Patent Abstract:
A method of manufacturing sanitary absorbent articles suitable for placement within a crotch portion of an undergarment of a wearer, the absorbent article having a main body and a flap projecting laterally from a respective longitudinal side of the main body, the first flap having to longitudinal sides, each longitudinal side projecting laterally outward from the first longitudinal side of said main body intermediate the transverse sides of said main body. The method includes the steps of providing a web of at least one layer of continuous material, severing from the web a first article and a second article arranged with respect to the other wherein when the second article is rotated with respect to the first article such that the first longitudinal side of the main body of each of the articles faces the first longitudinal side of the main body of the other of the articles and such that the first transverse side of each of the articles is aligned with the second transverse side of the other of the articles, an imaginary line generally parallel to, and located in-between the longitudinal center-lines of each of the main bodies of each of the articles simultaneously intersects the first flap of each of the articles.

Full Description:
This application is a national stage, filed under 35 USC 371 of PCT application CA97/00994, filed Dec. 30, 1997. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a sanitary absorbent article such a sanitary napkin, diaper, adult brief, incontinence pad and the like. More particularly, the invention relates to a novel sanitary absorbent article and to a component layer thereof that can be produced with less waste material generated, and to a method of and apparatus for the manufacture thereof. The invention also extends to a method and apparatus for manufacturing the novel absorbent article. 
     BACKGROUND OF THE INVENTION 
     The technology surrounding absorbent articles, particularly sanitary napkins, has undergone several advances over the past two decades. One of these advances was the addition of multi-functional flaps to the longitudinal sides of the napkin. When in use such flaps are folded over the sides of the wearer&#39;s undergarment and secured thereto. They thus more firmly secure the napkin to the undergarment, provide an increased absorptive area for bodily exudates, and help prevent the undergarment from becoming soiled. The flap concept has generally met with success in the marketplace, and napkins with flaps of various configurations and conformations are available to the consumer. 
     Such sanitary absorbent articles are ordinarily composed of several layers of various materials affixed together to form a laminated structure. They are generally manufactured in the following manner: A laminated web comprised of the materials forming each of the individual component layers of the final article is provided. At least one layer of material, and more likely several, is continuous throughout the web. The web is then sealed at various points and severed to form discrete articles. 
     Alternatively, although generally uncommon, each of the individual component layers which make up the article could be produced separately, through their severance from a continuous sheet of material of which the layer is formed. These various component layers could then be combined together (i.e. laminated) to form the article. 
     In either method, the articles or the component layers themselves (as the case may be) receive their shape as they are severed from the laminated web or the continuous material, respectively. 
     An example of a sanitary napkin and a severing pattern therefor currently employed in the art are illustrated in FIGS. 1 and 2, respectively, of the present specification. This severing pattern may be employed in either of the aforementioned methods for the manufacture of such articles. The article being produced by this pattern is symmetric about both imaginary longitudinal and transverse centre-lines. The transverse ends of successive articles are aligned and the longitudinal side of opposing flaps of successive articles are substantially in contact with one another. The shaded material is not used in the production of an article and is therefore discarded as waste. Depending on the shape of the item being manufactured, the amount of waste is substantial, which contributes to an increased manufacturing cost. 
     Heretofore it appears that manufacturers have sought to optimise the configuration and shape of the sanitary absorbent articles generally, and particularly the flaps, on the basis of characteristics present in the individual final product. In this respect wearer comfort, absorptive efficiency, and leakage prevention have generally been taken into consideration. While the cost of manufacturing is important, little attention has been paid to designing the individual articles with a view to reducing the amount of waste material produced during their mass-production by the methods described above. As such articles are mass-produced in significant amounts, a reduction in waste material would provide significant savings in the cost of manufacturing. 
     OBJECTS AND STATEMENT OF THE INVENTION 
     It is therefore an object of the present invention to provide an improved sanitary absorbent article with flaps, such as a sanitary napkin, or a component layer of a sanitary napkin, such as a cover layer, which has been designed so as to reduce the amount of waste material generated during the mass-production thereof. 
     It is a further object of the present invention to provide a method of production of such an absorbent article or a component layer. It is still a further object of the present invention to provide an apparatus for producing such an absorbent article or component layer. 
     In one aspect, as embodied and broadly described herein, the invention provides a plurality of component layers for use in sanitary absorbent articles, each component layer comprising: 
     (A) a main body, said main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and an imaginary longitudinal centre-line; 
     (B) a first flap projecting laterally from the first longitudinal side of said main body, said first flap having two longitudinal sides, and said first flap being positioned with respect to said main body such that when 
     (i) two of the component layers are placed longitudinal side by longitudinal side, and 
     (ii) one of the component layers is rotated with respect to the other of the component layers such that the first longitudinal side of said main body of each of the component layers faces the first longitudinal side of said main body of the other of the component layers, and 
     (iii) the first transverse side of said main body of each of the component layers is aligned with the second transverse side of said main body of the other of the component layers, and 
     (iv) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of said main bodies of each of the component layers simultaneously intersects said first flap of each of the component layers; 
     one of the longitudinal sides of said first flap of one of the component layers is substantially in contact with one of the longitudinal sides of said first flap of the other of the component layers, and 
     said first flaps of each of the component layers do not overlap. 
     In the present specification, the term “component layer of a laminated absorbent article” refers one of the discrete layers of which a laminated absorbent article is comprised as distinct from the other layers of which the same article is composed. For example, if the laminated absorbent article is a sanitary napkin, such component layer might be a fluid permeable cover layer, a fluid impervious barrier layer, a transfer layer or an absorbent core layer. A component layer need not be comprised of a single material, but may itself be a laminate or two or more materials otherwise combined to form an integral whole. 
     It is preferred that the main body of the component layer be generally rectangular in shape with rounded ends. When the component layer is of such a conformation, the first and second transverse sides are the shorter opposing sides and will generally have an arcuate shape. The first and second longitudinal sides are the longer opposing sides and will be straight or arcuate. Preferably, the longitudinal sides are in an hourglass shape wherein in a central portion of the article the cross-section is narrower than the cross-section at the transverse ends. It should be understood however that the shape of such sides is not essential to the invention, and thus the transverse or the longitudinal sides could be either arcuate or straight, or any combination thereof. Nor is it essential that the main body be generally rectangular, as component layers having main bodies in the shape of a square, parallelogram or any other polygon, or even that of an oval, hour-glass or dog-bone, are all within the scope of the present invention. Where such is the case (i.e. where the main body is not rectangular), the longitudinal sides of the layer will be considered to be those opposing sides of a greater relative length as compared with the other opposing sides of the main body. Where it is impossible to make such a determination, any opposing pair of sides may be considered to be the longitudinal sides, or at the limit, opposing portions of any two sides may be considered to be the longitudinal sides. In either case, the transverse sides are the pair of opposing sides which are intersected by the longitudinal centre-line of the component layer, as that line is defined below. 
     For most component layers, the longitudinal centre-line thereof is an imaginary line which extends along the longitudinal axis of the layer and bisects the layer into two identical or somewhat identical, yet not necessarily mirror-image, halves. 
     It is preferred that the flaps be of a generally trapezoidal shape with the base of the trapezoid being attached to the longitudinal side of the main body. In this manner, the flap will taper as it projects away from the main body, and the sides and top of the trapezoid will be generally straight and will form the longitudinal sides and lateral side of the flap respectively. It should expressly be understood, however, that such trapezoidal shape is not essential to the invention, and flaps of all shapes and sizes are included within the scope of the present invention. In such cases, the sides of the flaps generally parallel to the transverse sides of the component layer should be considered to be the longitudinal sides of the flap. Where the shape of the flaps is arcuate or other non-rectilinear shape, the portions of the side of the flap generally facing in the same direction as the transverse sides of the component layer should be considered to be the longitudinal sides of the flap. 
     It should be understood that the use of the word “flaps” in the present specification is intended to encompass extensions of the material of a component layer which directly form a flap or wing in the article into which the component layer is incorporated, and those which are indirectly used to form such a flap or wing. An example of an indirect formation would be situations where the extension is looped around and a portion thereof sealed against the barrier layer of the article. In such cases the remainder of the extension (i.e. the portion thereof from the barrier layer seal to the distal extremity) would form the flap or wing in the final article. 
     In the present context, the word “aligned” is used to indicate a position of a transverse side of one component layer relative to that of the other. Two transverse sides are aligned for the present purposes when an imaginary line connecting the point at which one transverse side in question is intersected by the longitudinal centre line of that layer, with the point at which the other transverse side in question is intersected by the longitudinal centre line of the other layer, is substantially perpendicular to the longitudinal centre-line of either layer. Two lines are substantially perpendicular if the angle between them at their point of intersection is not less than 70° (or more than 110°). 
     A line “generally parallel to the longitudinal centre-lines of the article” in the present specification is meant to include a line off from parallel with either one of the centre-lines by at most 20°. 
     In relation to a component layer of the present invention, the phrase “substantially in contact” is meant to indicate a situation where the two flaps in question are in physical contact with one another or where the distance between them is small as compared to the total width of the component layer (as measured from longitudinal side to longitudinal side along the transverse centre-line thereof. The transverse centre-line of a layer being an imaginary line in the plane of the layer which is perpendicular to the longitudinal centre-line). Preferably, in the case of a component layer for a sanitary napkin, this distance will not exceed ¼ of an inch (0.635 cm). 
     In a more preferred embodiment a component layer of the present invention further comprises a second flap projecting laterally from the second longitudinal side of said main body, said second flap having two longitudinal sides, and said second flap being positioned with respect to said main body such that when 
     (i) two of the component layers are placed longitudinal side by longitudinal side, and 
     (ii) one of the component layers is rotated with respect to the other of the component layers such that the second longitudinal side of said main body of each of the component layers faces the second longitudinal side of said main body of the other of the component layers, and 
     (iii) the first transverse side of said main body of each of the component layers is aligned with the second transverse side of said main body of the other of the component layers, and 
     (iv) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of said main bodies of each of the component layers simultaneously intersects said second flap of each of the component layers; 
     one of the longitudinal sides of said second flap of one of said component layers is substantially in contact with one of the longitudinal sides of said second flap of the other of said component layers, and 
     said second flaps of each of said component layers do not overlap. 
     As embodied and broadly described herein, the present invention further provides a plurality of sanitary absorbent articles, each article comprising: 
     (A) a main body, said main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and an imaginary longitudinal centre-line; 
     (B) a first flap projecting laterally from the first longitudinal side of said main body, said first flap having two longitudinal sides, and said first flap being positioned with respect to said main body such that when 
     (i) two of the articles are placed longitudinal side by longitudinal side, and 
     (ii) one of the articles is rotated with respect to the other of the articles such that the first longitudinal side of said main body of each of the articles faces the first longitudinal side of said main body of the other of the articles, and 
     (iii) the first transverse side of said main body of each of the articles is aligned with the second transverse side of said main body of the other of the articles, and 
     (iv) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of said main bodies of each of the articles simultaneously intersects said first flap of each of the articles; 
     one of the longitudinal sides of said first flap of one of the articles is substantially in contact with one of the longitudinal sides of said first flap of the other of the articles, and 
     said first flaps of each of the articles do not overlap. 
     Like terms used in the above description should be attributed the same meaning in the context of the present aspect as those previously described above in relation to component layers of the present invention. 
     In a more preferred embodiment each absorbent article of the present invention further comprises: 
     (C) a second flap projecting laterally from the second longitudinal side of said main body, said second flap having two longitudinal sides, and said second flap being positioned with respect to said main body such that when 
     (i) two of the articles are placed longitudinal side by longitudinal side, and 
     (ii) one of the articles is rotated with respect to the other of said articles such that the second longitudinal side of said main body of each of the articles faces the second longitudinal side of said main body of the other of the articles, and 
     (iii) the first transverse side of said main body of each of the articles is aligned with the second transverse side of said main body of the other of the articles, and 
     (iv) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of said main bodies of each of the articles simultaneously intersects said second flap of each of the articles; 
     one of the longitudinal sides of said second flap of one of the articles is substantially in contact with one of the longitudinal sides of said second flap of the other of the articles, and 
     said second flaps of each of the articles do not overlap. 
     In another aspect the invention provides a method of manufacturing a plurality of component layers for use in sanitary absorbent articles, each component layer comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; and 
     (ii) a first flap projecting laterally from the first longitudinal side of the main body, the first flap having two longitudinal sides; comprising the steps of: 
     (A) providing a continuous web of material; 
     (B) severing said web to form a first component layer and a second component layer arranged one with respect to the other such that: 
     (1) the second component layer is rotated with respect to the first component layer such that the first longitudinal side of the main body of one of the component layers faces the first longitudinal side of the main body of the other of the component layers, and 
     (2) the first transverse side of one of the component layers is aligned with the second transverse side of the other of the component layers, and 
     (3) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the component layers simultaneously intersects the first flap of each of the component layers. 
     The terms used to describe the component layer being manufactured by the present method should be given the same meaning as that of like terms set forth hereinabove in relation to the component layer itself. 
     It must be understood that for a proper understanding of these aspects of the invention (i.e. the methods), and those relating to the apparatus improvements described below, the evaluation of the positioning of the various component layers takes place after each layer has been severed (such that the layer in question exists as a discrete entity), but before it has been physically removed from the web of continuous material. 
     It will be appreciated that many conventional means known to those skilled in the art may be employed to sever the component layers from the web. The optimal means may vary depending on many factors including the material from which the layer is to be severed. In this respect, die-cutting will generally be the preferred method although all other conventional methods, such as laser or fluid-jet cutting for example, are within the scope of the present invention. 
     This method of manufacture of component layers from a continuous web of material will generate less wasted material than prior art techniques. 
     Preferably, the second component layer is severed from the web such that one of the longitudinal sides of the first flap of the second component layer is substantially in contact with one of the longitudinal sides of the first flap of the first component layer. In this context, the phrase “substantially in contact” is meant to indicate a situation where the distance between the two flaps in question is, at a minimum the clearance distance between layers required by the severing method being used in order to produce layers of the correct dimensions. This phrase also includes any greater distance which is small as compared with the total width of a component layer (as measured from longitudinal side to longitudinal side along the transverse centre-line thereof.) As an example, where die-cutting is the method of severance employed, the minimum clearance distance is generally in the order of {fraction (3/16)} of an inch (0.4763 cm). 
     More preferably, the present invention provides a method of manufacturing a plurality of component layers for use in absorbent articles, each component layer further comprising: 
     (iii) a second flap projecting laterally from the second longitudinal side of the main body, the second flap having two longitudinal sides; 
     further comprising the step of: 
     (C) severing from the web a third component layer arranged with respect to the second component layer such that: 
     (1) the third component layer is rotated with respect to the second component layer such that the second longitudinal side of the main body of the second component layer faces the second longitudinal side of the main body of the third component layer, and 
     (2) the first transverse side of the second component layer is aligned with the second transverse side of the third component layer, and 
     (3) the first transverse side of the third component layer is aligned with the second transverse side of the second component layer, and 
     (4) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of the main bodies of each of the second and third component layers simultaneously intersects the second flap of the second component layer and the second flap of the third component layer. 
     Most preferably, in order to minimize the amount of waste material generated, the third component layer is severed from the web such that one of the longitudinal sides of the second flap of the third component layer is substantially in contact with one of the longitudinal sides of the second flap of the second component layer. 
     As embodied and broadly described herein, the present invention also provides a method of manufacturing a plurality of sanitary absorbent articles, each sanitary absorbent article comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; and 
     (ii) a first flap projecting laterally from the first longitudinal side of the main body, the first flap having two longitudinal sides; 
     comprising the steps of: 
     (A) providing a web having at least one layer of continuous material; 
     (B) severing said web to form a first article and a second article arranged one with respect to the other such that: 
     (1) the second article is rotated with respect to the first article such that the first longitudinal side of the main body of one of the articles faces the first longitudinal side of the main body of the other of said articles, and 
     (2) the first transverse side of one of the articles is aligned with the second transverse side of the other of the articles, and 
     (3) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the articles simultaneously intersects the first flap of each of the articles. 
     Preferably, the present invention also provides a method of manufacturing a sanitary absorbent article wherein the second article is severed from the web such that one of the longitudinal sides of the first flap of the second article is substantially in contact with one of the longitudinal sides of the first flap of the first article. 
     More preferably, the present invention provides a method of manufacturing a plurality of sanitary absorbent articles, each sanitary absorbent article further comprising: 
     (iii) a second flap projecting laterally from the second longitudinal side of the main body, the second flap having two longitudinal sides; 
     further comprising the steps of: 
     (C) severing from the web a third article arranged with respect to the second article such that: 
     (1) the third article-is rotated with respect to the second article such that the second longitudinal side of the main body of the second article faces the second longitudinal side of the main body of the third article, and 
     (2) the first transverse side of the second article is aligned with the second transverse side of the third article, and 
     (3) the first transverse side of the third article is aligned with the second transverse side of the second article, and 
     (4) a imaginary line generally parallel to, located in-between, the longitudinal centre-lines of each of the main bodies of each of the second and third articles simultaneously intersects the second flap of the second article and the second flap of the third article. 
     Most preferably the present invention provides, a method of manufacturing a plurality of sanitary absorbent articles, wherein the third article is severed from the web such that one of the longitudinal sides of the second flap of the third article is substantially in contact with one of the longitudinal sides of the second flap of the second article. 
     Like terms used in the description of a method of manufacture of an absorbent article in respect of this aspect of the present invention should be attributed a similar meaning as with the terms used to describe the method of manufacture of a component layer of this aspect of the present invention. 
     As embodied and broadly described herein, in another aspect, the present invention further provides in an apparatus for the manufacture of a plurality of component layers for use in sanitary absorbent articles, each component layer comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body, the first flap having two longitudinal sides; 
     the improvement comprising a cutter providing for the severance of a first component layer and a second component layer from a continuous web of material, the first component layer and the second component layer arranged one with respect to the other such that: 
     (A) the second component layer is rotated with respect to the first component layer such that the first longitudinal side of the main body of one of the component layers faces the first longitudinal side of the main body of the other of said component layers, and 
     (B) the first transverse side of the first component layers is aligned with the second transverse side of the second component layer, and 
     (C) the first transverse side of the second component layers is aligned with the second transverse side of the first component layer, and 
     (D) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the component layers simultaneously intersects the first flap of each of the component layers. 
     Like terms used in the description of the component layers and their relationship to one another with respect to the present aspect of the invention should, to the extent not varied hereinbelow, be attributed a similar meaning to as described hereinabove with respect to other aspects of the invention. 
     The term “cutter” is employed in the present context to denote any device capable of severing a discrete item from a continuous web of material. All conventional cutters known to those skilled in the art are within the scope of this aspect of the present invention. In this respect, such a cutter may include a die, a blade or other cutting-edge, a laser, or a fluid-jet. 
     Advantageously, the cutter is further capable of severing the first component layer and the second component layer from the continuous web of material such that one of the longitudinal sides of the first flap of the first component layer is substantially in contact with one of the longitudinal sides of the second flap of the second component layer. 
     Preferably, as embodied and described herein, the present invention further provides in an apparatus for the manufacture of a plurality of component layers for use in sanitary absorbent articles, each component layer further comprising: 
     (iii) a second flap projecting from the second longitudinal side of the main body, the second flap having two longitudinal sides; 
     the improvement wherein said cutter further provides for the severance of a third component layer from the continuous web of material arranged with respect to the second component layer such that: 
     (A) the third component layer is rotated with respect to the second component layer such that the second longitudinal side of the main body of the second component layer faces the second longitudinal side of the main body of the third component layer, and 
     (B) the first transverse side of the second component layer is aligned with the second transverse side of the-third component layer, and 
     (C) the first transverse side of the third component layer is aligned with the second transverse side of the second component layer, and 
     (D) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of the second and of the third component layers simultaneously intersects the second flap of the second component layer and the second flap of the third component layer. 
     Advantageously, said cutter is further capable of severing the first component layer and the second component layer such that one of the longitudinal sides of the first flap of the first component layer is substantially in contact with one of the longitudinal sides of the first flap of the second component layer. 
     Of a similar advantage, said cutter is further capable of severing the second component layer and the third component layer such one of the longitudinal sides of the second flap of the second component layers is substantially in contact with one of the longitudinal sides of the second flap of the third component layer. 
     As embodied and broadly described herein, the present invention also provides in an apparatus for the manufacture of a plurality of sanitary absorbent articles, each sanitary absorbent article comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body, the first flap having two longitudinal sides; 
     the improvement comprising a cutter providing for the severance of a first article and a second article from a continuous web of material, the first and second article being arranged one with respect to the other such that: 
     (A) the second article is rotated with respect to the first article such that the first longitudinal side of the main body of each of the articles faces the first longitudinal side of the main body of the other of said articles, and 
     (B) the first transverse side of the first article is aligned with the second transverse side of the second article, and 
     (C) the first transverse side of the second article is aligned with the second transverse side of the first article, and 
     (D) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the articles simultaneously intersects the first flap of each of the articles. 
     Advantageously, said cutter is further capable of severing the first article and the second article from the continuous web of material such that one of the longitudinal sides of the first flap of the first article is substantially in contact with one of the longitudinal sides of the second flap of the second article. 
     Preferably, as embodied and broadly described herein the present aspect of the present invention further provides in an apparatus for the manufacture of a plurality of sanitary absorbent articles, each sanitary absorbent article further comprising: 
     (iii) a second flap projecting from the second longitudinal side of the main body, the second flap having two longitudinal sides; 
     the improvement wherein said cutter further provides for the severance of a third article from the continuous web of material arranged with respect to the second article such that: 
     (A) the third article is rotated with respect to the second article such that the second longitudinal side of the main body of the second article faces the second longitudinal side of the main body of the third article, and 
     (B) the first transverse side of the second article is aligned with the second transverse side of the third article, and 
     (C) the first transverse side of the third article is aligned with the second transverse side of the second article, and 
     (D) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the second and third sanitary absorbent articles simultaneously intersects the second flap of the second article and the second flap of the third article. 
     Advantageously, said cutter is further capable of severing the first article and the second article such that one of the longitudinal sides of the first flap of the first article is substantially in contact with one of the longitudinal sides of the first flap of the second article. 
     Of a similar advantage, said cutter is further capable of severing the second article and the third article such one of the longitudinal sides of the second flap of the second articles is substantially in contact with one of the longitudinal sides of the second flap of the third article. 
     In still another aspect, as embodied and broadly described herein, the present invention provides a method of manufacturing a plurality of component layers for use in sanitary absorbent articles, each component layer comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body; 
     (iii) a second flap projecting from the second longitudinal said of the main body; and 
     (iv) each of the flaps having a first longitudinal side, a second longitudinal side, and a lateral side; 
     (v) said flaps being located substantially at midpoint between said transverse sides; comprising the steps of: 
     (A) providing a web of continuous material; 
     (B) severing said web to form a first component layer and a second component layer arranged one with relation to the other such that: 
     (1) at least a portion of the first longitudinal side of the main body of the first component layer faces at least a portion of the second longitudinal side of the main body of the second component layer, and 
     (2) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the component layers simultaneously intersects the first flap of the first component layer and the second flap of the second component layer. 
     It will be appreciated that this aspect of the present invention is similar to the method previously described above. It differs, however, in that the present method allows for the production of component layers currently employed in the art that are symmetric about an imaginary transverse centre-line (such as the article illustrated in FIG.  1 ). Alternative component layers manufactured according to the present method need not be rotated. 
     Preferably, the second component layer is severed from the continuous web of material such that the first transverse side of the first component layer and the first transverse side of the second component layer are non-aligned. In this context the term “non-aligned” is used to indicate a situation where the angle formed between the longitudinal centre-line of the first component layer and the line connecting the point of intersection of the longitudinal centre-line of that layer with a transverse side thereof and the corresponding point on the second component layer is not 90°. 
     More preferably, the second component layer is severed from the web of continuous material such that the first longitudinal side of the first flap of the first component layer is substantially in contact with the second longitudinal side of the second flap of the second component layer. The term “substantially in contact” in this context has the same meaning as that of the previous method aspect of the present invention described hereinabove. 
     Most preferably, the second component layer is severed from the web of continuous material such that the lateral side of the first flap of the first component layer is substantially in contact with the second longitudinal side of the main body of the second component layer. 
     Alternatively, the second component layer is severed from the continuous web-of material-such that at least a portion of one of the longitudinal sides of the second flap of the second component layer faces at least a portion of one of the transverse sides of the first component layer. 
     Advantageously, the second component layer is severed from the continuous web of material such that at least a portion of one of the longitudinal sides of the second flap of the second component layer is substantially in contact with one of the transverse sides of the first component layer. 
     More advantageously, the second component layer is severed from the continuous web of material such that at least a portion of the first longitudinal side of the main body of the first component layer is substantially in contact with at least a portion of the second longitudinal side of the main body of the second component layer. 
     In another aspect, as embodied and broadly described herein, the present invention provides a method of manufacturing a plurality of sanitary absorbent articles, each sanitary absorbent article comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body; 
     (iii) a second flap projecting from the second longitudinal said of the main body; and 
     (iv) each of the flaps having a first longitudinal side, a second longitudinal side, and a lateral side; 
     (v) said flaps being located substantially at mid point between said transverse sides; 
     comprising the steps of: 
     (A) providing a web of continuous material; 
     (B) severing said web to form a first sanitary absorbent article and a second sanitary absorbent article arranged one with respect to the other such that: 
     (1) at least a portion of the first longitudinal side of the main body of the first article faces at least a portion of the second longitudinal side of the main body of the second article, and 
     (2) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the articles simultaneously intersects the first flap of the first article and the second flap of the second article. 
     Preferably, the second article is severed from the continuous web of material such that the first transverse side of the first article and the first transverse side of the second article are non-aligned. 
     More preferably, the second article is severed from the web of continuous material such that the first longitudinal side of the first flap of the first article is substantially in contact with the second longitudinal side of the second flap of the second article. 
     Most preferably, the second component layer is severed from the web of continuous material such that the lateral side of the first flap of the first component layer is substantially in contact with the second longitudinal side of the main body of the second component layer. 
     In this aspect of the present invention the terms used have a meaning similar to that described previously hereinabove in relation to a method of manufacture of a component layer for use in a sanitary absorbent article. 
     In yet another aspect, as embodied and broadly described herein, the present invention further provides in an apparatus for the manufacture of a plurality of component layers for use in sanitary absorbent articles, each component layer comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body; 
     (iii) a second flap projecting from the second longitudinal said of the main body; and 
     (iv) each of the flaps having a first longitudinal side, a second longitudinal side, and a lateral side; 
     (v) said flaps being located substantially at mid point between said transverse sides; 
     the improvement comprising a cutter providing for the severance of a first component layer and a second component layer from a continuous web of material, the first component layer and the second component layer being arranged one with respect to the other such that: 
     (A) at least a portion of the first longitudinal side of the main body of the first component layer faces at least a portion of the second longitudinal side of the main body of the second component layer, and 
     (B) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the component layers simultaneously intersects the first flap of the first component layer and the second flap of the second component layer. 
     Preferably, said cutter is further capable of severing the second component layer from the continuous web of material such that the first transverse side of the first component layer and the first transverse side of the second component layer are non-aligned. 
     More preferably, said cutter is further capable of severing the second component layer from the continuous web of material such that the first longitudinal side of the first flap of the first component layer is substantially in contact with the second longitudinal side of the second flap of the second component layer. 
     Most preferably, said cutter is further capable of severing the second component layer from the web of continuous material such that the lateral side of the first flap of the first component layer is substantially in contact with the second longitudinal side of the main body of the second component layer. 
     In another aspect, as embodied and broadly described herein, the present invention provides in an apparatus for the manufacture of a plurality of sanitary absorbent articles, each article comprising: 
     (i) a main body, the main body having a first transverse side, a second transverse side, a first longitudinal side, a second longitudinal side, and a longitudinal centre-line; 
     (ii) a first flap projecting from the first longitudinal side of the main body; 
     (iii) a second flap projecting from the second longitudinal said of the main body; and 
     (iv) each of the flaps having a first longitudinal side, a second longitudinal side, and a lateral side; 
     (v) said flaps being located at mid point between said transverse sides; 
     the improvement comprising a cutter providing for the severance of a first article and a second article from a continuous web of material, the first and second arranged one with respect to the other such that: 
     (A) at least a portion of the first longitudinal side of the main body of the first article faces at least a portion of the second longitudinal side of the main body of the second article, and 
     (B) an imaginary line generally parallel to, and located in-between, the longitudinal centre-lines of each of the main bodies of each of the articles simultaneously intersects the first flap of the first article and the second flap of the second article. 
     Preferably, said cutter is further capable of severing the second article from the continuous web of material such that the first transverse side of the first article and the first transverse side of the second article are non-aligned. 
     More preferably, said cutter is further capable of severing the second article from the continuous web of material such that the first longitudinal side of the first flap of the first article is substantially in contact with the second longitudinal side of the second flap of the second article. 
     Most preferably, said cutter is further capable of severing the second article from the web of continuous material such that the lateral side of the first flap of the first article is substantially in contact with the second longitudinal side of the main body of the second article. 
     In this aspect of the present invention the terms used have a meaning similar to that described previously hereinabove in relation to a apparatus for the manufacture of a component layer for use in a sanitary absorbent article. 
    
    
     Other objects and features of the invention will become apparent by reference to the following specification and the drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A detailed description of the preferred embodiments of the present invention is provided hereinbelow with reference to the following drawings, in which: 
     FIG. 1 illustrates a top elevational view of a sanitary absorbent article of the prior art; 
     FIG. 2 illustrates a plurality of prior art absorbent articles, depicting the severing pattern employed for separating the absorbent articles from one another. 
     FIG. 3 illustrates a top elevational view of a sanitary absorbent article of the present invention. 
     FIG. 3 a  is a cross-sectional view of the napkin shown in FIG. 3; 
     FIG. 4 schematically illustrates the process for manufacturing absorbent articles in accordance with the present invention. 
     FIG. 5 illustrates a plurality of absorbent articles, depicting the severing pattern of the present invention employed for separating the absorbent articles from one another. 
     FIG. 6 illustrates a severing pattern of the present invention for the manufacture of the absorbent article, or a component layer thereof, depicted in FIG. 1; and 
     FIG. 7 illustrates a severing pattern of the present invention for the manufacture of absorbent articles or component layers thereof, in accordance with a variant. 
    
    
     In the drawings, preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purposes of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In FIG. 3 of the drawings there is illustrated a sanitary napkin with flaps, designated comprehensively by the reference numeral  110 , having a flap configuration of the present invention. Referring to FIG. 3 a , the napkin is of a laminated construction and preferably comprises a fluid-permeable cover layer  112 , an absorbent system  114 , a fluid-impervious barrier layer  120 , and adhesive strips  122  and  124 . 
     Cover Layer 
     The cover layer  112  may be a relatively low density, bulky, high-loft non-woven web material. The cover layer  112  may be composed of only one type of fibre, such as polyester or polypropylene or it may be composed of bi-component or conjugate fibres having a low melting point component and a high melting point component. The fibres may be selected from a variety of natural and synthetic materials such as nylon, polyester, rayon (in combination with other fibres), cotton acrylic fibre and the like and combinations thereof. 
     Bi-component fibres may be made up of a polyester core and a polyethylene sheath. The use of appropriate bi-component materials results in a fusible non-woven fabric. Examples of such fusible fabrics are described in U.S. Pat. No. 4,555,430 issued Nov. 26, 1985 to Mays. Using a fusible fabric increases the ease with which the cover layer may be mounted to the adjacent transfer layer and/or to the barrier layer. 
     The cover layer  112  preferably has a relatively high degree of wettability, although the individual fibres comprising the cover may not be particularly hydrophilic. The cover material should also contain a great number of relatively large pores. This is because the cover layer  112  is intended to absorb body fluid rapidly and transport it away from the body and the point of deposition. Preferably, the fibres which make up the cover layer  112  should not loose their physical properties when they are wetted, in other words they should not collapse or loose their resiliency when subjected to water or body fluid. The cover layer  112  may be treated to allow fluid to pass through it readily. The cover layer  112  also functions to transfer the fluid quickly to the other layers of the absorbent structure  114 . Thus, the cover layer  112  is preferably wettable, hydrophilic and porous. When composed of synthetic hydrophobic fibres such as polyester or bi-component fibres, the cover layer  112  may be treated with a surfactant to impart the desired degree of wettability. 
     Most preferably, the cover layer  112  is made of polymer film having large pores. Because of such high porosity, the film accomplishes the function of quickly transferring body fluid to the inner layers of the absorbent system. Apertured co-extruded films such as RETICULON™ brand, for example, described in U.S. Pat. No. 4,690,679 are useful as cover layers in the absorbent structures of this invention. 
     The cover layer  112  may be embossed to the remainder of the absorbent system  114  in order to aid in promoting hydrophilicity by fusing the cover to the next layer. 
     Absorbent System—Transfer Layer 
     Adjacent to the cover layer  112  on its inner side and bonded to the cover layer  112  is a fluid transfer layer  116  that forms part of the absorbent system  114 . The transfer layer  116  provides the means of receiving body fluid from the cover layer  112  and holding it until the highly-dense absorbent core has an opportunity to absorb the fluid. 
     The transfer layer  116  is, preferably, more dense than and has a larger proportion of smaller pores than the cover layer  112 . These attributes allow the transfer layer  116  to contain body fluid and hold it away from the outer side of the cover layer  112 , thereby preventing the fluid from re-wetting the cover layer  112  and its surface. However, the transfer layer is, preferably, not so dense as to prevent the passage of the fluid through the layer into the absorbent core. 
     The transfer layer  116  may be composed of fibrous materials, such as wood pulp, polyester, rayon, flexible foam, or the like, or combinations thereof. The transfer layer  116  may also comprise thermoplastic fibres for the purpose of stabilizing the layer and maintaining its structural integrity. The transfer layer  116  may be treated with surfactant on one or both sides in order to increase its wettability, although generally the transfer layer  116  is relatively hydrophilic and may not require treatment. The transfer layer  116  is preferably bonded on both sides to the adjacent layers, i.e. the cover layer  112  and the absorbent core  118 . 
     Absorbent System—Absorbent Core 
     Immediately adjacent to and bonded to the transfer layer  116  is the absorbent core  118 . The absorbent core  118  is preferably a highly dense layer having a fine porosity. It has a large liquid holding capacity and it is extremely retentive. Most preferably, the absorbent core  118  is composed of compressed sphagnum moss material. More specifically, the sphagnum moss is formed as a board by air or wet laying and calendering to obtain a relatively thin, i.e. from about 0.01 to 0.10 inch (0.0254 cm to 0.254 cm) thick, relatively dense, i.e. from about 0.2 to 1.0 g/cm 3  sheet like structure. The structure may include a layer of Kraft tissue laminated on one or both surfaces of the sphagnum moss layer. Preferably, a fibrous component is admixed with the sphagnum moss material. The fibrous component is suitably a natural or synthetic textile fibre such as rayon, polyester, nylon, acrylic or the like, having a length of from about 0.25 to 1.5 inches (0.635 cm to 3.81 cm) and a denier of from about 1.0 to 5. The fibrous component may be present in an amount from about 2 to 20% by weight, most preferably from 4 to 8%. The absorbent core  118  may also comprise other components such as wood pulp, synthetic wood pulp, thermo-mecanical pulp, mechanically ground pulp, polymers; surfactants, superabsorbents and the like. 
     In an alternative embodiment the absorbent system  114  includes a single layer of pulp fluff material (the transfer layer is omitted). The absorbent core  116  preferably comprises a pulp fluff material and may optionally include other absorbent materials or non-absorbent materials which aid in stabilizing the absorbent structure such as conjugate fibres, fusible fibres, binders, sphagnum peat moss particles, superabsorbents, and the like and combinations thereof. and may optionally include other absorbent materials or non-absorbent materials which aid in stabilizing the absorbent structure such as conjugate fibres, fusible fibres, binders, sphagnum peat moss particles, superabsorbents, and the like and combinations thereof. 
     Barrier Layer 
     Underlying the absorbent system  114  is a barrier layer  120  comprising liquid-impervious film material so as to prevent liquid that is entrapped in the absorbent core from egressing the sanitary napkin and staining the wearer&#39;s undergarment. Most preferably, the barrier layer  120  is made of polymeric film, such as polyethylene which is both inexpensive and readily available. The polyethylene is capable of fully blocking the passage of liquid or gas that may emanate from the absorbent system  114 . In a variant, breathable films may be used that allow passage of gases while blocking liquid. 
     The cover layer  112  and the barrier layer  120  are joined along their marginal portions so as to form an enclosure that maintains the absorbent system  114  captive. The joint may be made by means of adhesives, heat-bonding, ultrasonic bonding, radio frequency sealing, mechanical crimping, and the like and combinations thereof. The peripheral seal line is shown in FIG. 3 by the reference numeral  121 . 
     Adhesive Strips 
     To retain the sanitary napkin  110  to the wearer&#39;s underpants, adhesive zones  122  and  124  are provided on the barrier layer  120 . The adhesive zones  124 , located over the flaps  126  and  128 , bond the flaps to the garment facing surface of the wearer&#39;s underpants, while the adhesive zone  122  serves to retain the sanitary napkin  110  to the body facing surface of the underpants. 
     Flaps 
     The flaps  126  and  128  are designed to be folded over the side edges of the wearer&#39;s underpants in the crotch portion and to be fastened to the garment facing surface of the underpants. The flaps  126  and  128  aid in securing the sanitary napkin  110  in place on the wearer&#39;s underpants, and in maintaining the structural integrity of the sanitary napkin  110  by providing a “spring-back” action during body movements of the wearer. The overall effect of the flaps  126  and  128  is to fasten and keep the sanitary napkin  110  in an optimal exposed shape to provide the maximum fluid-absorbing surface, whereby reducing the incidence of failure. 
     Flap Configuration—Prior Art 
     In FIG. 1 there is illustrated a sanitary napkin  010  with flap configuration of the prior art. Such a napkin is comprised of a main body  030  having a first transverse side  032 , an opposing second transverse side  034 , a first longitudinal side  036 , and an opposing second longitudinal side  038 . A first flap  026  and a second flap  028  project laterally from the main body  030  from the first longitudinal side  036  and the second longitudinal side  038 , respectively. The flaps  026  and  028  are in the shape of a bilaterally symmetrical trapezoid, with the base being located at the longitudinal side of the article. The top of the trapezoid forms the lateral side  040  and  042  of each flap  026  and  028 , respectively. 
     The contour of the sanitary napkin  010  is symmetric about both an imaginary centre-line  044  extending longitudinally down the sanitary napkin and an imaginary centre-line  046  extending transversely across the sanitary napkin  010 . Thus, there exists a line  048  which simultaneously symmetrically bisects the flaps  026  and  028 , and that line  048  is collinear with the transverse centre-line  046  of the napkin  010 . 
     In FIG. 2 there is illustrated a cutting pattern employed in the prior art to manufacture the napkin depicted in FIG. 1 from a web of at least one layer of continuous material. In such pattern, like transverse sides of successive napkins are aligned, i.e. the points of intersection  050   a ,  050   b ,  050   c  of the transverse side  032   a ,  032   b ,  032   c  of each napkin with the longitudinal centre-line  044   a ,  044   b ,  044   c  of the napkin are collinear, that line  052  is parallel to the transverse centre-line  046  of the article  010 , and that line  052  is perpendicular to the longitudinal centre-lines  044   a ,  044   b ,  044   c  of the napkins. The lateral sides of opposing flaps of successive articles face one another (e.g. the lateral side  040   a  of the first flap  026   a  of the first article  010   a  faces the lateral side  042   b  of the second flap  028   b  of the second article  010   b ). Such opposing lateral sides  040   a  and  042   b  are substantially in contact in that the distance between them within the pattern is the minimum clearance distance dictated by the die being used to sever them from the web. 
     The shaded area in between is not used to produce a napkin from the web of material and must be discarded as waste during the manufacturing process. 
     Flap Configuration—Present Invention 
     Referring to FIG. 3, a sanitary napkin  110  having a flap configuration of the present invention is comprised of a main body  130  having a first transverse side  132  and an opposing second transverse side  134 . Each transverse side is arcuate in shape with no particular curvature being essential to the present invention. The sanitary napkin  110  further has a first longitudinal side  136  and an opposing second longitudinal side  138 , each being generally straight. The shape of the napkin  110  when viewed from above, as shown in FIG. 3, is nearly rectangular. 
     A first flap  126  and a second flap  128  project laterally from the main body  130  from the first longitudinal side  136  and second longitudinal side  138 , respectively. Each of these flaps  126  and  128  is in the shape of a bilaterally symmetrical trapezoid, with the base being located at the longitudinal side of the article. The first flap  126  has a first longitudinal side  154  and a second longitudinal side  156  formed of the sides of the trapezoid, and a lateral side  140  formed of the top of the trapezoid. Similarly, the second flap  128  has a first longitudinal side  158  and a second longitudinal side  160  formed of the sides of the trapezoid, and a lateral side  142  formed of the top of the trapezoid. The first longitudinal side  154  of the first flap  126  and the first longitudinal side  158  of the second flap  128  each face in the same direction as does the first transverse side  132  of the main body  130  of the napkin  110 . In the same respect, the second longitudinal side  156  of the first flap  126  and the second longitudinal side  160  of the second flap  128  face in the same direction as does the second transverse side  134  of the main body  130  of the napkin  110 . 
     The contour of the sanitary napkin  110  is symmetric about an imaginary centre-line  144  extending longitudinally down the sanitary napkin  110 . A single line  148  simultaneously symmetrically bisects both the first flap  126  and the second flap  128 . A second centre-line  146  extends transversely across the sanitary napkin  110 , from which the flaps  126  and  128  are offset. By offset it is meant that the line  148  which symmetrically bisects the flaps is not collinear with the transverse centre-line  146  of the napkin  110 . The amount by which the flaps  126  and  128  are offset is described below in relation to the cutting pattern for the present napkin. 
     In FIG. 5 there is illustrated a cutting pattern of the present invention to be employed in the manufacture of sanitary napkins of the present invention from a web of a least one continuous material. In such a pattern successive napkins  110 ,  210 ,  310  are positioned side-by-side, and are rotated. The first transverse side  132  of the first napkin  110 , the second transverse side  234  of the second napkin  210 , and the first transverse side  332  of the third napkin  310  all face in a similar direction. Similarly, the second transverse side  134  of the first napkin  110 , the first transverse side  232  of the second napkin  210 , and the second transverse side  334  of the third napkin  310  all face in the same direction. The alternating sides of successive articles are aligned within the pattern, i.e. the points of intersection  150 ,  250 ,  350  of these transverse sides  132 ,  234 ,  332  (respectively) of these napkins  110 ,  210 ,  310  with their longitudinal centre-lines  144 ,  244 ,  344  (respectively) are collinear, the line  152  formed by connecting such points  150 ,  250 ,  350  is parallel to the transverse centre-lines  146 ,  246 ,  346  of the napkins, and that line  152  is perpendicular to the longitudinal centre-line  144 ,  244 ,  344  of the napkins. 
     Further, in the pattern illustrated in FIG. 5, like longitudinal sides of successive articles face one another. Thus, the first longitudinal side  136  of the first napkin  110  faces the first longitudinal  236  of the second napkin  210 , and the second longitudinal side  238  of the second napkin  210  faces the second longitudinal side  338  of the third napkin  310 , and so on. 
     The first flap  126 ,  226 ,  326  and the second flap  128 ,  228 ,  328  of the napkin  110 ,  210 ,  310  are positioned with respect to the main body  130 ,  230 ,  330  (i.e. are offset from the transverse centre-line  146 ,  246 ,  346 ) such that like longitudinal sides of like flaps of successive napkins are substantially in contact with one another. In FIG. 5, the second longitudinal side  156  of the first flap  126  of the first napkin  110  is in complete contact with the second longitudinal side  256  of the first flap  226  of the second napkin  210 . Similarly, the second longitudinal side  260  of the second flap  228  of the second napkin  210  is in complete contact with the second longitudinal side  360  of the second flap  328  of the third napkin  310 . 
     When such flaps are in complete contact, the lateral sides of the flaps will be substantially in contact with the longitudinal side of the facing napkin. Thus, as is shown, the lateral side  140  of the first flap  126  of the first napkin  110  is in contact with first longitudinal side  236  of the main body  230  of the second napkin  230  and the lateral side  240  of the first flap  226  of the second napkin  210  is in contact with the first longitudinal side  136  of the main body  130  of the first napkin  110 . Similarly, the lateral side  242  of the second flap  228  of the second napkin  210  is in contact with the second longitudinal side  338  of the main body  330  of the third napkin  310 , and the lateral side  342  of the second flap  328  of the third napkin  310  is in contact with the second longitudinal side  238  of the main body  230  of the second napkin  210 . 
     The shaded area in between successive napkins is not used in the manufacture of any napkin and must be discarded as waste. By positioning the flaps of the napkin in accordance with the present invention, the amount of waste material generated is significantly reduced as compared with napkins of the prior art, as graphically illustrated in FIGS. 2 and 5. 
     Method of Manufacture of Napkins of the Present Invention 
     FIG. 3 illustrates schematically the various steps in the assembly process of the sanitary napkin. In a first step, there is provided a continuous strip  400  of fluid impervious material which will form the barrier layer of the napkin which has the desired thickness and is of appropriate width. This width is equal to the length of longitudinal centre-line of the articles being manufactured plus any additional width necessary for the handling of the material by the manufacturing apparatus. 
     In a subsequent step, absorbent cores  402  are serially applied to the continuous web in a spaced apart relationship in the desired position. The position of each absorbent core on the web is selected according to the pattern by which the final products will be severed from the web. The exact application and positioning of the cores along the web may be accomplished by several means including a conveyor belt or vacuum drum. 
     In a subsequent step, a transfer layer  404  is applied to the absorbent core by a similar means as with the cores. A second continuous strip  406  of fluid-permeable material forming the cover layer of the final articles then applied. This strip will contact the transfer layers disposed along the first web, and the barrier layer strip in areas where no absorbent core/transfer layer is located. 
     The superposed layers are sealed together at sealing station  408  along the margins of the absorbent cores in a desired pattern to form a continuous compound web. There are a number of methods which may be used to accomplish this task, such as adhesives, heat-sealing, and mechanical crimping, among others. A continuous, laminated, sealed web of material is thus formed. Adhesive strips are then applied (not shown) to the exterior surface of the barrier layer material. 
     It should be noted that the method described above could be modified to form the sanitary napkins upside down, which involves starting with the cover layer rather than the barrier layer. This variant also requires to change the order of deposition of the transfer layer and the absorbent core, the transfer layer being placed first followed by the absorbent core. Finally, the barrier layer is put in place and the compound web is sealed. 
     The final step in the process is to sever the individual articles from the continuous, laminated, sealed web of material, at cutting station  410  that uses a die-cutting roll  412 . In this respect, individual articles are severed along the dark line appearing in FIG. 5 by die-cutting. 
     A second aspect of the present invention allows for the manufacture of sanitary absorbent articles having a prior art flap configuration as depicted in FIG. 1 with less waste material generated. This method of manufacture is generally the same as that previously described with respect to the first aspect, except that the absorbent cores/transfer layers are positioned within the web according to the cutting pattern described hereinbelow. 
     In this configuration, the napkins  010   a ,  010   b ,  010   c ,  010   d  are positioned side-by-side with successive articles being of the same orientation (i.e. Opposite longitudinal sides of successive napkins face one another. Thus, the first longitudinal side  036   a  of the first article  010   a  faces the second longitudinal  038   b  of the second article  010   b  and the first longitudinal side  036   b  of the second article  010   b  faces the second longitudinal side  038   c  of the third article  010   c .) The points of intersection  050   a ,  050   b ,  050   c ,  050   d  of like transverse sides  032   a ,  032   b ,  032   c ,  032   d  of each napkin  010   a ,  010   b ,  010   c ,  010   d  with the longitudinal centre-line  044   a ,  044   b ,  044   c ,  044   d  of that napkin are collinear. However, note that line  052  is not parallel to the transverse centre-line  046   a ,  046   b ,  046   c ,  046   d  of the napkins, nor is that line  052  perpendicular to the longitudinal centre-line  044   a ,  044   b ,  044   c ,  044   d  of each napkin. 
     Opposite longitudinal sides of opposite flaps of successive napkins are substantially in contact with one another. Thus, the first longitudinal side  054   a  of the first flap  026   a  of the first napkin  010   a  is substantially in contact with the second longitudinal side  060   b  of the second flap  028   b  of the second napkin  010   b . Similarly, the first longitudinal side  054   b  of the first flap  026   b  of the second napkin  010   b  is substantially in contact with the second longitudinal side  060   c  of the second flap  028   c  of the third napkin  010   c . Similarly, the lateral side  040   b  of the first flap  026   b  of the second napkin  010   b  is substantially in contact with the second longitudinal side  038   c  of the main body  030   c  of the third napkin  010   c , and the lateral side  042   c  of the second flap  028   c  of the third napkin  040   c  is in substantially in contact with the first longitudinal side  036   b  of the main body  030   b  of the second napkin  010   b.    
     A third aspect of the present invention also allows for the manufacture of sanitary absorbent articles having a prior art flap configuration is depicted in FIG. 1 with less waste material generated. This method of manufacture is generally the same as those previously described with respect to the first and second aspects, except that once again the absorbent cores/transfer layers are positioned within the web according to the cutting pattern described hereinbelow. In this respect, illustrated in FIG. 7 is the positioning of final articles within the continuous sealed web of the present embodiment, and the cutting pattern therefor. 
     In this configuration, the napkins  010   a ,  010   b ,  010   c  are positioned side-by-side with successive articles being of the same orientation as the last, however, only a portion of opposite longitudinal sides of successive napkins face one another. Thus, a portion of the first longitudinal side  036   a  of the first article  011   a  faces a portion of the second longitudinal  038   b  of the second article  010   b  and a portion of the first longitudinal side  036   b  of the second article  010   b  faces a portion of the second longitudinal side  038   c  of the third article  010   c . The points of intersection  050   a ,  050   b ,  050   c  of like transverse sides  032   a ,  032   b ,  032   c  of each napkin  010   a ,  010   b ,  010   c  with the longitudinal centre-line  044   a ,  044   b ,  044   c  of that napkin are collinear. However, note that line  052  is not parallel to the transverse centre-line  046   a ,  046   b ,  046   c  of the napkins, nor is that line  052  perpendicular to the longitudinal centre-line  044   a ,  044   b ,  044   c  of each napkin. 
     As is illustrated in FIG. 7, it is preferred that the contacting portions of the longitudinal sides of successive articles be substantially in contact with one another in order to minimize waste material generated. 
     The above description of a preferred embodiment should not be interpreted in any limiting manner since variations and refinements are possible which are within the spirit and scope of the present invention. The scope of the invention is defined in the appended claims and their equivalents.

Technology Classification (CPC): 8