbent product10with second portion22of absorbent product10such that wearer facing surface15of absorbent article42can remain in a sanitary condition prior to use of absorbent article42.

Absorbent products10according to the present disclosure may be further processed or packaged to facilitate individual sales. For example, absorbent product10may be further folded along second lateral axis64, shown inFIG. 5, to reduce the length of absorbent product10. A small amount of selective adhesive or cohesive may be placed on garment-facing side17of backsheet16to help maintain absorbent product10in a bi-folded position. Absorbent product10may be folded along additional lateral and/or longitudinal axes (not shown) to further reduce perimeter40of the folded product, as desired. One or more absorbent products10intended for individual sale may be placed in a bulk package for convenient shipping and for convenient handling and storage. For example, 5, 10, 12, 15, 20 or more absorbent products may be stacked together and placed in a box, plastic overwrap, or other packaging. A retailer or purchaser may then remove individual units from the bulk package as desired. The bulk packaging may be designed to help keep the absorbent products clean, dry, and neatly folded until sale. For example, the bulk packaging may provide an opening that encourages or facilitates the removal of a single individual product at a time, such that absorbent products are not scattered, shuffled, dropped, or otherwise handled when an individual unit is removed from the bulk packaging.

Because the overwrap or packaging is not necessarily conveyed to the consumer or user of the product, individual absorbent products may have printing on backsheet16or visible through backsheet16. For example, individual absorbent products10may be printed with brand images such as the trade name or trade mark for the product, or with indicia useful to the consumer or user, such as the size or variety of the absorbent article (such as Small, Medium, Large, Sensitive, Overnight Protection, Diaper Rash Prevention, etc.), or with instructions for using absorbent product10. For example, removable trim region44may be printed with instructions for removing the trim region, or tab60may be printed with instructions for opening seal38. Methods and materials for printing on individual absorbent products10are well known in the art, and may be selected for compatibility with the materials and construction of chassis12. Printing methods and materials may be selected which will withstand high moisture or water exposure, or the printing may be disposed on a layer subjacent to and visible through backsheet16, particularly, but not exclusively, in embodiments of absorbent product10intended to provide a watertight barrier to contaminants.

Individual absorbent products10may be provided with individual overwraps, boxing, or other packaging. Although seal38and/or removable trim region44are configured to protect wearer-facing surface15from contamination, the exposed portions of backsheet16would still be susceptible to contamination and damage, particularly if the absorbent products are roughly handled or stored for an extended period of time. Using the embodiments of the present disclosure, even if an overwrap is desired, it may be possible to use a thinner, less robust overwrap, since wearer-facing surface15of absorbent article42is already protected. Thus, the present disclosure may allow for using thinner materials or using less robust materials for individual overwraps, which may in turn allow for improvements in environmental impact (less overall material disposed, less overall weight to be transported, ability to use less robust biodegradable or recyclable overwrap materials instead of new, petroleum-derived plastics) or reduced cost (less overall material, less robust materials).