Patent Description:
Improvements in manufacturing techniques and developments in materials technologies have allowed manufacturers of disposable diapers to reduce the quantities of materials used in manufacture and reduce the size, bulk and/or weight of various components of such products. For example, the development and improvement of superabsorbent polymers (also known as absorbent gelling materials), and improvements in absorbent core designs, have enabled manufacturers to reduce the size and bulkiness of absorbent core components. Improvements in polymer materials and processing techniques have enabled manufacturers to use lower basis weight components including lower basis weight nonwoven web materials and film materials. This has enabled per-unit savings in costs of materials and shipping, without compromising the absorbency or containment functions of the products.

As a result of these improvements, current diaper designs, while relatively light, non-bulky and economical, also may have attributes perceived negatively by some consumers. In some current designs, the upper waist regions of the diapers may have relatively little or no absorbent material and may consist only of a few layers of relatively low basis weight, thin web materials. In such current designs, the upper waist regions may have an insubstantial, flimsy feel to the consumer. Additionally, with reduction of materials basis weights (and associated reduction of caliper), the upper waist regions may be less stiff than those of other/earlier products, and thereby less supportive of traditional fastening systems and more prone to wrinkling, flipping or sagging on the wearer, particularly when the diaper is loaded with the weight of the wearer's exudates and/or the wearer is relatively active.

Consequently, any cost-effective methods and/or features for improving the waist region structure and the fastening systems may provide the manufacturer of the product a competitive advantage.

<CIT> discloses a method of providing an absorbent article with a belt attached to the back region of the article. The belt comprises first and second belt halves which are in overlapping arrangement and one of which is provided with a fastening component in the form of hook material. In use, the first and second belt halves encircle the wearer's waist.

<CIT> discloses a method of providing a closure system for an absorbent article. The closure system, once assembled into the absorbent article, comprises a pair of fastening tabs arranged in a back region of the article and a centrally-positioned attachment portion in a front region of the article.

<CIT> discloses a method of manufacturing fastening tapes which are assembled into the back waist region of an absorbent article.

The invention provides a method according to claim <NUM>. Optional features of the method are set out in the dependent claims,.

"Absorbent article" means a device that absorbs and contains body exudates and, more specifically, devices that are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Exemplary absorbent articles include diapers, refastenable diapers or pant-type diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene garments such as panty liners, absorbent inserts, and the like.

"Disposed" refers to an element being located in a particular place or position. A feature that is disposed on a surface or side of a component may be integral with said component or may be joined to said component.

"Elastic" and "elastomeric" mean the ability of a material to stretch by at least <NUM>% without rupture or breakage at a given load, and upon release of the load the elastic material or component exhibits at least <NUM>% recovery (i.e., has less than <NUM>% set) in one of the directions as per the Hysteresis Test described herein. Stretch, sometimes referred to as strain, percent strain, engineering strain, draw ratio, or elongation, along with recovery and set may each be determined according to the Hysteresis Test described in more detail below. Materials that are not elastic are referred as inelastic.

"Integral with" a component means being formed from or formed by said component, or portions thereof, as opposed to being joined to the component.

"Joined" means configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) that in turn are affixed to the other element.

"Longitudinal" means a direction lengthwise in a component such that the longitudinal direction runs parallel to the maximum linear dimension in the x-y plane of the component. In an absorbent article as described herein, the longitudinal direction runs substantially perpendicular from a waist end edge to an opposing waist end edge when the absorbent article is in a flat out, uncontracted state, or from a waist end edge to the bottom of the crotch in a bifolded article.

"Lateral" refers to a direction generally perpendicular to the longitudinal direction. In the absorbent article described herein, the lateral direction runs substantially parallel from a side edge to an opposing side edge.

"Length" refers to a dimension in the longitudinal direction. The "width" of a feature is its dimension in the lateral direction.

"Inboard," with respect to a first feature of an article and its position relative a second feature or location on the article, means that the first feature lies closer to a respective axis of the article than the second feature or location, along a horizontal x-y plane approximately occupied by the article when laid out flat, extended to the full longitudinal and lateral dimensions of its componentweb materials against any contraction induced by any included pre-strained elastomeric material, on a horizontal surface. Laterally inboard means the first feature is closer to the longitudinal axis, and longitudinally inboard means the first feature is closer to the lateral axis. Conversely, "outboard," with respectto a first feature of an article and its position relative a second feature or location on the article, means that the first feature lies farther from the respective axis of the article than the second feature or location.

"Machine direction," with respect to a material or assembly of materials moving through a processing or manufacturing line, means a direction parallel to the direction of movement through the line. "Cross direction" means a direction perpendicularto the direction of movement through the line.

The "outward-facing" surfaces of a diaper or a component thereof are the surfaces that face away from the wearer when the diaper is worn.

"Registration," "register," "registered," or "registering" refer to a machine control process or system for controlling the placement of objects (e.g., indicia, ears, fastening components) on a substrate or laminate at target positions. Target positions may be determined by preset intervals and/or relative to specific locations or features disposed on the substrate or laminate.

The "wearer-facing" surfaces of a diaper or a component thereof are the surfaces that face toward the wearer when the diaper is worn.

<FIG> are plan views of an exemplary, nonlimiting examples of an absorbent article <NUM> in the form of a diaper <NUM>, shown on the outward-facing side <NUM>. The absorbent article may be disposable. <FIG> is a plan view of an exemplary, nonlimiting example of a diaper <NUM> with the wearer-facing side <NUM> facing the viewer. As shown in <FIG>, the absorbent article <NUM> comprises a chassis <NUM> formed of a liquid permeable topsheet <NUM>, a liquid impermeable backsheet <NUM>, and an absorbent core <NUM> disposed therebetween. The article <NUM> may further include an acquisition distribution system <NUM> disposed between the topsheet and absorbent core. In some nonlimiting examples, the absorbent core includes one or more channels <NUM>.

The article <NUM> and chassis <NUM> have a front waist region <NUM>, a rear waist region <NUM> opposed to the front waist region <NUM>, and a crotch region <NUM> located between the front waist region <NUM> and the rear waist region <NUM>. The article <NUM> includes a longitudinal centerline <NUM> and a lateral centerline <NUM>. The outer periphery of the article <NUM> is defined by longitudinal edges <NUM> and waist edges (front waist edge <NUM> in front waist region <NUM> and rear waist edge <NUM> in rear waist region <NUM>). The article <NUM> may have opposing longitudinal edges <NUM> that are oriented generally parallel to the longitudinal centerline <NUM>. However, for better fit, longitudinal edges <NUM> may be curved or angled to produce, for example, an "hourglass" shape article when viewed in a plan view as shown in <FIG>.

Returningto <FIG>, one or more cuff structures <NUM> may be disposed on the wearer-facing side and may have portions affixed thereto by any suitable mechanism. Cuff structures <NUM> may have any form known for disposable diapers, and are variously known as barrier cuffs, standing cuffs, barrier leg cuffs, longitudinal cuffs, barrier flaps, etc. In some examples, the cuff structures <NUM> may have the configurations and materials described in, for example, <CIT> and <CIT>. Free distal edges <NUM> of cuff structures <NUM> may have longitudinally-oriented elastic strands, strips or other cuff elastic members <NUM> disposed therealong, contraction of which will cause the cuff structures to gather longitudinally along their free edges <NUM> and provide a gasketing barrier along the wearer's body through the crotch region <NUM> to help contain exudates. The cuff elastic members <NUM> may be disposed in the cuff structures in a longitudinally pre-strained condition.

The article may comprise one ormore waist features <NUM>, which may be disposed in the front and/or rear waist regions. In some nonlimiting examples, one or both of the article's waist edges <NUM>, <NUM> may be at least partially defined by a waist feature as illustrated in <FIG>. In further nonlimiting examples, a waist feature may be disposed inboard of the closest waist edge. A waist feature may be integral with one or more layers of the chassis, cuff structures and/or other elements in the waist region, or may be joined to one or more layers of the chassis, leg cuff structures and/or other elements disposed in the waist region. The waist feature may be joined between layers (<FIG> in front waist region), on the outward-facing surface <NUM> of the article (<FIG> in rear waist region), or on the wearer-facing surface <NUM> of the article (<FIG>). The waist feature may be extensible or elastic. An elasticized waist feature <NUM> is generally intended to expand and contract to dynamically fit the wearer's waist. Elasticized waist features include waistbands, waist cuffs having pockets formed from a portion of the waist feature that is unattached from the chassis, and waist panels designed to fit securely about the abdomen of the wearer. Nonlimiting examples of elasticized waist features are disclosed in <CIT>, published as <CIT>; and <CIT>, published as <CIT>. Elasticized waist features may comprise one or more nonwoven layers and one or more elastic elements <NUM>. In nonlimiting examples, the elasticized waist feature comprises elastic strands joined to the nonwoven layer(s). In further nonlimiting examples, the elasticized waist feature comprises a laminate of one or more nonwoven layers and one or more films.

In alternative embodiments, the waist feature may be inelastic. In such configurations, the waist feature may provide additional anchoring about the waist of the wearer.

A waist feature can be used in conjunction with an ear to provide desirable stretch and flexibility, or otherwise enhance fit of the article on the wearer.

Longitudinal edges <NUM> may be formed of the longitudinal edges of any of the backsheet <NUM>, topsheet <NUM>, laterally outboard portions of cuff structures <NUM>, or a layered combination of any of these. Longitudinal edges <NUM> may be cut and/or contoured as suggested in <FIG>, or may be straight as suggested in <FIG>. Longitudinal edges <NUM> also may have longitudinally-oriented elastic strands, strips or other leg band elastic members <NUM> disposed therealong, to cause the longitudinal edges <NUM> to gather about the wearer's legs, as shown in <FIG>. For example, leg band elastic members <NUM> may be sandwiched between the topsheet <NUM> and the backsheet <NUM>, or between the material forming the cuff structures <NUM> and the backsheet <NUM>, between the material forming the cuff structures <NUM> and the topsheet <NUM>, or within a fold or layers of material forming the cuff structures <NUM>, proximate to the longitudinal edges. The leg band elastic members <NUM> may be disposed along the longitudinal edges <NUM> in a pre-strained condition.

Returning to <FIG>, the article <NUM> may include a fastening system <NUM>, which may comprise a fastening component <NUM> disposed on a base member <NUM> in the rear waist region <NUM>. In nonlimiting examples, the article may include a pair of base members, respectively extending laterally away from the longitudinal edges, and away from the longitudinal axis <NUM> of the diaper in the rear waist region <NUM>, and a pair of fastening components <NUM> disposed proximate to opposite longitudinal edges. Base members <NUM> may be formed of continuous lateral extensions of the material forming backsheet <NUM> and/or topsheet <NUM> as suggested in <FIG>; or, as suggested in <FIG>, may each be formed of a separate piece of material that is affixed to the chassis, for example, to the topsheet <NUM> and/or the backsheet <NUM>, at attachment locations via chassis attachment bonds <NUM>. Chassis attachment bonds <NUM> may be present to bond the base members to materials of one or more of the topsheet, backsheet and cuff structure via heat and/or compression (causing a mechanical intertangling and/or intermixing and fusing of materials), adhesive, or any combination thereof. Base members <NUM> may be affixed to the outward-facing side of the backsheet <NUM>, or to the wearer-facing side of the topsheet <NUM>, or to a wearer-facing side of material forming the cuff structures <NUM>. Alternatively, base members <NUM> may be sandwiched between the layers of the chassis <NUM> or between the chassis and cuff structure. A base member <NUM> may be in the form an ear <NUM>, such that the base member <NUM> extends laterally outboard of the longitudinal edge <NUM> in the crotch region, as shown for example in <FIG>.

A base member may comprise on or more polymeric layers. In a non-limiting example, base members <NUM> may be formed of a material configured to exhibit elastic stretch and contraction in the lateral direction, enhancing comfort and secure fit of the diaper about the wearer. The base member may comprise an elastic laminate, which may comprise a combination including an elastomeric polymeric material (such as a film, or laterally-oriented strips or strands formed of elastomeric polymer) layered, laminated or interspersed with one or more layers of nonwoven material. In some examples, the base member may comprise a laminate of an elastomeric film sandwiched between two layers of nonwoven material. Suitable laminate materials are described in, for example, PCT Application No. <CIT>, and U. Application Publication Nos. <CIT>; <CIT>; <CIT> and <CIT>. The base member <NUM> may comprise a gathered laminate, wherein one of the layers is strained to a greater degree than a remaining layer during lamination and/or bonding. In this way, the less extensible layer (i.e., a nonwoven) will form gathers when the laminate is in a relaxed state. Corrugations then form in the nonwoven layer(s) when the subsequently formed laminate is in a relaxed state. The base member may comprise an ultrasonically bonded laminate as is disclosed for example in <CIT>, <CIT>; <CIT>; and <CIT>. Alternatively, the base member <NUM> may be activated by processes disclosed in <CIT>, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT> for example.

Still referring to <FIG>, the article may comprise a primary fastening system <NUM>, which includes a primary first component <NUM>. In nonlimiting examples, the diaper may include a pair of primary first components <NUM> each disposed respectively on a wearer-facing side of one of respective left and right base members <NUM>. The primary fastening system also may comprise one or more primary second components <NUM> disposed on an outward-facing side of the front waist region <NUM>. The primary first component is operatively engageable with the primary second component such that the primary fastening system secures the article about the waist and/or hip of the wearer. Nonlimiting examples of engageable fastening components include tape tabs, hook and loop fastening components, interlocking fasteners such as tabs & slots, buckles, buttons, snaps, and/or hermaphroditic fastening components. Some exemplary surface fastening systems are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. An exemplary interlocking fastening system is disclosed in <CIT>. The primary first component and/or the primary second component may further include a release tape or other material that protects the component from insult prior to use. In nonlimiting examples, the primary first component and/or the base member is foldable and may be folded prior to use such that the primary first component engages with material (e.g., base member material) that protects it from insult.

A base member <NUM> may terminate at a distal end <NUM> via a section of tape, strip or other suitable end member affixed to the main portion of the base member <NUM>. Alternatively, the end portion of the base member <NUM> may simply be formed of extension(s) of one or more of the material(s) forming the main portion of base member <NUM>. Each base member <NUM> may have a primary first component <NUM> disposed thereon proximate to distal end <NUM>, attached thereto by adhesive, thermal and/or compression bonding or any other suitable attachment mechanism. Primary first component <NUM> may be any suitable type of fastening component configured to fastenably engage an outward-facing surface of the diaper at a landing zone <NUM> disposed in the front waist region <NUM>. In a nonlimiting example, primary first component <NUM> may be a patch of hooks, and landing zone <NUM> may be defined by and/or be formed of a material adapted to receive and fastenably engage the hooks, thereby providing the primary second component <NUM> in a hook-and-loop fastening system. Primary second component <NUM> may be formed of a section of web material <NUM> overlying the backsheet to the outward-facing side thereof. In particular non-limiting examples, the section of web material <NUM> may be a nonwoven web material. The nonwoven web material formed of bicomponent or multicomponent fibers such as, for example, described in <CIT>; U. <NUM>/<NUM>; <NUM>/<NUM> and <CIT>. Itmay be desirable that the force required to detach the primary first component from the web material <NUM> be at least about <NUM> N shear force to ensure secure and prolonged fastening. In further nonlimiting examples, the section of web material <NUM> may comprise a film or a laminate of nonwoven and film material.

In some examples, the primary first component <NUM> may be separately applied sections or patches of hooks material that are bonded by heat, compression, adhesive, ultrasonic bonding or any combination thereof. In other examples, primary first components may be patches of hooks that are formed directly on a section of the base member, more particularly formed directly on a section of a polymeric layer of the base member. For example, the hooks may be produced via application of molten polymer resin onto the layer, and subsequent formation of hooks in and from the melted, applied resin via known methods. The primary first components may be integrally formed from the polymeric material by heating and softening a portion of the material and pressing it into hook-forming cavities, as is disclosed in <CIT>. The primary first components may be integrally formed from the polymeric material through a single continuous process as is disclosed in commonly assigned <CIT>, published as <CIT>.

Many disposable diapers currently marketed include front ears <NUM>, laterally extending from the front waist portion of the diaper near the front waist edge, proximate to and/or extending from the left and right longitudinal edges. Front ears serve to provide the caregiver a laterally protruding front portion of the diaper to easily grasp and tug along each side, facilitating fastening of each fastening member <NUM> to the landing zone <NUM> of the front waist region. Front ears also serve to provide additional coverage of the wearer's skin in the hip regions. Current designs have front ears which are either extensions of one or more of the backsheet and topsheet materials, or alternatively, are formed of separate sections of material bonded to one or more of the topsheet, backsheet and/or cuff structure so as to extend laterally from the left and right sides of the main chassis.

Where the front ears are extensions of one or more of the backsheet and topsheet materials, manufacturing necessarily includes a profiled cutting of these materials to provide the extending front ear portions, and associated material waste. When the front ears are formed of separate sections of material bonded to one or more of the topsheet, backsheet and/or cuff structure, manufacturing must include steps associated with placing and bonding these front ear components to the chassis.

As an alternative, however, a section of web material <NUM> may be selected so as to be suitable for not only serving as the primary second component <NUM>, but also for forming and providing one or more front ears <NUM>, when cut to a size which allows for the section of web material <NUM> to extend laterally beyond the chassis along the longitudinal side(s). In some nonlimiting examples, at least a portion of the web material <NUM> may be adapted to receive and fastenably engage hooks included as or with primary first components <NUM>, and thereby serve as the loops component of a hook-and-loop primary fastening system. In further examples, a portion of the nonwoven web material may be pattern bonded in a pattern of thermal bonds configured to enhance the strength and reliability of the material and of the loops structures it provides, as well as the fastening properties of the material. Suitable pattern bonding is disclosed in <CIT> under attorney docket number <NUM>.

This dual use of such a section of web material <NUM> can serve to both provide or support a suitable primary second component <NUM> and provide front ears <NUM>, eliminating the need for other configurations and steps for providing front ears as described above. Additionally, the inclusion of the section of web material <NUM> to supplement the other materials of the chassis provides apparent and actual added lateral tensile strength, bending resistance, caliper and robustness to the front waist region.

The section of web material <NUM> that both (i) provides and/or supports a second component <NUM> of a fastening system and (ii) forms one or more ears <NUM>, will also be referred to as "a combination belt structure" <NUM> herein.

As shown in <FIG>, the combination belt structure may comprise a maximum longitudinal length, N, of about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, reciting for each range every <NUM> increment therein. The combination belt structure may comprise a maximum lateral width, M, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, reciting for each range every <NUM> increment therein.

The combination belt structure may be bonded or adhered to an outward-facing surface of the backsheet <NUM> or other material forming an outward-facing surface of the diaper in the front waist region <NUM>, by any suitable bonding mechanism including, for example, adhesive material(s). In some embodiments, the bonding pattern should not exceed backsheet edge <NUM> and preferably ends inboard of longitudinal edge <NUM> to avoid exposing adhesive to the wearer's skin. Additionally, or alternatively, the web material <NUM> may be decoupled from the chassis and/or other material that forms the outward-facing surface of the diaper in one or more areas in the front waist region. In the nonlimiting example shown in <FIG>, the layers of the belt structure and chassis may be joined in an anchoring zone <NUM>, which is bounded by a perimeter P. Outside of said perimeter, the layers may be unattached, attached in a weaker and/or more extensible manner than in the anchoring zone (e.g., activated to increase extensibility), thereby creating a decoupled zone <NUM>. The decoupled zone is adjacent to one or more portions of the perimeter. The perimeter may comprise substantially straight portions and/or curvilinear portions. In some nonlimiting examples, straight portions may be disposed at angle of <NUM>-<NUM>° with respect to the lateral or longitudinal axis.

Referring to <FIG> and <FIG>, in some examples, two discrete sections of web material <NUM> may be provided to provide respective left and right front ears <NUM> and provide or support respective left and right primary second components <NUM>. In some circumstances, this configuration may simplify and/or reduce costs of manufacturing. For the avoidance of doubt, the discrete sections comprise a combination belt structure <NUM> as they each provide both support for a primary second component <NUM> and form an ear <NUM>.

Referring to <FIG>, in some examples, the inboard and/or outboard lateral edges <NUM>, <NUM> of the section(s) of web material <NUM> may be curved rather than straight. In the example depicted in <FIG>, the inboard lateral edge <NUM> in the front ear portion <NUM> has a concave curvature laterally outboard of the chassis. Such a curvature may provide for a comfortable and/or visually attractive fit of the diaper about the wearer, at the hip areas. Such a curvature may be accompanied by a curvature of the outboard lateral edges <NUM> having a profile that is parallel to that of the inboard lateral edge <NUM>, which allows for nesting of shapes for the section(s) of web material <NUM> during manufacturing, enabling maximum usage of the web material component and/or minimization of waste.

In further nonlimiting examples, it may be desired that the inboard lateral edges <NUM> of front ears <NUM> extend downward toward the lateral axis of the diaper, outboard of the longitudinal edges <NUM> of the chassis. This may be desired in some circumstances to provide greater coverage of the wearer's skin at the hip areas, or to provide greater assurance that a portion of the section of web material <NUM> forming the front ears is presentto protect the wearer's skin from possible contact with a fastening component.

Further to the above, a front ear <NUM> may be configured to fit about the upper thighs and hip region of the wearer. When the ear is provided as a portion of a combination belt structure <NUM>, the belt <NUM> may be adapted to be fit the complex geometry that includes both the front waist area and at least a portion of the hip and upper thigh regions of the wearer. As shown in <FIG> and <FIG> for example, the beltmay have a varying width throughout at least a portion of its longitudinal length. As illustrated in <FIG>, a longitudinal edge <NUM> may comprise a curvilinear shape. The curvilinear shape may have at least two convexities <NUM> and <NUM> and at least one concavity <NUM> disposed intermediate the two convexities. The convexities may be disposed at different lateral positions, such that one is more laterally inboard relative to the other. In some embodiments, one convexity <NUM> may be disposed both laterally outboard and longitudinally outboard of the other convexity <NUM>. In embodiments where the article (orbelt) comprises two ears disposed on opposite lateral sides, each ear may comprise two convexities with one concavity therebetween. In such embodiments, the lateral distance between longitudinally outboard convexities <NUM> may be greater than the lateral distance between the two longitudinally inboard convexities <NUM> (see <FIG>). Without wishing to be bound by theory, it is believed these embodiments allow the belt to fit smoothly into the body's complex geometry and provides a more comfortable wearing experience by allowing the wearer's legs to move with less hindrance from material (i.e., the belt is narrower near the upper thighs) while maintaining a secure fit around the waist. In addition, minimizing the amount of material proximate to the inboard edge reduces the likelihood of the material folding over when positioned beneath the base member during application, and thereby increases fit and comfort.

Referring to <FIG>, the ear <NUM> may comprise a grip portion <NUM>. The grip portion <NUM> is an area of the ear that may be used to pull the front ear flat while wrapping the rear waist region about the wearer to fasten. In certain embodiments, the grip portion is located closer to the outboard lateral edge <NUM> of the ear than the inboard lateral edge <NUM>. The ear may be configured to identify the grip portion. In nonlimiting examples, the ear (or combination belt structure comprising the ear) comprises its largest width at a convexity <NUM> as shown in <FIG>. Without being bound by theory, it is believed that such configuration intuitively indicates an area suitable for a thumb and/or finger grip as shown in <FIG>. Additionally, or alternatively, the grip portion <NUM> may be provided with a signal <NUM> to distinguish the area from the remaining ear. The signal may comprise a color, a texture, pattern (e.g., bond pattern), and/or indicia (e.g., words, logos, trademarks).

Additionally, or alternatively, the front waist region may comprise a variation in stiffness. The stiffness of the front waist region may vary in the lateral direction. Turning to <FIG>, in certain embodiments, the front waist region comprises a bending resistant zone <NUM>, which is at least partially disposed outboard of the longitudinal edge <NUM>. The bending resistant zone <NUM> may comprise a Stiffness of at least about <NUM> N/mm, or at least about <NUM> N/mm up to about <NUM> N/mm, or up to about <NUM> N/mm, or from about <NUM> N/mm to about <NUM> N/mm, or from about <NUM> N/mm to about <NUM> N/mm reciting for said range each <NUM> N/mm increment therein, according to the Stiffness Test Method herein. The bending resistant zone may include a portion of the combination belt structure. In nonlimiting examples, the bending resistant zone includes at least a portion of a front ear <NUM>. The bending resistant zone may be formed from the layers of the front ear (or layers of the combination belt structure comprising the front ear). One or more stiffening components <NUM>, such as additional nonwoven layer(s), may also be used to form the bending resistant zone.

The stiffening component may provide more stiffness to an ear <NUM> and/or provide or support a primary second component <NUM>. Additionally, or alternatively, the stiffening component may provide or support a secondary first component <NUM>. The stiffening component <NUM> may comprise a separate layer of material as shown in <FIG> and/or a folded layer of material, such as a folded belt or ear, as shown in <FIG>. The stiffening component may comprise a nonwoven, a film, an adhesive and combinations thereof. Additionally, or alternatively, the stiffening component may comprise intermittent bonding to create a three-dimensional structure, such structure being more bending resistant than flat structures formed from continuous bonding In nonlimiting examples, the stiffening component is disposed in overlapping relationship with the attachment means <NUM> of the combination belt structure - chassis composite. It is also contemplated that the stiffening element <NUM> be joined to the combination belt structure or to the chassis outside or separate from the area of attachment.

The stiffening component may have dimensions that correspond to the combination belt structure. Alternatively, the stiffening component may be different in shape or area than the combination belt structure. The stiffening component may comprise a maximum width, SW, of about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, reciting for each range every <NUM> increment therein. In nonlimiting examples, the stiffening component may comprise a maximum width, SW, that is less than the maximum width, M, of the combination belt structure as shown for example in <FIG>. In this way, less material may be utilized, and the stiffening component may be positioned only where enhanced stiffness is desired. In other nonlimiting examples, the stiffening component comprise a maximum width, SW, that is greater than or equal to the maximum width, M, of the combination belt structure. In further nonlimiting examples, the stiffening component may extend laterally outboard of a longitudinal edge <NUM> of the combination belt structure. In such examples, the stiffening component may serve to provide additional coverage of the wearer's skin in the hip region and/or allows for the use of different nonwovens (e.g., softer nonwovens) against the wearer's skin.

Returning to <FIG>, the stiffening component may comprise a maximum length, SL. The combination belt structure may comprise a maximum length, O, in the area of overlap between the stiffener and combination belt structure. The stiffener maximum length, SL, may be substantially equal to the maximum length of the combination belt structure in the overlap area, O, as shown in <FIG>, for example. Alternatively, the maximum length of the stiffening component, SL, may be greater than or less than the maximum length of the belt structure in the overlap area, O. In further nonlimiting examples, the stiffening component may extend laterally outboard of a lateral edge <NUM>, <NUM> of the combination belt structure. In such nonlimiting examples, the stiffening component may provide additional material around a fastening component, and thereby prevent exposure of the component (e.g., hooks) to the wearer's skin.

In further nonlimiting examples, an article comprises a first bending resistant zone <NUM> and a second bending resistant zone <NUM>, which may be disposed proximate to opposite longitudinal edges <NUM>, as shown in <FIG>. The second bending resistant zone may include a portion of the combination belt structure, such as at least a portion of a front ear, and is at least partially disposed outboard of the longitudinal edge <NUM>. The second bending resistant zone may comprise the same magnitude of stiffness as the first bending zone or the two zones may differ in stiffness.

Additionally, or alternatively, a bending resistant zone <NUM>, <NUM> may vary in the magnitude of stiffness from a reference zone <NUM> by at least about <NUM>%, or at least about <NUM>%, or at least about <NUM>%, or from about <NUM>% to about <NUM>% as determined by the Stiffness Test Method herein, reciting for said range every <NUM>% increment therein. The reference zone <NUM> is disposed entirely inboard of the longitudinal edges <NUM>. The reference zone may at least partially include a portion of the combination belt structure.

In some embodiments, the rear waist region comprises variations in stiffness as described herein with respect to the front waist region.

To supplement the primary fastening system, the article may include a secondary fastening system <NUM>, as is shown in <FIG> for example. The secondary fastening system may comprise a secondary first component <NUM> and a secondary second component <NUM>. In nonlimiting examples, the diaper may include a pair of secondary first components <NUM> disposed on an outward-facing surface of the front waist region and a pair of secondary second components <NUM> disposed on a wearer-facing surface of the rear waist region. The secondary first components <NUM> may be any suitable fastening component configured to fastenably engage with the secondary second components <NUM>, and vice versa. The secondary fastening first and second components may have any of the features noted above with respect to the primary first and second components respectively. The secondary fastening system may comprise any of the nonlimiting examples of engageable fastening components referenced above. In a particular example, secondary first components <NUM> may be patches of hooks, and material disposed on or forming the outward-facing sides of the base member may be, or include, material that serves as the loops component of a hook-and-loop fastening system. In nonlimiting examples, a wearer-facing layer forming the base member <NUM> may include a nonwoven material adapted to serve as a secondary second component <NUM> and fastenably engage with hooks constituting the secondary first components <NUM>. The secondary second component <NUM> may be formed from extensible material or substantially non-extensible material. As described above with respectto the primary first component, the secondary first component may be a separate patch of material joined to the web material or may be integrally formed from the web material by process described above.

Turningto <FIG>, in embodiments comprising a decoupledzone <NUM> and an anchoring zone <NUM>, the secondary first component may be at least partially disposed within the perimeter P of the anchoring zone.

In further nonlimiting examples, the web material comprising the secondary first component (e.g., hooks) may also comprise the primary second component (e.g., loops). Additionally, or alternatively, the polymeric material comprising the primary first component (e. g, hooks) may also comprise the secondary second component (e.g., loops). In such nonlimiting examples, said substrates (i.e., the web material, the polymeric material) may comprise a first constraint, where in any identifiable linear path along the section of material that.

at least partially overlies a bond or bonds in the pattern at a plurality of locations along the path. Further, the substrate may additionally comprise a second constraint, where the maximum identifiable dimension between locations at which bonds are overlaid by any such path is from <NUM> to <NUM>, more preferably from <NUM> to <NUM>, and even more preferably from <NUM> to <NUM>.

Further to the above, integral first components may be formed with varying directionality to provide different benefits in different sections of the component. For instance, hooks which are asymmetric about their vertical centerline (such that create an inverted J-shape or similar hook configuration) may be formed so that the open portion is pointed in the direction of expected engagement. In further nonlimiting examples, hooks in a front waist region may be imparted with directionality approaching or along the lateral direction and extending toward the longitudinal axis of the diaper. Such directionality provides mechanical structure extending in a direction opposite the ordinary direction of shear forces (directed away from the longitudinal axis in the front region) that would be exerted on the hooks in that region while the hooks are engaged during wear, providing for added fastening strength and/or more secure attachment, as compared with non-directional hooks of similar size, material utilization (shape volume) and numerical density. Hooks in the rear waist region may be imparted with directionality toward the longitudinal axis of the diaper (when the fastening member is in the open position). Such directionality would oppose the ordinary direction of shear forces that would be exerted on the hooks in the front waist region when the hooks are engaged (i.e., fastened) during wear, providing for added fastening strength and/or more secure attachment, as compared with non-directional hooks of similar size, material utilization (shape volume) and numerical density.

In certain embodiments, a fastening component may be longitudinally offset from a lateral edge of the component to which the fastening component is attached. As shown in <FIG> for example, a secondary second component <NUM> may be longitudinally offset from an outboard lateral edge <NUM> of the combination belt structure by at least about <NUM>, or at least about <NUM>, or at least about <NUM>, or from about <NUM> to about <NUM>, reciting for said range every <NUM> increment therein. In nonlimiting examples, a fastening component does not coincide with any lateral edge <NUM>, <NUM> of the component to which it is attached. It may be desired, for example, that each secondary first component <NUM> is disposed with its surface area and outer edges entirely within the surface area and outer edges of the component (e.g., combination belt structure <NUM>)to which it is joined.

The fastening component may have a maximum longitudinal length, Lmax, that is equal to or less than the longitudinal length of the component to which the fastening component is attached. For example, the maximum longitudinal length, Lmax, of the secondary second component may be less than the average longitudinal length of the component, L, in the area where the secondary second component is attached. Lmax, may be about <NUM>% or less, or <NUM>% or less, or <NUM>% or less, or from about <NUM>% to about <NUM>%, or from about <NUM>% to about <NUM>% of L, or from about <NUM>% to about <NUM>% or L, reciting for said range every <NUM>% increment therein. Additionally, or alternatively, Lmax may be less than L by at least about <NUM>, at least about <NUM>, or from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, reciting for each range every <NUM> increment therein. Without being bound by theory, it is believed that offsetting the fastening component from a lateral edge prevents exposing the fastening component to a wearer's skin. Tension on areas of the article may result in folding or collapsing of materials surrounding the fastening component. By positioning the fastening component away from an edge, folding and collapsing is less likely to result in exposing the fastening elements to the skin. In other words, the material would be required to deform more before such exposure could occur.

Additionally, or alternatively, a fastening component may be laterally offset from a longitudinal edge of a component to which it is attached. For instance, an outboard longitudinal edge <NUM> of a secondary first component <NUM> may be laterally inboard of a longitudinal edge of an ear <NUM> by at least about <NUM>, or at least about <NUM>, or at least about <NUM>, or from about <NUM> to about <NUM>, reciting for said range every <NUM> increment therein. In nonlimiting examples, the outboard edge <NUM> of the secondary second component may be laterally inboard of a longitudinal edge <NUM>.

It may be desired to cut or otherwise impart at least the lower edges of secondary first components <NUM> with rounded profiles or profiles other than <NUM> degree corners, rather than sharp corners as in a rectangular shape as depicted in the figures. This may be deemed desirable for purposes of reducing chances of chafing of the wearer's skin that might otherwise occur, through localized concentrations of pressure against the wearer's skin at sharp corners of components <NUM>. Thus, it may be desired that, for example, patches of hooks material constituting secondary first components <NUM> have a circular, oval, elliptical, rounded rectangle or other shape lacking sharp corners, at least on the edges of the lower half of the length thereof.

Addition of a secondary fastening system can provide a greater surface area for fastening and thereby de-concentrate lateral tensile forces communicated through the fastening location(s) as the rear waist region is pulled toward the front waist region, and vice versa, when the diaper is worn. In addition, having two distinct fastening locations reduces the tendency of the front portion of the article to pivot (i.e., pivot around the single fastening location of the primary fastening system). Further, the secondary system helps to create a line of tension closer to the front waist edge, which may reduce the likelihood of folding or flipping over of the front waist edge during wear. Further still, the secondary system may create an anchoring geodesic to direct forces from the crotch region to over the hips in orderto prevent sagging during wearer. The secondary system may also help to secure the front ear or combination belt structures in place during wear. Each of the foregoing can serve to provide for more effective and durable fastening and less longitudinal and/or lateral flexing, sagging and/or wrinkling of the diaper materials about the fastening areas during wear. To most effectively provide these benefits, particular locations for the fastening components, relative the other features of the diaper, may be desired.

Turning to <FIG>, the article <NUM> may include leg band elastic members <NUM>. Each band elastic member <NUM> may have an active portion extending between a front end <NUM> and a rear end <NUM> thereof, in which the elastic member is pre-strained and thereby effects longitudinal contraction and gathering of materials along the proximate longitudinal edge <NUM>. In some examples, the legband elastic members <NUM> may have inactive portions extending beyond the front and rear ends <NUM> and <NUM>, where they are not pre-strained, or have been deactivated in some manner. The leg band elastic members <NUM> will lie along or intersect front leg band lines 123f. Referring to <FIG>, where a leg band elastic member <NUM> is curved, its associated front leg band line 123f is the line that connects the point of intersection of the leg band elastic member <NUM> with the lateral axis <NUM>, and the front end <NUM> of the active portion of the elastic member <NUM>. It will be appreciated that the front leg band line 123f and the elastic member <NUM> are collinear when the active portion of the elastic member <NUM> is straight. For purposes herein, a leg band line lies along the most laterally outboard leg band elastic member (where, for example, more than one leg band elastic member is present along a longitudinal edge <NUM>), and the most laterally outboard edge thereof.

For purposes of most effectively providing the benefits noted above, it may be desired that the secondary first component <NUM> be located along the lateral direction such that it lies tangent to, or along, the front leg band line 123f. Such a location places the secondary first component along the line of generally longitudinal tension created by the leg band elastic member, providing desirably located support and thereby helping to prevent twisting or skewing of the front waist region of the diaper about the primary first component when the diaper is fastened about a wearer. For these purposes, it may be even more particularly desired that the middle third of the width <NUM> of the secondary first component <NUM> (see <FIG>) be located such that it lies tangent to, or along, the front leg band line 123f.

Still referring to <FIG> and <FIG>, base members <NUM> that are formed of sections of materials that are discrete from those of the chassis may be bonded to the chassis by chassis attachment bonds <NUM>. Chassis attachment bonds <NUM> may each be a single bond, or a series of bonds, with its longer dimension generally aligned in the longitudinal direction. It may be desired the chassis attachment bond <NUM> be tangent to, or along, the rear leg band line 123r. Such a location places the bond <NUM> (which is generally, relatively stiff) along the line of generally longitudinal tension created by the leg band elastic member <NUM>, providing desirably located structural stiffness and resulting support and thereby helping to prevent twisting or skewing of the rear waist region of the diaper about the bond when the diaper is fastened about a wearer. Referring to <FIG>, where a leg band elastic member <NUM> is curved, its associated rear leg band line 123r is the line that connects the intersection of the leg band elastic member <NUM> with the lateral axis <NUM>, and the rear end <NUM> of the active portion of the elastic member <NUM>. It will be appreciated that the rear leg band line 123r and the elastic member <NUM> are collinear when the active portion of the elastic member <NUM> is straight.

To maximize the likelihood that the secondary first component <NUM> will be covered, and otherwise will be unlikely to come into undesirable contact with the wearer's skin during wear, it may be desired to locate the secondary first component <NUM> in a suitable location along the longitudinal direction relative to the other portions of the diaper. Returning to <FIG>, each base member <NUM> has a top edge <NUM> and a bottom edge <NUM>. Top edge <NUM> meets longitudinal edge <NUM> of the chassis at upper intersection point <NUM>. Bottom edge <NUM> meets longitudinal edge <NUM> of the chassis at lower intersection point <NUM>. Lower intersection point <NUM> lies distance D2 from the rear waist edge <NUM>. Upper intersection point <NUM> lies a distance D1 from the rear waist edge <NUM>. When the fastening members <NUM> are integral extensions of one or more of the topsheet and backsheet as suggested in <FIG>, for purposes herein the upper intersection point <NUM> lies at the intersection of the rear waist edge <NUM> and a line perpendicular to the front waist edge and tangent to the longitudinal edge <NUM> where the diaper not including front ears <NUM> is widest forward of lateral axis <NUM>, as illustrated in <FIG>. Similarly, the lower intersection point <NUM> lies at the intersection or meeting of the lower edge <NUM> with the line just described. The secondary first component <NUM> may be longitudinally located entirely between distances D1 and D2, from the front waist edge. When the fastening members are suitably shaped, such longitudinal location can help ensure that secondary first component <NUM> will be entirely covered by the base member when the diaper is fastened about a wearer for which the diaper is sized.

Referring again to <FIG>, an inboard intersection point <NUM> of the inboard lateral edge <NUM> of the web material <NUM> and the chassis may be located a distance D4 from the front waist edge <NUM>. It may be desired that secondary first component <NUM> be located entirely outboard of the inboard lateral edge <NUM>. It may further be desired that the secondary first component be located at a distance from the front waist edge <NUM> that is entirely less than distance D4 from the front waist edge <NUM>. Such a location will help ensure that a portion of section of web material <NUM> is available to provide shielding and cushioning for the wearer's skin, against possible irritation that may be caused by the lower edges of secondary first component <NUM>.

It may also be desired that secondary first component <NUM> be located closer to the outboard lateral edge <NUM> of the section of web material than to the inboard lateral edge <NUM> of the section of web material. This may be generally desired so as to locate the secondary first components as close the frontwaist edge <NUM> as practical, so as to help minimize or avoid flipping over of portions of the chassis proximate the front waist edge <NUM>, when the diaper is worn.

As shown in <FIG>, the inward-most extent <NUM> of the primary first component <NUM> is located a distance D3 from the rear waist edge. It may be desired that distance D3 be less than distance D4. This will help ensure that a portion of the section of web material <NUM> is disposed below the primary first component <NUM> when the diaper is fastened and worn, thereby providing shielding and cushioning for the wearer's skin, against possible irritation that may be caused by the lower edges of primary first component <NUM>. This may be particularly desirable in a situation in which a caregiver desires to fit the diaper as loosely on the wearer as possible, by, e.g., affixing the primary first component <NUM> to the front ear, laterally outboard of the longitudinal edge of the chassis rather than at a more laterally inward location on the front waist region/landing zone <NUM>.

For purposes of avoiding flipping or roping of the base member <NUM> about a line of lateral tension that would otherwise be localized about a primary first component <NUM> when the diaper is fastened, the secondary first component <NUM> may have a longitudinal length that is greater than the length of a primary first component <NUM>. In other circumstances, however, it may be desired that the length of a secondary first component <NUM> be less than that of a primary first component <NUM>, which may help reduce chances of irritation or chafing of the wearer's skin proximate edges of secondary first components <NUM> due to localized concentration of pressure proximate to such edges.

Turning to <FIG>, it may be desired to provide the absorbent article in a folded configuration, including folding the front ears. In certain embodiments, folding may serve to cover a fastening component which may be disposed on the chassis, combination belt structure or a combination thereof. By way of nonlimiting example, prior to or following the attachment of the section of web material <NUM> to the chassis, the front ears <NUM> may be folded laterally back over along longitudinal front ear fold lines <NUM>, such that distal ends <NUM> of front ears <NUM> in such folded configuration are disposed laterally inboard of longitudinal edges <NUM> following attachment of the section of web material <NUM> to the chassis. As shown in <FIG> for example, the front ear <NUM> may be folded toward the outward-facing surface <NUM> along the longitudinal front ear fold line <NUM>. A portion of the combination belt structure <NUM> may then be folded inward along another fold line <NUM> as shown in <FIG>, resulting in a z-fold configuration wherein the secondary first component is covered by the ear as shown in <FIG>. In another configuration shown in <FIG>, the front ear <NUM> may be folded toward the wearer-facing surface <NUM>, in an e-fold configuration. In some examples having a set of opposing front ears, at least one of secondary first component <NUM> may be covered the opposite ear in the folded configuration as shown in <FIG>.

A folded front ear configuration may provide several advantages. First, it provides for control over the front ears <NUM> as the chassis moves through any further downstream processing folding and/or packaging, reducing chances that front ears <NUM> will snag in any equipment, with possible resulting damage. Second, where secondary first components <NUM> of a secondary fastening system are included, folding the ears <NUM> over one or more secondary first components <NUM> will shield and protect the secondary first components from unwanted contact and interaction with other portions of the diaper prior to its use. For example, where secondary first components <NUM> are patches hooks material, it may be undesirable to have them exposed when, e.g., the entire diaper is folded for packaging as will be described below, because they may undesirably snag and/or undesirably attach to other portions of the diaper in such folded diaper configuration. In order to reduce chances of a negative caregiver perception of design and/or process quality, it may be desired that each fold line <NUM> be located no more than <NUM> percent of the front ear <NUM> width, from the proximate longitudinal edge <NUM>.

Front ears <NUM> may be held in place in such folded ear configurations, for example, by releasable attachment to a secondary first component <NUM>. A front ear may be held through pressure or friction. Alternatively, or in combination, each front ear <NUM> may be held in placed in such folded ear configuration by one or more releasable tack bonds bonding the section of web material <NUM> to itself. The releasable tack bonds may be adhesive bonds, thermal bonds or any other suitable bonding mechanism by which attachment between components is effected, but substantially non-destructive detachment thereof may be effected by gently tugging the front ear laterally outward. In one non-limiting example, releasable tack bonds may be formed by a frangible bonding agent such as described in <CIT>, disposed between the components to be attached to one another. Such a frangible bonding agent may have good adhesive strength when freshly deposited but may lose adhesive strength over time, thereby providing for good holding during manufacturing but providing for easy, nondestructive detachment at the time of consumer use. An example of a frangible bonding agent is PHO <NUM> type fugitive hot-melt adhesive available from H. Fuller, St. Paul, Minnesota. In another non-limiting example, a frangible bonding agent may be a material forming a relatively weak bond (i.e., weaker than that formed by typical diaper construction adhesives) such as but not limited to a wax, for example, paraffin wax, microcrystalline wax, synthetic wax, beeswax and other natural waxes.

Regardless of any mechanism used to hold the front ears <NUM> in a folded ear configuration, however, it may be desired that a front ear <NUM> may be relatively easily peeled away from the surface from which the secondary first component is attached to facilitate unfolding without tearing or damage to the ear and/or said surface. In nonlimiting examples, the secondary first component may be peeled away by a peel force of about <NUM> N or less, or from about <NUM> N to about <NUM> N, or about <NUM> N to about <NUM> N, reciting for each range every <NUM> N therein. This peel force limit may be observed to reduce chances of caregiver difficulty and/or dissatisfaction with the diaper product, during deployment of the front ears <NUM> for application to a wearer. Peel force may be adjusted by techniques that will be apparent to those skilled in the art, e.g., selection and sizing of hook material to be used as secondary first components <NUM>; selection of web material to be used as section of web material <NUM>; selection of adhesive to be used to form releasable tackbonds, size and/or pattem of releasable tack bonds, etc..

It is generally desirable that diapers of the type contemplated herein be folded to a more compact configuration for efficient packaging and shipping. Accordingly, in a first step, left and right side margins <NUM> of the diaper may be folded laterally inwardly, about left and right longitudinal diaper folding lines <NUM> as indicated by the curving arrows in <FIG>, to bring the diaper to a first interim folded configuration depicted in <FIG>, with left and right longitudinal folded edges <NUM>. Referring to <FIG> and <FIG>, in a next step, the diaper may be folded over on itself and approximately in half lengthwise, wearer-facing surfaces in, about a lateral fold line <NUM>, to bring it into a folded diaper configuration as shown in <FIG>, which is a neat and compact configuration suitable for efficient stacking of a plurality of diapers, packaging and shipment. While <FIG> illustrate ears that are folded toward the outward-facing surface, it is to be appreciated that the folding of side margins and lateral folding can be applicable when ears are folded toward the wearer-facing side. By way of nonlimiting example, <FIG> illustrate a folded article where the ears <NUM> are folded toward the wearing-facing surface <NUM> along with the article side margins <NUM>. In such examples, the ears <NUM> are not folded toward the outward-facing surface prior to folding the side margins. The front ears may be folded as in <FIG> such that neither secondary first component is covered by an area of the front waist region. Alternatively, the front ears may be folded as shown in <FIG>, such that at least one secondary first component is covered by, and can be engaged with, an opposing front ear (i.e., the right secondary first component is covered by the left front ear or vice versa). Portions of the rear waist region may overlap with, and may be engageable with, secondary first components when the article is folded as is illustrated in <FIG>.

In certain embodiments, the section of web material <NUM>, and the front ears <NUM>, may be suitably sized, and the front ear fold lines <NUM> may be suitably located relative the chassis, such that the distal ends <NUM> of the front ears <NUM> are visible and easily identified and grasped by the caregiver when the diaper is in a folded diaper configuration. Referring again to <FIG> (depicting an example of a diaper with wearer-facing surfaces facing the viewer), front ears <NUM> are folded toward the outward-facing surface and are thereby located behind the diaper in the view shown. In <FIG>, it can be seen that tab portions <NUM> and distal ends <NUM> of front ears are not folded about the folded edges <NUM>, but rather, are left free to protrude laterally outboard of folded edges <NUM>. In <FIG>, it can be seen that tab portions <NUM> of front ears <NUM> extend laterally away from the folded diaper in both the interim (<FIG>) and final (<FIG>) folded diaper configurations, and as such are readily visible and available to be grasped by the caregiver upon removal from the package and partial unfolding. The section of web material <NUM> forming the front ears <NUM> may be suitably sized, and longitudinal front ear fold lines <NUM> (see <FIG>) may be suitably located, relative the chassis and longitudinal diaper fold lines <NUM> (see <FIG>), to provide such laterally extending tab portions <NUM>.

Components of the disposable absorbent article can at least partially be comprised of bio-sourced content as described in <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>. These components include, but are not limited to, topsheets, backsheet films, backsheet nonwovens, side panels, leg gasketing systems, superabsorbent, acquisition layers, core wrap materials, adhesives, fastener systems, and land zones. In at least one embodiment, a disposable absorbent article component comprises a bio-based content value from about <NUM>% to about <NUM>%, or from about <NUM>% to about <NUM>%, or from about <NUM>% to about <NUM>% using ASTM D6866-<NUM>, method B. In order to apply the methodology of ASTM D6866-<NUM> to determine the bio-based content of any disposable absorbent article component, a representative sample of the disposable absorbent article component must be obtained for testing. In at least one embodiment, the disposable absorbent article component can be ground into particulates less than about <NUM> mesh using known grinding methods (e.g., WILEY® mill), and a representative sample of suitable mass taken from the randomly mixed particles.

Referring now to <FIG> and <FIG>, combination belt structures <NUM> may be manufactured from a strip of web material <NUM> having a cross direction width and side edges <NUM> along the machine direction. Web material <NUM> may be any web material suitable for serving as, or support, a primary second component of a primary fastening system and as material suitable for forming front ears. In some examples, web material <NUM> may be a nonwoven web material, adapted to receive and fastenably catch hooks included with primary first components, and thereby serve as the "loops" component of a hook-and-loop primary fastening system. In a more particular example, the section of nonwoven web material may be pattern bonded in a pattern of thermal bonds configured to enhance the strength and reliability of the material, and of the "loops" it provides. In a still more particular example, the section of nonwoven web material may be as described in any of the above-cited publications.

If, for example, a secondary fastening system is to be included with the diaper, strip of web material <NUM> may be conveyed along the machine direction MD to fastening component process equipment <NUM> configured to receive a supply of fastening components or fastening component material, and to affix fastening components <NUM> or fastening component material to the strip of web material <NUM>. The fastening components may be registered with the web material such that any of the aforementioned positioning can be achieved, including for example placement of the fastening component entirely between the distances D1 and D2 on the final article, at a distance from the front waist edge <NUM> that is entirely less than distance D4 from the front waist edge <NUM>, closer to the outboard lateral edge <NUM> of the section of web material than to the inboard lateral edge <NUM> of the section of web material, and/or such that the fastening component lies tangent to, or along, the front leg band line. Registration may be done in the machine direction (i.e., placing fastening components at specific MD distances or with reference to specific MD positions), cross-machine direction, with reference to cut lines (discussed below), fold lines or margins, leg elastic band lines (discussed above) or any combination thereof. Registration can be achieved by any suitable process. In some embodiments, sensors are used to recognize registration feature(s) on the material. The sensor may communicate the presence of the registration feature to a controller to identify the appropriate position or process timing for placement of the fastening component. Registration features may include printed graphics, variance in web path, optimal markers and/or physical discontinuities such as notches, protrusions, depressions, or holes formed in a substrate and/or components. Some registration processes are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> and <CIT>.

If edge margins of the strip of web material <NUM> are to be cut away from the strip of web material, the strip of web material <NUM> may be conveyed along the machine direction to side edge cutting equipment <NUM> configured to cut away edge margins. Such cutting may be desired, for example, when needed to impart a consistent cross-direction width and neat side edges to the strip of web material <NUM> and/or to provide profiled side edges <NUM> to the strip, and thereby to provide profiled tab portions and distal ends to the front ear portions of the combination belt structure <NUM>. If the combination belt structure is to be provided with front ear portions folded over as suggested in the description above, the strip of web material <NUM> may be conveyed along the machine direction to folding equipment <NUM>, configured to fold side margin portions <NUM> over the strip <NUM>, along machine direction fold lines <NUM>. Folding the side margin portions <NUM> over the strip <NUM> prior to cutting away of individual combination belt structures <NUM>, may in some circumstances be more simple, efficient and reliable than folding over front ear portions of separate individual belt structures. The folded side margin portions may subsequently become the folded front ear portions of the combination belt structures <NUM>.

At any point in the manufacturing of combination belt structures <NUM> following the first step, the strip of web material may be gathered on a roll for efficient storage and transport to downstream manufacturing steps, at which time the strip may be unrolled for further manufacturing steps. For example, the strip of web material may be gathered on a roll following application of fastening components <NUM>; or following side edge cutting; or following folding along machine direction fold lines <NUM> as described above, or following completion of all of these steps.

Referring to <FIG>, the processed strip of web material <NUM> may be (if gathered on a roll, unrolled and) conveyed along the machine direction MD to cross-direction cutting equipment <NUM> configured to cut away individual combination belt structures <NUM> along cross direction cut lines <NUM>. This step may be incorporated as part of the manufacturing process for diapers, in which a continuous supply of the combination belt structures are provided on a roll prior to cutting and separation into individual belt structures <NUM> for application to diaper chasses.

Where profiled side edges are to be provided, the side edge cutting equipment <NUM> may be configured to cut material <NUM> along any profile shape desired for the tab and distal end portions of the front ear portions of the combination belt structures <NUM>. In some circumstances, it may be desired to provide a series of connecting convexly-curved side edge profiles as suggested in <FIG>, <FIG> and <FIG>, which will result in convexly-curved tab and distal end portions of front ears. Referring to <FIG>, in some circumstances it may be desired to provide a series of side edge profiles that include alternating convex portions 516a and concave portions 516b. This alternating convex/concave side edge profile configuration may provide the manufacturer with some room for process variation in location of cross direction cut lines <NUM>, such that a minor machine-direction variance or deviation from the specified location of cut lines <NUM> is unlikely to result in the creation of a sharply pointed, laterally protruding, esthetically undesirable sliver of material at an outside end/corner of a front ear intended to have a simple rounded tab profile. (For purposes of the immediately-preceding description, the term "convex" is not limited to a rounded curve, but also includes an outward-directed (relative the machine direction axis of the strip of web material) sharp corner in a profile, and the term "concave" is not limited to a rounded curve, but also includes an inward-directed (relative the machine direction axis of the strip of web material) sharp corner in a profile. Thus, a side edge cut having an alternating/reversing step-wise profile with sharp corners would have "convex" and "concave" portions.

<FIG> depict alternative possible folding and cutting arrangements which may be desired in varying circumstances. When the manufacturer desires that the front ears <NUM> extend from the chassis downward toward the lateral axis of the diaper as described above, a pattern of cross-direction cut lines <NUM> such as depicted in <FIG> or <FIG> may be desired. It will be appreciated that cut lines <NUM> provide for nested shapes of belt structures to be successively cut away from the strip of web material <NUM>, minimizing material waste. In some examples, cut lines <NUM> may be curved rather than straight or straight-sectioned as depicted.

<FIG> depicts a possible cutting arrangement that may be used to produce a pair of left and right belt structures with front ears such as are depicted in <FIG>. An additional machine direction cut line <NUM> is included, to separate the left and right portions.

Obtain samples of subject material sufficient to provide for a gauge length of at least <NUM> along the direction of stretch in the Test, and should be of a constant width (perpendicular to the direction of stretch in the Test) of at least <NUM>.

The Hysteresis Test can be used to various specified strain values. The Hysteresis Test utilizes a commercial tensile tester (e.g., from Instron Engineering Corp. (Canton, MA), SINTECH-MTS Systems Corporation (Eden Prairie, MN) or equivalent) interfaced with a computer. The computer is used to control the test speed and other test parameters and for collecting, calculating, and reporting the data. The tests are performed under laboratory conditions of <NUM> ± <NUM> and relative humidity of <NUM>% ± <NUM>%. The samples are conditioned for <NUM> hours prior to testing.

A computer data system records the force exerted on the sample during the test as a function of applied strain. From the resulting data generated, the following quantities are reported (note that loads are reported as force divided by the width of the sample and do not take into account the thickness of the sample):.

The testing is repeated for six separate samples and the average and standard deviation reported.

The Hysteresis Test can be suitably modified depending on the expected attributes and/or properties of the particular material sample to be measured. For example, the Test can be suitably modified where a sample of the length and width specified above are not available from the subject diaper.

The Stiffness Test measures the bending properties of a sample.

Identify the waist region by measuring the length of the article along the longitudinal centerline from the front waist edge to the rear waist edge, and dividing said length into three equal sections. For samples in the front waist region, remove the specimens from the front third of the article. For samples in the rear waist region, remove the specimens from the lastthird of the article.

Cut a rectangular section of material measuring at least <NUM> by <NUM>, excluding any primary first components or secondary first components. Cut the specimen such that the <NUM> dimension in the longitudinal direction of the article and parallel to the longitudinal axis. Maintain the longitudinal direction relative to the product and note the garment facing side of the specimen. If the specimen does not allow these dimensions, smaller samples can be used.

Specimens are conditioned at <NUM> ± <NUM> and <NUM>% ± <NUM>% relative humidity two hours prior to testing.

The bending properties of a sample are measured on a constant rate of extension tensile tester (a suitable instrument is the MTS Alliance using Testworks <NUM> Software, as available from MTS Systems Corp. , Eden Prairie, MN) using a load cell for which the forces measured are within <NUM>% to <NUM>% of the limit of the cell. All testing is performed in a room controlled at <NUM> ± <NUM> and <NUM>% ± <NUM>% relative humidity.

The bottom stationary fixture of the tensile tester consists of two bars <NUM> in diameter by <NUM> in length, made of polished stainless steel each mounted on its own fork in linear ball bearing to reduce COF affect. These two bars are mounted horizontally, aligned front to back and parallel to each other, with top radii of the bars vertically aligned. Furthermore, the fixture allows for the two bars to be move horizontally away from each other on a track so that a gap can be set between them while maintaining their orientation. The top movable fixture consists of a third bar also <NUM> in diameter by <NUM> in length, made of polished stainless steel mounted on a fork in linear ball bearing to reduce COF affect. When in place the bar of the top fixture is parallel to, and aligned front to back with the bars of the bottom fixture. Both fixtures include an integral adapter appropriate to fit the respective position on the tensile tester frame and lock into position such that the bars are orthogonal to the motion of the crossbeam of the tensile tester.

Set the gap between the bars of the lower fixture to <NUM> ±<NUM> (center of bar to center of bar) with the upper bar centered at the midpoint between the lower bars. Set the gage (bottom of top bar to top of blower bars) to <NUM>.

Measure the caliper of each specimen, using a digital caliper (e.g. Ono Sokki GS-<NUM> or equivalent) fitted with a <NUM> diameter foot that applies a confining pressure of <NUM> PSI. Read the caliper (mm) <NUM> sec after resting the foot on the sample and record to the nearest <NUM>.

Program the tensile tester for a compression test, to move the crosshead down at a rate of <NUM>/sec until the upper bar touches the top surface of the specimen, then continue for an additional <NUM> collecting force (N) and displacementmm data at200 Hz, and return the crosshead to its original gage. Orient specimens with garment facing side toward the upper bar. Load the specimen such that it spans the two lower bars with its lateral centerline centered under the upper bar and its longitudinal centerline aligned to the center point of the upper bar's length. Zero the crosshead and load cell. Start the run and collect data.

Construct a graph of force (N) verses displacement (mm). Read the Maximum Peak Force (N) from the graph and record to the nearest <NUM>. Report the slope as N/mm to the nearest <NUM>.

Measures are repeated in like fashion for <NUM> specimens from the same location. The arithmetic average slope of the three specimens is reported as the sample's Stiffness to the nearest <NUM>.

Claim 1:
A method for providing successive individual combination front belt structures (<NUM>) each comprising a pair of fastening components, the method comprising the steps of:
providing a machine-direction continuous strip of web material (<NUM>) having a pair of machine-direction outer side edges (<NUM>), opposing side margin portions (<NUM>), and a cross-direction width therebetween;
conveying the web material along the machine direction to fastening component process equipment (<NUM>);
operating the fastening component process equipment (<NUM>) to continuously affix successive fastening components (<NUM>) to the web material as it moves along the machine direction, wherein the affixing step comprises affixing successive pairs of fastening components (<NUM>) to the web material such that each front belt structure comprises a pair of fastening components;
conveying the web material to cross-direction cutting equipment (<NUM>); and
operating the cross-direction cutting equipment (<NUM>) to cut individual combination front belt structures (<NUM>) from the web material along predominately cross-direction cut lines (<NUM>), each front belt structure comprising a pair of the affixed fastening component (<NUM>),
wherein the individual combination front belt structures (<NUM>) are each incorporated into an absorbent article to form a combination front belt structure (<NUM>) of the absorbent article; and
wherein the web material (<NUM>) of the combination front belt structure (<NUM>) provides and/or supports a second component (<NUM>) of a fastening system of the absorbent article and forms a pair of front ears (<NUM>) of the absorbent article.