Patent Publication Number: US-2023143833-A1

Title: Elasticized waistband for use in an absorbent garment and method of making same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a 371 of international application number PCT/US2021/070077, filed on Jan. 25, 2021 which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/966,112, filed Jan. 27, 2020, the disclosures of which are incorporated herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a disposable absorbent sanitary product or garment and more specifically, to an apparatus and method for making an elasticized waistband material with elastic activation and deactivation zones and to refastenable disposable garments incorporating said elastic waistband material and method for making same. 
     Disposable products of the children&#39;s training pant type or of the adult incontinence type are typically provided with waist elastics on opposite sides of a garment blank, which, after folding together, are sealed or adhered together at formed side seams to entirely encircle the waist area of the finished garment. The construction of the side seams in this manner allows the product to be donned as one would don undergarment briefs or pants. That is, by inserting one&#39;s feet and legs through the leg openings of the training pant and pulling the pants up to the wearer&#39;s waist, the training pant can be worn without needing to fold and fasten ears of a disposable product constructed in a manner similar to that of baby diapers. 
     However, the construction of the side seams of the training pant in this manner prevents non-destructive separation of a portion of the waist area therefrom. For example, in the case where the training pant is to be removed from the wearer by opening the waist section and therefore the leg openings in order to remove the training pant without sliding it down the legs of the wearer, the waist section must be broken in a destructive manner. Once broken, the waist section of the training pant can no longer be used by itself to support the product around the waist of the wearer. 
     While the pre-formed waist section of the training pant provides convenience in donning the product, a need exists for a product offering the convenience of the typical training pant while providing a refastenable option allowing the waist of the training pant to be opened in a non-destructive manner. A further need exists for an apparatus and method that enables product changeover from one size of refastenable pant to another size of refastenable pant in an easy and efficient manner with minimal equipment change. 
     BRIEF STATEMENT OF THE INVENTION 
     Embodiments of the present invention relate to disposable garments and more specifically, to an apparatus and method for making disposable garments. More specifically, embodiments of the invention relate to a pant-type absorbent garment with one or more re-fastenable seams and an apparatus and method for making same. 
     In operation, a manufacturing assembly performs a perforation cut in a running waist web. About the perforation cut, the assembly attaches one or more pre-folded panels fitted with a portion of a re-fastenable joining means such as a gripping portion of a refastening tape or a hook portion of a hook-and-loop type fastening device. The running waist web may also be fitted with the corresponding loop tape configured to mate with the hook tape. The running waist web is subsequently separated at the perforation cut such that the separated running waist web remains joined together via the attached panel(s). Further processing includes folding the running waist web, which may be a front (or back) waist web, with an adjacent running back (or front) waist web and joining the front and back waist webs together to create side seams typical of disposable pant type garments that are permanently sealed via adhesive or mechanical, thermal, or ultrasonic bonds. The position of the break in the waist web created during the separation of the running waist web at the perforation cut is between the side seams in either the front or back waist portion. For the user&#39;s convenience, the break and corresponding panel are formed in the front waist portion. In some embodiments, the attached panel corresponding to the break may form no part of the side seam. In other embodiments the attached panel may extend into and be integrated with a side seam. 
     The disposable product of the present invention provides a benefit for allowing the garment to be put on in a manner similar to that of undergarment briefs while allowing the waist of the product to be opened and re-fastened in a non-destructive manner. 
     In accordance with one aspect of the invention, an apparatus for manufacturing an elasticized waistband for a refastenable absorbent garment includes a perforation cutter configured to form a series of perforation cuts in a continuous waist web comprising one or more elastic elements positioned between facing web layers. The apparatus also includes a panel applicator configured to cut a folded panel web comprising refastenable, fastener material into discrete panels and attach the discrete panels to the continuous waist web about the perforation cut. The apparatus further includes a breakage system configured to separate the continuous waist web at the perforation cuts and unfold the discrete panels. 
     In accordance with another aspect of the invention, a refastenable absorbent garment includes a first portion having opposing ends, the first portion comprising a central panel releasably attached to a pair of elasticized side panels by releasable fasteners, a second portion having opposing ends coupled to the opposing ends of the first portion, and an absorbent core having a first end coupled to the central panel of the first portion and a second end coupled to the second portion. 
     In accordance with another aspect of the invention, a method of manufacturing a refastenable absorbent garment includes applying a refastenable material to a continuous panel web, folding the continuous panel web to form a folded continuous panel web, cutting the folded continuous panel web into a plurality of discrete folded panels, and aligning the plurality of discrete folded panels with a series of perforations in a continuous elasticized waist web. The method also includes coupling the plurality of discrete folded patches to the continuous elastic web via the refastenable material, breaking the series of perforation cuts to form a first continuous waistband, coupling a plurality of absorbent cores between the first continuous waistband and a second continuous waistband, and cutting the first and second continuous waistbands to form at least one refastenable absorbent garment. 
     These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate embodiments presently contemplated for carrying out the invention. 
       In the drawings: 
         FIG.  1    is a schematic view of a manufacturing assembly for producing a refastenable absorbent garment according to an embodiment of the invention. 
         FIG.  1 A  is a detailed view of a portion of the waist web  18  shown in  FIG.  1    during the deactivation and perforation process according to an embodiment of the invention. 
         FIG.  2    is a schematic view of a continuation of the manufacturing assembly of  FIG.  1    according to an embodiment of the invention. 
         FIG.  2 A  is a schematic front view of a refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  1    according to an embodiment of the invention. 
         FIG.  2 B  is a schematic back view of the refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  1    according to an embodiment of the invention. 
         FIG.  2 C  is a cross-section view of the refastenable absorbent garment taken along line  2 C- 2 C of  FIG.  2 A  according to an embodiment of the invention. 
         FIG.  3    is a cross-section view of a folded panel web taken along line  3 - 3  of  FIG.  1    according to an embodiment of the invention. 
         FIG.  4    is a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to another embodiment of the invention. 
         FIG.  5    is a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to another embodiment of the invention. 
         FIG.  5 A  is a cross-section view of a refastenable absorbent garment manufactured using the manufacturing assemblies of  FIGS.  1  and  5    according to an embodiment of the invention. 
         FIG.  6    is a schematic view of a manufacturing assembly for producing a refastenable absorbent garment according to another embodiment of the invention. 
         FIG.  6 A  is a schematic view of a continuation of the manufacturing assembly of  FIG.  6    according to an embodiment of the invention. 
         FIG.  6 B  is a schematic front view of a refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  6    according to an embodiment of the invention. 
         FIG.  6 C  is a schematic back view of a refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  6    according to an embodiment of the invention. 
         FIG.  6 D  is a cross-section view of the refastenable absorbent garment taken along line  6 D- 6 D of  FIG.  6 B  according to an embodiment of the invention. 
         FIG.  7    is a cross-section view of a folded panel web taken along line  7 - 7  of  FIG.  6    according to an embodiment of the invention. 
         FIG.  8    is a schematic view of a manufacturing assembly for producing a refastenable absorbent garment according to another embodiment of the invention. 
         FIG.  8 A  is a schematic front view of a refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  8    according to an embodiment of the invention. 
         FIG.  8 B  is a schematic back view of a refastenable absorbent garment manufactured by the manufacturing assembly of  FIG.  8    according to an embodiment of the invention. 
         FIG.  8 C  is a cross-section view of the refastenable absorbent garment taken along line  8 C- 8 C of  FIG.  8 B  according to an embodiment of the invention. 
         FIG.  9    is a schematic view of a manufacturing assembly for producing an absorbent garment according to another embodiment of the invention. 
         FIG.  9 A  is a schematic front view of the absorbent garment manufactured by the manufacturing assembly of  FIG.  9    according to an embodiment of the invention. 
         FIG.  9 B  is a schematic back view of the absorbent garment manufactured by the manufacturing assembly of  FIG.  9    according to an embodiment of the invention. 
         FIG.  9 C  is a cross-section view of the absorbent garment taken along line  9 C- 9 C of  FIG.  9 B  according to an embodiment of the invention. 
         FIG.  10    is a schematic view of a manufacturing assembly for producing a refastenable absorbent garment product according to another embodiment of the invention. 
         FIG.  10 A  is a cross-section view of a folded panel web taken along line  10 A- 10 A of  FIG.  10    according to an embodiment of the invention. 
         FIG.  11    is a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to another embodiment of the invention. 
         FIG.  12    is a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to another embodiment of the invention. 
         FIG.  13    is a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Although the disclosure hereof is detailed to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify aspects of the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
       FIG.  1    illustrates a schematic view showing a manufacturing assembly line  10  configured to carry out a method for producing a disposable product according to an embodiment of the invention. One or more elastic elements  12  are inserted between and joined to a first web layer  14  and a second web layer  16  to form a continuous, elasticized waist web  18 . While web layers  14 ,  16  are illustrated as separate components in  FIG.  1   , the web layers  14 ,  16  may be formed from a single, folded web in an alternate embodiment. 
     In one embodiment, an optional adhesive applicator  20  applies adhesive to the first and/or second webs  14 ,  16 , which are pressed together with the elastic element(s)  12  therebetween via a joining assembly  22 . In another embodiment, joining assembly  22  includes a thermal or ultrasonic bonding unit for joining the webs  14 ,  16  and elastic element(s)  12  together. For example, first web  14  and second web  16  may be materials capable of fusing to one another upon application of an applied energy that causes one or both of the webs  14 ,  16  to soften or melt and join together without the use of an intermediate layer of adhesive material such as glue. The facing pair of web layers  14 ,  16  may be the same type of material or different materials according to alternative embodiments. As non-limiting examples, first and second web layers  14 ,  16  may include nonwoven materials, woven materials, films, foams, and/or composites or laminates of any of these material types. The elastic element(s)  12  may be composed of any suitable elastic material including, for example, film or sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or elastic strands, as non-limiting examples. While elastic element(s)  12  are illustrated in the drawings as multiple, discrete elements and referred to throughout the remainder of the description as “elastic threads  12 ”, it will be understood that any of the aforementioned types of elastic materials may be utilized in any of the disclosed embodiments. Each elastic thread  12  may be provided in the form of an individual elastomeric strand or be a manufactured multifilament product that includes many individual elastomeric filaments joined together, such as by a dry-spinning manufacturing process, to form a single, coalesced elastic thread  12 . Elastic threads  12  may have any suitable cross-sectional shape that facilitates formation of an elastic composite structure having desired elasticity, visual aesthetic, and manufacturability. As non-limiting examples, elastic threads  12  may have a cross-sectional shape that is round, rectangular, square, or irregular as may be the case where each elastic thread  12  is a multifilament product. 
     Joining assembly  22  may be any known ultrasonic welding system in alternative embodiments, including, as non-limiting examples, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, joining assembly  22  includes a rotary anvil  24  and an ultrasonic rotary horn  26 , which cooperate with each other to bond (i.e., fuse) the first web layer  14  to the second web layer  16 . Alternative embodiments may include one or more fixed blade horns also known as sonotrodes. During the bonding process the elastic threads  12  are secured or anchored in position relative to the first and second web layers  14 ,  16  by the resulting pattern of bonds or welds, which are sized and spaced relative to the elastic threads  12  in a manner that maintains the elastic threads  12  in position relative to the web layers  14 ,  16 . The bonds or welds may be arranged in pairs disposed on either side of a respective elastic thread  12 , creating a pinch point that anchors the elastic thread in position relative to the facing web layers  14 ,  16 , or may be positioned to partially or fully overlap the elastic thread  12  and fuse the elastic thread  12  to the facing web layers  14 ,  16 , according to alternate embodiments. 
     The elastic threads  12  are attached to the web layers  14 ,  16  in a manner that defines elastic activation and deactivation zones in the continuous waist web  18 . In embodiments that utilize adhesive applicator  20 , the applicator  20  is configured to deposit the adhesive in an intermittent manner that creates regions where the elastic threads  12  are bonded to the web layers  14 ,  16  (referred to hereafter as activation zones) and regions where the elastic threads  12  are not bonded to the web layers  14 ,  16 . In embodiments where adhesive applicator  20  is omitted and joining assembly  22  is a thermal or ultrasonic bonding unit, the bonding unit is configured to create a bonding pattern that results in alternating pattern of bonded, activation zones and non-bonded regions. The bonded regions and non-bonded regions are formed in an alternating pattern in the machine direction (MD)  27  as further described with respect to  FIG.  1 A . 
     Downstream of the joining assembly  22  in the machine direction (MD)  27  is a break assembly  28  comprising a pair of anvils  30 ,  31  configured to break the elastic threads  12  in a non-bonded region of the continuous waist web  18  when the tensioned elastic threads  12  pass therethrough without cutting or perforating the first or second web layers  14 ,  16 . More specifically, anvil  31  includes a break bar  32  that extends outward from the face of the anvil  31 . The pair of anvils  30 ,  31  are spaced apart from one another by a distance that defines a nip or gap through which the continuous waist web  18  passes through. At the point of rotation when the break bar  32  of anvil  31  is positioned facing anvil  30 , the gap between the break bar  32  and anvil  30  is smaller than the overall thickness of the continuous waist web  18  and a pressure or pinching force is exerted on the elastic threads  12 . The pressure imparts a stress on the elastic threads  12  that breaks the elastic threads  12  without cutting through the web layers  14 ,  16 . In an alternative embodiment, the break bar  32  of anvil  31  may be replaced with a knife blade that creates a series of small cuts in the web layer  16  while also severing the elastic threads  12  at the break point. As illustrated in a cutaway portion  34  of the waist web  18  where the first sheet  14  is removed for clarity, since the severed ends of the elastic threads  12  are not bonded to the web layers  14 ,  16  at the break point, the ends of the elastic threads  12  retract away from the break point to create a deactivation zone where no elasticity is provided in the waist web  18 . However, the elastic threads  12  are restrained from pulling too far away from the break due to their attachment to the first and second web layers  14 ,  16  in the adjacent activation zones. 
       FIG.  1 A  provides a detailed view of a portion of the waist web  18  during the deactivation and perforation process. A wider portion of the web layer  14  has been cutaway in the view shown in  FIG.  1 A  to more clearly illustrate the relative locations of the activation and deactivation zones. The elastic threads  12  are bonded to the web layers  14 ,  16  via adhesive or mechanical, thermal, or ultrasonic bonds in activation zones  19  of the waist web  18 . These activation zones  19  are formed in an alternating pattern with deactivation zones  21  in which the elastic threads  12  are not bonded to the web layers  14 ,  16 . 
     Referring again to  FIG.  1    with continued reference to  FIG.  1 A  as appropriate, as the waist web  18  moves downstream from the break assembly  28 , a perforation cutter  36  introduces a perforation  38  into the waist web  18  in the deactivation zone  21  that pierces both the first and the second web layers  14 ,  16 . Perforation cutter  36  may include a rotary knife  40  with a blade  42  having a perforation cut pattern and a rotary anvil  44  against which the rotary knife  40  presses to make the perforation cut. In alternative embodiments, perforation cutter  34  may include a die instead of a knife blade or be a laser cutting device. As described below, the perforation cut  38  allows the waist web  18  to be broken as it is pulled apart in a later step of the process. As illustrated in another cutaway portion  46  of the waist web  18  as well as in  FIG.  1 A , the perforation  38  is positioned between broken elastic strands  12  in the deactivation zone  21 . In an alternative embodiment, the perforation cutter  36  may create the deactivation zone  21  by cutting the stretched elastic threads  12  in addition to the first and the second web layers  14 ,  16 . In this embodiment, the break assembly  28  may be eliminated. 
     In another part of the assembly line  10 , a panel web  48  with first and second side edges  50 ,  52  is fed into a folding assembly  54  where the panel web  48  is folded along fold axes  56 ,  58 ,  60 ,  62  aligned with the machine direction (MD)  63  of the panel web  48 . The panel web  48  may be composed of nonwoven materials, woven materials, films, foams, and/or composites or laminates of any of these material types. Folding assembly  54  folds the panel web  48  so that fold axes  56 ,  62  are positioned adjacently to one another in the central region of the panel web  48  while the distance between fold axes  58 ,  60  defines the folded width of the folded panel web  48 . An optional tack bond unit  64  may be positioned downstream of the folding assembly  54  to place temporary bonds between folded layers of the panel web  48  to maintain the folds during further processing. The temporary bonds are later broken as described below. Tack bond unit  64  may form the bonds using any known means, including, for example with a bonding unit that applies ultrasonics, heat and/or pressure to mechanical couple material layers or with adhesive. 
     Referring to  FIG.  3   , a cross-section view of folded panel web  48  is illustrated taken along line  3 - 3  of  FIG.  1   . The spacing between the overlapping layers of the panel web material are exaggerated for clarity in the illustration, but in practice, the layers are touching or very nearly touching as a result of being folded. As illustrated, a plurality of temporary bonds  66  may be put into the folded panel web  48  in order to hold the folds in place as the panel web  48  is handled by the process to attach individual panels to the waist web  18 . In one embodiment, the temporary bonds  66  may be ultrasonically or thermally formed, although other methods of joining the layers together such as by adhesive are also contemplated herein. Temporary bonds  66  are not permanent bonds so that when the material of the folded panel web  48  is pulled apart, the temporary bonds  66  break without harm to the panel web material to which they are bonded. In this manner, the folded panel web  48  may be un-folded during a later step of the manufacturing process as described below. 
     Referring back to  FIG.  1   , the folded panel web  48  proceeds downstream to a tape applicator  68  configured to apply a portion  70  of a refastenable, hook-and-loop type fastener material  70  to the continuous panel web  48 . In one embodiment, the applied portion of the fastener material is a hook portion  70 . As used herein, “tape” refers to a length of webbing with or without adhesive having been pre-applied to the webbing. Accordingly, a tape may be self-adhesive or may be fastenable to a base substrate via an applied adhesive, sewing, or other fastening means known in the industry. In one embodiment, panel web  48  comprises a material capable of joining with the hook tape  70  to create a temporary bond without the need to have a corresponding loop tape portion. Accordingly, the material provides a substitute for loop tape. In an alternative embodiment, a loop tape may be applied to the continuous waist web  18  upstream of the tape applicator  68 . In one embodiment, tape applicator  68  provides a cutting roll  72  positioned to cut a refastenable material or releasable fasteners  74 , referred to herafter as tape segments  74 , from a continuous infeeding web of hook tape material  70  against a rotating anvil  76 . The anvil  76 , which is traveling at a speed equal to or very close to that of the infeeding tape web  70 , carries the tape segments  74  to a point on its tangency where the folded panel web  48  traveling at a higher speed most nearly approaches, at which point the traveling folded panel web  48  is displaced slightly toward the anvil  76  by means of a protuberance  78  acting against the web  48 . This movement causes web  48  to come into contact with the next available tape segment  74 , which becomes attached to the higher-speed traveling web  48 . Since the panel web material is capable of forming a connection with the hook tape  70 , the cut segments  74  are placed hook-side toward the running folded panel web  48  so that when the protuberance  78  acts against the web  48 , the hooks become engaged with and attached to the web material. An adhesive applicator  80  positioned adjacently to the running folded panel web  48  applies an adhesive  81  ( FIG.  2 C ) to the tape segments  74  to later become adhered to the waist web  18 . 
     Alternatively, tape applicator  68  may be a slip-and-cut applicator in which the tape web  70  is fed at a relatively low speed along the vacuum face of the rotating anvil  76 , which is moving at a relatively higher surface speed and upon which the tape web  70  is allowed to “slip.” A knife-edge  82 , mounted on the rotating knife roll  72 , cuts a segment  74  of tape from the tape web  70  against the anvil face. This knife-edge  82  is preferably moving at a surface velocity similar to that of the circumference of the anvil  76 . Once cut, the tape tab segment  74  is held by vacuum drawn through holes on the face of the anvil  76  as it is carried at the anvil&#39;s speed downstream to the transfer point where the tape segment  74  is transferred to the traveling waist web  18 . 
     The panel web  48  proceeds downstream to a cross direction (CD) panel applicator  84  that cuts discrete panels  86  from the panel web  48  and applies them to the running waist web  18 . The panel applicator  84  includes a rotary knife or die rotary knife  88 , with one or more cutting edges  90 , that turns against and in coordination with a corresponding vacuum anvil  92 . The infeeding folded panel web  48  is fed along the surface  94  of the anvil  92 , which is rotating at a surface  94  velocity equal to or only somewhat greater than that of the panel web  48 . As the panel web  48  passes the nip created between the knife-edges  90  and the anvil surface  94 , individual discrete panels  86  are created but not significantly displaced upon the anvil surface  94 . The discrete panels  86  continue downstream on the anvil surface  94 , held securely by forces induced by a vacuum source directed to one or more holes provided for each segment in the anvil surface  94 . 
     At a point downstream and along the surface  94  of the anvil where the panels  86  are adjacent to the running waist web  18  at a transfer position, the waist web  18  to which the discrete panels  86  are to be attached is brought into close proximity with the anvil  92 . At the transfer position, the traveling waist web  18  is proceeding in a direction that is skew to the tangent of the rotational direction of the anvil  92  and the panels  86  are aligned with perforations  38 . A device, which may be as simple as a protuberance  96  or multiple protuberances on a rotating cylinder  98 , presses a target zone of the traveling waist web  18  against the exposed hook tape segments  74  of a discrete panel  86  as it is presented by the anvil surface  94 . The protuberance  96  preferably has a surface velocity substantially identical to that of the traveling web and a curvature similar to that of the anvil surface  94 . 
     The waist web  18  with attached panels  86  travels downstream toward a perforated cut breakage system  100 . As shown, breakage system  100  includes a first pair of rollers  102  and a second pair of rollers  104  that are spaced apart in the machine direction (MD)  27 . The surfaces of rollers  102  are travelling at a speed substantially identical to the speed of the running waist web  18  upstream of the rollers  102 . That is, the speed of the first pair of rollers  102  is closely matched with the speed of the incoming waist web  18 . The speed of the second pair of rollers  104  (i.e., the “post-break speed”), however, is faster than the speed the incoming waist web  18 . Accordingly, the second pair of rollers  104  will induce a pulling force on the waist web  18  in the travelling direction or in the machine direction (MD)  27 . The pulling force on the waist web  18  causes the perforation  38  to break, separating the waist web  18  at the perforation breaks. Once separated, the pulling force also causes any temporary bond  66  formed in the attached discrete panel  86  passing between the first and second pair of rollers  102 ,  104  to break, causing the panel  86  to unfold and straighten out. The unfolding of the panel  86  extends the length of the waist web  18  such that an unfolded distance  106  between adjacent panels  86  is greater than the folded distance  108  between adjacent panels  86 , thereby forming a continuous front elasticized waistband  111 . The unfolded distance  106  more closely matches the distance of the waist width of the end product of the refastenable absorbent garment than the folded distance  108 . 
     An optional hook reinforcement tack bonder unit  110  may be used downstream of the perforated cut breakage system  100  to create temporary tack points or bonds between the layers of waist web  18 , hook tape  70 , and panel  86  to provide extra reinforcement to keep the layers together throughout the rest of the packaging process. 
     In a preferred embodiment, the waist web  18  is a front waist web configured to be donned in a forward-facing position on the wearer. A continuous back waist web or waistband  112  is fed into a position adjacent to the front waist web  18  at a speed substantially identical to the post-break speed. An absorbent core  114  is attached to and between the front waistband  111  in its unfolded state and the continuous back waistband  112  downstream of the perforated cut breakage system  100 . In another embodiment, the front and back waistbands may be reversed such that the front waistband  111  is a back waistband and waistband  112  is a front waistband. 
     As continued in  FIG.  2   , the joined webs  18 ,  112  are folded together such that the front waistband  111  and the back waistband  112  overlap. The overlapping waistbands  111 ,  112  are sealed by a bonding unit  113  to create side seams  116  in a manner known in the art, and are separated by a knife unit  115  to create individual refastenable absorbent garments  117 . Thereafter, the individual refastenable garments  117  may move on to be further processed (e.g., folded into smaller units) and packaged. 
     As shown in  FIG.  2    and in further detail in  FIGS.  2 A and  2 B , the individual garments  117  include a first portion  119  having opposing ends located adjacent the side seams  116 . The first portion  119  includes a central panel  86  that is releasably attached to a pair of elasticized side panels  121  constructed from the front waist web  18 . As shown in  FIG.  2 A , the central panel  86  is positioned to overlap the inboard facing edges  123  of the elasticized side panels  121 . Tape segments  74  positioned on the inward-facing surface of central panel  86  are are releasably fastened to the outward-facing surface  125  of the elasticized side panels  121 . Individual garments  117  also include a second portion  127  ( FIG.  2 B ), that is constructed from the rear waist web  112 , and has opposing ends  129  coupled to the opposing ends  131  of the first portion  119  via side seams  116 . While the first portion  119  is described herein as forming the front panel of individual garments  117  and the second portion is described as forming the rear panel of individual garments  117 , the configuration could be reversed in alternative embodiments to place the three-panel waistband at the rear of the garment  117 . In yet other embodiments, the front and rear panels could be similarly constructed to each include a three-panel construction with a central panel  86  attached to a pair of elasticized side panels  121 . The central panel  86  of each of the front and rear waistbands may be releasably attached to adjacent side panels  121  in one embodiment. Alternatively, releasable fasteners may be employed to couple the central panel  86  of one of the front or rear waistband to side panels  121  while the other central panel  86  is permanently coupled to its adjacent side panels  121 . With respect to  FIG.  2 C  and to the other cross-sectional views provided herein, it will be understood that the spacing between the stacked and/or overlapping layers of web material and other product components are exaggerated for clarity in the illustration, but in practice, the layers are touching or very nearly touching. 
       FIG.  4    shows a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to an alternate embodiment. As illustrated, assembly line  10  does not include a break assembly  28  as is found in the assembly line  10  of  FIG.  1   . Instead, prior to reaching the perforation cutter  36 , the running waist web  18  has not had a deactivation zone created by a break assembly. Instead, the blade  42  of the perforation cutter  36  is designed such that the perforation cuts created in the first and second sheets  14 ,  16  are positioned to simultaneously cut each of the elastic strands  12 . Once cut and broken, the elastic strands  12  separate to create the deactivation zone as shown in cutaway portion  46 . While not shown in  FIG.  4   , the remainder of assembly line  10  downstream of cutaway portion  46  is the same as described relative to  FIG.  1   . 
       FIG.  5    shows a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to an alternate embodiment. As illustrated, a portion of the panel web  48  and folding assembly  54  are shown. In this embodiment, a tape applicator  118  configured to apply a loop tape  120  of a hook-and-loop type fastener to the panel web  48  configured to mate with the hook tape segments  74  attached downstream as illustrated in  FIG.  1   . Loop tape segments  122  might be used to provide a stronger bond than use of the panel web material alone. Tape applicator  118  includes a cutting roll  124 , a rotating anvil  126 , and a protuberance  128  similar to that of tape applicator  68  and function in a similar manner. An adhesive applicator  130  configured to apply adhesive  81 A ( FIG.  5 A ) to both loop tape webs  120  is provided. Loop tape segments  122  may be added upstream of the folding assembly  54  as illustrated or downstream of the folding assembly  54  in alternate embodiments depending on product design and process specifications. 
       FIG.  5 A  depicts a cross-sectional view of refastenable garment  117 E manufactured according to the alternate embodiment described in  FIG.  5   . As shown, garment  117 E includes all of the same components as described with respect to  FIGS.  1 ,  2 A,  2 B, and  2 C  and further includes loop tape  120  that is coupled to the central panel  86  via adhesive  81 A. 
       FIG.  6    illustrates a schematic view showing a manufacturing assembly line  132  configured to perform a metho for producing a disposable product according to another embodiment of the invention. As shown, many of the components of assembly line  132  are similar to those of assembly line  10 . For the components that function the same or similarly to those of assembly line  10  and are not described with respect to  FIG.  6   , see their descriptions as described above. 
     While the assembly line  10  has been described as forming and making a single panel  86 , assembly line  132  shows another embodiment for making and attaching two panels to the waist web  18  of each discrete refastenable absorbent garment. First panel web  48  and a second panel web  134 , which may comprise any of the same materials described above for web  48 , are processed to provide oppositely-facing panels  86 ,  136  attached to waist web  18 . As illustrated, panel web  48  includes a single z-fold provided by folding assembly  54  rather than the pair of z-folds illustrated with respect to assembly line  10 .  FIG.  7    illustrates a cross-section view of folded panel web  48  is illustrated taken along line  7 - 7  of  FIG.  6   . Optionally, a non-hook side of the continuous hook tape  70  may be coupled to first panel web  48  using an adhesive  138  dispensed by an adhesive applicator  140 . When used, adhesive  138  and adhesive applicator  140  may be applied as shown upstream of the folding assembly  54  or may be applied downstream of the folding assembly  54  and/or downstream of the tack bond unit  64  according to alternative embodiments. 
     Second panel web  134  is formed in a similar manner as that of first panel web  48  except that the folds therein are mirrored to those of first panel web  48  along the machine direction  135  of the second panel web  134 . In this manner, the panel applicator  142  that applies the panels  136  to the waist web  18  applies the panel  136  with the hook tape  70  on the opposite side of the respective perforation  38  as that of the panels  86 . The perforated cut breakage system  100  thus breaks two perforations  38  for each discrete disposable product, unfolding panels  86 ,  136  to extend the waist web  18  to match the distance  106 . 
       FIG.  6    also illustrates an alternative and optional loop tape application in which an optional loop tape applicator  144  attaches loop tape  146  to an adhesive  148  applied to waist web  18  by an optional adhesive applicator  150  about the perforations  38  formed therein. The adhesive  148  may be applied in separate blocks on both sides of the perforations  38  or may be a continuous adhesive block applied to the waist web  18 . The panel applicators  84 ,  142  applying panels  86 ,  136  to the waist web  18  apply the respective hook tapes  70  of the panels  86 ,  136  to respective segments of the loop tape  146 . It is contemplated that the loop tape applicator  144  may be omitted in embodiments where the hook tape  70  will attach directly to the waist web  18 . 
     After attachment of the absorbent cores  114  to the front and back waistbands  111 ,  112 , final processing of the products  117 A is performed in a similar manner as described above with respect to  FIG.  2   .  FIG.  6 A  illustrates the continued manufacture in more detail. As continued in  FIG.  6 A , the joined waistbands  111 ,  112  are folded together such that the front and back waistbands  111 ,  112  overlap. The overlapping waistbands  111 ,  112  are sealed by a bonding unit  113  to create side seams  116  in a manner known in the art, and are separated by a knife unit  115  to create individual refastenable garments  117 A. Thereafter, the individual refastenable garments  117 A may move on to be further processed (e.g., folded into smaller units) and packaged. 
     As shown in  FIG.  6 A  and in further detail in  FIGS.  6 B and  6 C , the individual garments  117 A include a first portion  119 A having opposing ends located adjacent the side seams  116 . The first portion  119 A includes a central panel  18 A constructed from the front waist web  18  that is releasably attached to a pair of oppositely-facing panels  86 ,  136  via hook tape segments  70  positioned on the outward-facing surfaces of panels  86 ,  136  and optional loop segments  146  coupled to the inward-facing surface of central panel  18 A. These panels  86 ,  136  are coupled to elasticized side panels  121 A constructed from the front waist web  18  via adhesive or ultrasonic bonds in alternative embodiments. As shown in  FIG.  6 B , the panels  86 ,  136  are postioned to overlap the inboard facing edges  123 A of the elasticized side panels  121 A and the outboard facing edges  133 A of the central panel  18 A. Individual garments  117 A also include a second portion  125 A ( FIG.  6 C ), that is constructed from the rear waist web  112 , and has opposing ends  129 A coupled to the opposing ends  131 A of the first portion  119 A via side seams  116 . While the first portion  119 A is described herein as forming the front panel of individual garments  117 A and the second portion  127 A is described as forming the rear panel of individual garments  117 A, the configuration could be reversed in alternative embodiments to place the five-panel waistband at the rear of the garment  117 A. In yet other embodiments, the front and rear panels could be similarly constructed to each include a five-panel construction with a central panel  18 A attached to a pair of oppositely-facing panels  86 ,  136 , which in turn are attached to respective elasticized side panels  121 A. The central panel  18 A of each of the front and rear waistbands may be releasably attached to adjacent oppositely-facing panels  86 ,  136  in one embodiment. Alternatively, releasable fasteners may be employed to couple the central panel  18 A of one of the front or rear waistband to oppositely-facing panels  86 ,  136  while the other central panel  18 A is permanently coupled to its adjacent side panels  121 A. 
       FIG.  8    illustrates a schematic view showing a manufacturing assembly line  152  configured to carry out a method for producing a disposable product according to another embodiment of the invention. Assembly line  152  comprises many of the same components as that of assembly line  132  of  FIG.  6    and similar part numbering is used for like components as appropriate. However, in contrast to assembly line  132 , assembly line  152  applies multiple panels  86  to waist web  18  having the same orientation. That is, panels  86  face the same direction and have their respective hook tapes  70  attached to the same side of their respective perforations  38 . In this manner, the number of components of the assembly line  152  is less than that of the assembly line  132  of  FIG.  6    for a simpler system. However, the user experience of separating the panel  86  from the finished product waist web  18  created by the assembly line  152  differs from that of the product produced by the assembly line  132 . 
     After the absorbent cores  114  are attached to the front and back waist webs  18 ,  112 , final processing of the disposable products  117 D ( FIG.  8 A ) is performed in a similar manner as described above with respect to  FIG.  6 A . Namely, the joined waistbands  111 ,  112  are folded together such that the front and back webs  112  overlap, the overlapping waistbands  111 ,  112  are sealed by a bonding unit  113  ( FIG.  6 A ) to create side seams  116  in a manner known in the art, and are separated by a knife unit  115  ( FIG.  6 A ) to create individual refastenable garments  117 D. Thereafter, the individual refastenable garments  117 D may move on to be further processed (e.g., folded into smaller units) and packaged. 
     As shown in  FIGS.  8 A and  8 B , the individual garments  117 D include a first portion  119 A having opposing ends located adjacent the side seams  116 . The first portion  119 A includes a central panel  18 A constructed from the front waist web  18  that is releasably attached to a pair of panels  86  via hook tape segments  70  positioned on the outward-facing surfaces of panels  86  and optional loop segments  146  coupled to the inward-facing surface of central panel  18 A. These panels  86  are coupled to elasticized side panels  121 A constructed from the front waist web  18  via adhesive or ultrasonic bonds in alternative embodiments. As shown in  FIG.  8 B , the panels  86  are postioned to overlap the inboard facing edges  123 A of the elasticized side panels  121 A and the outboard facing edges  133 A of the central panel  18 A. Individual garments  117 D also include a second portion  125 A ( FIG.  8 B ), that is constructed from the rear waist web  112 , and has opposing ends  129 A coupled to the opposing ends  131 A of the first portion  119 A via side seams  116 . While the first portion  119 A is described herein as forming the front panel of individual garments  117 D and the second portion  127 A is described as forming the rear panel of individual garments  117 D, the configuration could be reversed in alternative embodiments to place the five-panel waistband at the rear of the garment  117 D. In yet other embodiments, the front and rear panels could be similarly constructed to each include a five-panel construction with a central panel  18 A attached to a pair of panels  86 , which in turn are attached to respective elasticized side panels  121 A. The central panel  18 A of each of the front and rear waistbands may be releasably attached to adjacent panels  86  in one embodiment. Alternatively, releasable fasteners may be employed to couple the central panel  18 A of one of the front or rear waistband to panels  86  while the other central panel  18 A is permanently coupled to its adjacent side panels  121 A. 
       FIG.  9    illustrates a schematic view showing a manufacturing assembly line  154  configured to carry out a method for producing an absorbent garment  117 B ( FIGS.  9 A,  9 B ) according to another embodiment of the invention. As shown, many of the components of assembly line  154  are similar to those of assembly line  10 . For the components that function the same or similarly to those of assembly line  10  and are not described with respect to  FIG.  1   , see their descriptions as described above. 
     While the assembly line  10  has been described as forming and making a single panel  86  attached to the waist web  18  via a re-fastenable means such as by a hook-and-loop type fastener means, in the alternative assembly line  154  illustrated in  FIG.  9   , the single panels  86  are attached to the waist web  18  in a more permanent manner. Adhesive applicator  80  is configured to apply adhesive directly to the panel web  48  in a series of discrete applications or as a running application. Adhesive applicator  80  may apply the adhesive downstream of the tack bond unit  64  as shown or may be positioned to apply the adhesive upstream of the tack bond unit  64 , upstream of the folding assembly  54 , downstream of the rotary knife  88 , or another location prior to attachment of the single panels  86  to the waist web  18 . In another embodiment, assembly line  154  may alternatively, or in addition, include an adhesive applicator such as adhesive applicator  150  described with respect to  FIG.  6    for applying adhesive  148  to the waist web  18  in lieu of or additionally to the adhesive applied by the adhesive applicator  80 . A removal or other separation of all or a portion of a panel  86  from the waist web  18  to which it is adhesively attached in this embodiment results in a destructive separation that can no longer be used by itself to support the product around the waist of the wearer. 
       FIG.  9    also shows an embodiment usable in any of the other embodiments herein where the back waist web  112  is formed in a similar manner as the front waist web  18  in having a permanent or re-fastenable panel applied thereto. Accordingly, both the front and back waist webs  18 ,  112  include areas of elastic deactivation. 
     As shown in  FIGS.  9 A,  9 B and  9 C , the front and back sides of individual garments  117 B include a central panel  86  coupled to adjacent elasticized side panels  121  via a bond  81 . The bond  81  can be formed with adhesive or via ultrasonic bonding according to alternative embodiments. Side edges  129 ,  131  of the side panels  121  are bonded together via a side seam bond  116  in a similar manner as described with respect to the other embodiments above. 
       FIG.  10    illustrates a schematic view showing a manufacturing assembly line  156  configured to carry out a method  156  for producing a refastenable absorbent garment according to another embodiment of the invention. As shown, many of the components of assembly line  156  are similar to those of assembly line  10  shown in  FIG.  1  or  5   . For the components that function the same or similarly to those of assembly line  10  and are not described with respect to  FIG.  10   , see their descriptions as described above. 
     As shown in  FIG.  10   , the tape applicator  68  is positioned upstream of the folding assembly  54  so that the cut segments  74  are attached prior to folding the panel web  48 . In embodiments where the hook tape material  70  is provided without adhesive on its non-hook side, an optional adhesive applicator  130  may be configured to apply patches of adhesive  158  to the panel web  48  upstream of the tape applicator  68 . The cut segments  74  are attached to the adhesive patches  158  with their hook-side toward the rotating anvil  76  so that the non-hook side is adhesively attached to the panel web  48 . When later joined with the waist web  18 , the discrete panels  86  are coupled to the waist web  18  via the hooks of the cut segments  74 . If desired, an optional temporary bonding unit  80  may create temporary tack bonds  160  to assist with placement of the discrete panels  86  on the waist web  18 . Bonding unit  80  may be an adhesive applicator or thermal, pressure, or ultrasonic bonding unit according to alternate embodiments. These temporary bonds  160  are broken during the breaking of the perforations  38  by the breakage system  100 . After attaching absorbent cores  114 , further processing continues in the manner discussed with respect to  FIG.  2    to create individual garments  117 . 
       FIG.  11    shows a schematic view of a portion of the manufacturing assembly of  FIG.  1    according to an alternate embodiment. In contrast to the elasticized waist web formed from pairs of sheets  14 ,  16  together with elastic threads  12 , the waist web  18  illustrated in  FIG.  11    is formed from a stretch film material that includes one or more layers of stretchable material. Accordingly, the perforation cutter  36  may still be used to create the perforation  38 , but without the separate sheets  14 ,  16  or elastic threads  12 , the adhesive applicator  20 , the joining assembly  22 , and the break assembly  28  are not necessary and can be eliminated. 
       FIGS.  12  and  13    show schematic views of a portion of the manufacturing assembly of  FIG.  1    according to alternate embodiments. In each of the embodiments shown in  FIGS.  12  and  13   , the area on either side of the perforations  38  are reinforced to strengthen the bonding of the first sheet  14  to the second sheet  16  and minimize separation of the sheets  14 ,  16  from each other in the areas of elastic deactivation. As shown in  FIG.  12   , a bonding apparatus  162  is positioned downstream of the perforation cutter  36 . The bonding apparatus  162  bonds the first sheet  14  to the second sheet  16  at bonding sites  164  to create adjacent lines of bonds that are oriented in a cross-machine direction (CD)  165  and couple together the facing sheets  12 ,  14  on either side of the perforations  38 . Bonding apparatus  162  may be any known thermal, pressure, or ultrasonic welding system in alternative embodiments, including, as non-limiting examples, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, bonding apparatus  162  includes a rotary anvil  166  and an ultrasonic fixed blade horn  168 , also known as a sonotrode, which cooperate with each other to bond (i.e., fuse) the first sheet  14  to the second sheet  16 . Alternative embodiments may include multiple fixed blade horns or one or more rotary horns. 
     The ultrasonic emission or energy from bonding apparatus  162  is concentrated at specific bond points where frictional heat fuses the layers of web together without the need for consumable adhesives. While bonding apparatus  162  is described herein as an ultrasonic bonding assembly that ultrasonically fuses layers of web together, it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse together two or more material layers without the use of adhesive, including sonic, thermal, or pressure bonding techniques and various other forms of welding known in the industry. 
     As shown in  FIG.  13   , a bonding zone  170  is created on opposing sides of each perforation  38  by either the break assembly  28  or the perforation cutter  36 . In one embodiment, the break assembly  28  is constructed to serve a dual function of severing the elastic threads  12  and bonding the first sheet  14  to the second sheet  16  to create the bonding zone  170 . In another embodiment, the perforation cutter  36  is a dual function roller that includes a knife component that creates perforation cuts  28  and a bonding apparatus that creates the bonding zone  170 . The bonding zone  170  may be created by known welding or bonding techniques that fuse together two or more material layers without the use of adhesive, including sonic, thermal, or pressure bonding techniques and various other forms of welding known in the industry. 
     The above disclosure is intended to provide a general description of the basic parts of disposable absorbent products such as pant-style diapers and the like as they are known in the art. The description is not intended to be limiting. Any and all of various known elements, features and processes of known pant-style diapers, and the like can be incorporated in the disposable garment of the present invention as desired or needed for commercial manufacture, or for particular use benefits. 
     Therefore, according to one embodiment of the invention, an apparatus for manufacturing an elasticized waistband for a refastenable absorbent garment includes a perforation cutter configured to form a series of perforation cuts in a continuous waist web comprising one or more elastic elements positioned between facing web layers. The apparatus also includes a panel applicator configured to cut a folded panel web comprising refastenable, fastener material into discrete panels and attach the discrete panels to the continuous waist web about the perforation cut. The apparatus further includes a breakage system configured to separate the continuous waist web at the perforation cuts and unfold the discrete panels. 
     According to another embodiment of the invention, a refastenable absorbent garment includes a first portion having opposing ends, the first portion comprising a central panel releasably attached to a pair of elasticized side panels by releasable fasteners, a second portion having opposing ends coupled to the opposing ends of the first portion, and an absorbent core having a first end coupled to the central panel of the first portion and a second end coupled to the second portion. 
     According to yet another embodiment of the invention, a method of manufacturing a refastenable absorbent garment includes applying a refastenable material to a continuous panel web, folding the continuous panel web to form a folded continuous panel web, cutting the folded continuous panel web into a plurality of discrete folded panels, and aligning the plurality of discrete folded panels with a series of perforations in a continuous elasticized waist web. The method also includes coupling the plurality of discrete folded patches to the continuous elastic web via the refastenable material, breaking the series of perforation cuts to form a first continuous waistband, coupling a plurality of absorbent cores between the first continuous waistband and a second continuous waistband, and cutting the first and second continuous waistbands to form at least one refastenable absorbent garment. 
     While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description but is only limited by the scope of the appended claims.