BACKGROUND OF THE INVENTION

[0001 ] Embodiments of the invention relate generally to absorbent sanitary products and, more particularly, to an improved system and method for attaching and folding ears on a running web during manufacturing of an absorbent sanitary product.

[0002] Absorbent sanitary products, such as disposable diapers, are constructed to generally include an absorbent insert (i.e. , core) and a chassis, which, when the diaper is worn, supports the insert proximate a wearer's body. Additionally, diapers may include other various components or features, including an ear or wing that is part of the chassis and that is grasped and pulled around the waist of a wearer to secure the diaper on a wearer. Typically, ears are secured to the diaper at a first end, and a second free end is equipped with securing means, such as a pressure sensitive adhesive, or hook and loop material. As a user grasps an ear and pulls the ear, elasticity provided about the waist region of the diaper allows the free end to be snugly pulled about the waist of a wearer and coupled to the diaper.

[0003] During fabrication of a diaper, discrete ears are typically formed by providing a web of ear material that is slit into two lanes, one for a left side of a diaper and the other for a right side of a diaper. The two lanes of ear material are then cut into discrete ears and applied to a running web (e.g., topsheet of nonwoven material) by use of a slip-and-cut applicator. A slip-and-cut applicator is typically comprised of a cylindrical rotating vacuum anvil, a rotating knife roll, and a transfer device. Each lane of ear web material may be fed at a relatively low speed along the vacuum face of a respective rotating anvil, which is moving at a relatively higher surface speed and upon which the incoming ear web is allowed to “slip.” A knife-edge, mounted on the rotating knife roll, cuts off a segment of the incoming ear web against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the anvil's surface. Once cut, the discrete ear is held by vacuum drawn through holes on the anvil's face as it is carried at the anvil's speed downstream to the transfer point, where the discrete ear is transferred/affixed to the topsheet. Subsequent processing steps can then be performed, including providing the absorbent insert and elastics and bonding a backsheet to the topsheet. [0004] In transferring discrete ears to the running web, each ear is positioned relative to the web at a desired location that provides for attachment or bonding of the ear to the web. This attachment and folding of the ear relative to the running web can be performed according to a number of known methods. In one embodiment, and as shown in the process flow diagram of FIGS. 1A-1C and 1 B-B-1 D-D, an ear 2 is placed on the topsheet 4 with a small “flap” portion 6 (e.g., 20-40mm typically) hanging off the edge of the topsheet. The discrete ear flap 6 is then folded onto the other side of the topsheet 4 and bonded thereto via an adhesive bond. A backsheet 8 is then provided and combined with the topsheet 4, with the ear flap 6 laminated between the topsheet 4 and backsheet 8. In another embodiment, and as shown in FIGS. 2A-2C and 2B-B- 2D-D, an ear 2 is placed on the topsheet 4 such that a majority of the ear 2 is outboard of the topsheet 4 and with only a small portion (e.g., 20-40mm typically) overlapping the topsheet 4. The portion of the ear 2 overlapping the topsheet 4 is bonded to the topsheet 4 via an adhesive or ultrasonic bond. A backsheet 8 is then provided and combined with the topsheet 4, with the overlapped portion of the ear 2 being laminated between the topsheet 4 and backsheet 8. The portion of the ear 2 outboard of the topsheet 4 is then folded over onto the topsheet 4 prior to packaging.

[0005] It is recognized that there are several drawbacks associated with the prior art ear attachment and folding methods described above. First, by placing the ear such that a portion thereof hangs off the edge of the topsheet, full control of the ear may not be maintained, and the ear may shift before it is secured (i.e., adhesively, or ultrasonically bonded) to the topsheet. Second, the folding of discrete ears individually, along with the small fold width of each individual fold, can lead to problems with regard to folding consistency. That is, in performing such individual folds, the ears are pushed through a folding apparatus, and this pushing-type folding action may lead to issues with fold consistency and/or lead to misfeeds or folding errors occurring. Still further, it is recognized that in the manufacture of absorbent diapers where ear attachment is performed, elastics are typically introduced at the same time as the absorbent insert and backsheet, i.e., all the components are added at a single combining point in the system. This placement of the elastics at the combining point adds to the congestion of materials added at the combining point and increases the complexity of the manufacturing process. [0006] Accordingly, there is a need for an improved system and method for attaching ears to a running web and subsequently folding the ears during manufacturing of an absorbent sanitary product. The improved system and method would provide for full control when positioning and attaching the ears on the running web, minimize the complexity and occurrence of errors when folding the ears, and more generally provide for efficiency gains in the manufacturing of the absorbent sanitary product.

BRIEF DESCRIPTION OF THE INVENTION

[0007] In accordance with one aspect of the invention, a laminate for use in an absorbent article includes a topsheet comprising a first surface and a second surface, a backsheet positioned facing the second surface of the topsheet, and a plurality of ears positioned on the first surface of the topsheet to form an ear-web assembly, with a first ear of the plurality of ears having an outer edge aligned with a first edge of the topsheet and a second ear of the plurality of ears having an outer edge aligned with a second edge of the topsheet opposite from the first edge. The ear-web assembly comprises a continuous edge folded portion adjacent each of the first and second edges thereof extending a length of the topsheet, wherein a portion of each of the plurality of ears is folded within the continuous edge folded portion.

[0008] In accordance with another aspect of the invention, a method of manufacturing a laminate for use in an absorbent article is provided. The method includes providing a topsheet running in a machine direction, attaching a plurality of ears onto the topsheet on a top surface thereof such that an outer edge of each of the plurality of ears is aligned with one of a first edge and a second edge of the topsheet, and continuously folding each of the first edge and the second edge of the topsheet away from the top surface and onto a back surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to the continuous folding of the first and second edges. The method also includes attaching a backsheet to the back surface of the topsheet. The continuous folding of the first edge and the second edge of the topsheet, and the accompanying folding of each of the plurality of ears, forms a pair of folded portions positioned between the backsheet and an unfolded portion of the topsheet.

[0009] In accordance with yet another aspect of the invention, a machine for manufacturing an absorbent article includes a means for attaching a plurality of ears onto a top surface of a running topsheet such that an outer edge of each of the plurality of ears is generally aligned with one of a first edge and a second edge of the topsheet, and a means for continuously folding each of the first edge and the second edge of the topsheet away from the top surface and onto a bottom surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to the continuous folding of the first and second edges, so as to form a pair of folded portions. The machine also includes a means for attaching a backsheet to the bottom surface of the topsheet such that the pair of folded portions is positioned between the backsheet and an unfolded portion of the topsheet.

[0010] In accordance with still another aspect of the invention, a machine for manufacturing an absorbent article includes a first cut and re-pitch apparatus configured to cut a first continuous ear web into discrete first ears and re-pitch the discrete first ears, a second cut and re-pitch apparatus configured to cut a second continuous ear web into discrete second ears and re-pitch the discrete second ears, and a transfer and combining unit configured to transfer the first discrete ears and the second discrete ears from the first cut and re-pitch apparatus and the second cut and re-pitch apparatus, respectively, onto a top surface of a running topsheet, the transfer and combining unit attaching the first discrete ears and the second discrete ears onto the top surface of the running topsheet such that an outer edge of each of the discrete first ears is generally aligned with a first edge of the topsheet and an outer edge of each of the discrete second ears is generally aligned with a second edge of the topsheet. The machine also includes a folding apparatus configured to continuously fold each of the first edge and the second edge of the topsheet away from the top surface and onto a bottom surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to folding of the first and second edges, so as to form a pair of folded portions. The machine further includes a bonding unit configured to attach a backsheet to the bottom surface of the topsheet such that the pair of folded portions is positioned between the backsheet and an unfolded portion of the topsheet.

[0011] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0013] In the drawings:

[0014] FIGS. 1A-1C illustrate plan views of a process flow for forming an ear-web assembly, according to the prior art.

[0015] FIGS. 1 B-B, 1 C-C, and 1 D-D are cross-sectional views of the prior art process flow shown in FIGS. 1 B and 1 C.

[0016] FIGS. 2A-2C illustrate plan views of an alternative process flow for forming an ear-web assembly, according to the prior art.

[0017] FIGS. 2B-B, 2C-C, and 2D-D are cross-sectional views of the prior art process flow shown in FIGS. 2B and 2C.

[0018] FIGS. 3A-3C illustrate plan views of a process flow for forming an ear-web assembly, according to an embodiment of the invention.

[0019] FIGS. 3A-A, 3B-B, 3C-C, and 3D-D are cross-sectional views of the process flow shown in FIGS. 3A-3C.

[0020] FIGS. 4A-4C illustrate plan views of a process flow for forming an ear-web assembly, according to another embodiment of the invention.

[0021] FIGS. 4A-A, 4B-B, 4C-C, and 4D-D are cross-sectional views of the process flow shown in FIGS. 4A-4C.

[0022] FIGS. 5A-5C illustrate plan views of a process flow for forming an ear-web assembly, according to another embodiment of the invention.

[0023] FIGS. 5A-A, 5B-B, 5C-C, and 5D-D are cross-sectional views of the process flow shown in FIGS. 5A-4C. [0024] FIGS. 6A-6C illustrate plan views of a process flow for forming an ear-web assembly that includes elastic strands, according to another embodiment of the invention.

[0025] FIGS. 6A-A, 6B-B, 6C-C, and 6D-D are cross-sectional views of the process flow shown in FIGS. 6A-6C.

[0026] FIGS. 7A-7C illustrate plan views of a process flow for forming an ear-web assembly that includes elastic strands, according to another embodiment of the invention.

[0027] FIGS. 7A-A, 7B-B, 7C-C, and 7D-D are cross-sectional views of the process flow shown in FIGS. 7A-6C.

[0028] FIG. 8 illustrates a plan view of a step of a process flow for forming an earweb assembly, according to yet another embodiment of the invention.

[0029] FIG. 8-8 is a cross-sectional view of the process flow shown in FIG. 8.

[0030] FIG. 9 illustrates a system for forming a disposable diaper, according to an embodiment of the invention.

DETAILED DESCRIPTION

[0031] Embodiments of the present invention provide for a system and method for attaching and folding ears on a running web during fabrication of an absorbent article. An edge of each ear is aligned with an edge of the running web and the edges of the running web are continuously folded, such that the edges of the ears are folded along with the topsheet edges.

[0032] FIGS. 3A-3C and 3A-A - 3D-D illustrate a process flow for forming a laminate 10 (referred to hereafter as an “ear-web assembly 10”) such as would be incorporated into a disposable diaper or other absorbent sanitary product, according to an embodiment of the invention. The ear-web assembly 10 generally includes a topsheet 12, backsheet 14, and ears (i.e. , wings) 16 - with the ears 16 comprising back ears 16a and optionally front ears 16b (as shown in phantom in FIGS. 3A-3C). Topsheet 12 may be formed of a non-woven fabric and configured as a liquid-permeable layer that constitutes a skin-facing side of the disposable diaper that comes into contact with a wearer. The backsheet 14 may be formed of a non-woven fabric and configured as a liquid-impermeable layer that constitutes a non-skin-facing side of the disposable diaper. Typically, ears 16 are secured to the topsheet 12 at a first end, and a second free end is equipped with securing means, such as a pressure sensitive adhesive, or hook and loop material. As a user grasps an ear and pulls the ear 16, elasticity provided about the waist region of the diaper allows the free end to be snugly pulled about the waist of a wearer and coupled to the diaper.

[0033] In providing ears 16 to ear-web assembly 10, ears 16 are positioned on topsheet 12 such that an outer edge 18 of each ear is aligned with an edge 20 of topsheet 12, as shown in FIG. 3A. That is, the ears 16 are positioned on topsheet 12 such that an outer edge 18 of each ear is flush or nearly flush (i.e. , within 1 -6 mm) with edge 20 of topsheet 12. The ears 16 are bonded to topsheet 12 via a bond 22 formed adjacent the edge 20 of the topsheet 12, with the bonds 22 being any of a number of suitable bond types known in the art, including adhesive bonds, ultrasonic bonds, heat/pressure bonds, as non-limiting examples. As an example, bonds 22 may extend inward from the topsheet edge 20. Optionally, a second end 24 of each ear 16 may also be bonded to topsheet 12 via a tack bond or other temporary bond 26 that allows for the second end 24 to be pulled off from topsheet 12 when grasped and pulled by a wearer when in use.

[0034] Upon bonding of ears 16 to topsheet 12, a folding of the topsheet 12 and ears 16 is performed as shown in FIG. 3B. The folding operation is performed as a continuous fold along a fold line 28 (FIG. 3A) positioned proximate each of edges 20, with a folded portion 30 between each fold line 28 and respective edge 20 of topsheet 12 being folded inward toward the longitudinal centerline 29 of the topsheet 12. Thus, with ears 16 being attached to an upward facing surface of topsheet 12 as shown in FIG. 3B, a continuous edge fold is performed on topsheet 12. In folding topsheet 12, each of ears 16 is also folded as part of the folding of the topsheet 12, and a width of the fold of the topsheet 12 and ears 16 is thus identical. The width of the folded portion 30 can, according to one non-limiting and exemplary embodiment, be in the range of 20-40 mm per side of topsheet 12, and ideally would be of a width that results in the bonds 22 between ears 16 and topsheet 12 being completely included in the folded portion 30 of the topsheet/ears. The exact width of the folded portion 30 can be determined and controlled, at least in part, by the initial width of the topsheet 12 and a desired width of the completed ear-web assembly 10 after folding.

[0035] As shown in FIG. 3C, backsheet 14 is applied and bonded to topsheet 12 and the intermittent absorbent core (not shown). Bonding may be done via any known bonding means, including adhesive, thermal, pressure, or ultrasonics as non-limiting examples. Where adhesive is used for the bonding process, a lamination adhesive (not shown) may be applied to the select portions of the facing surfaces of the topsheet 12 and/or backsheet 14. The backsheet 14 is applied such that the folded portion 30 of topsheet 12 and ears 16 is sandwiched between the unfolded portion of topsheet 12 and backsheet 14. While backsheet 14 is shown in FIG. 3C as a flat backsheet, it is recognized that backsheet 14 could instead be folded before being attached to topsheet 12 and ear 16 combination. According to one embodiment, backsheet 14 could also include waist elastics attached thereto prior to being combined with topsheet 12 and ears 16. Upon securing of backsheet 14 to topsheet 12, a completed ear-web assembly 10 is formed, with it being recognized that additional components would subsequently be added to the assembly, e.g., elastics and an absorbent core, to result in construction of a disposable diaper or other absorbent sanitary product. [0036] While ears 16 are shown in FIGS. 3A-3C as being simple rectangular tabs, alternate embodiments may include ears 16 of different shapes or configurations, including trapezoidal-shaped ears as shown in FIGS. 5A-5C, die cut ears with curved edge features, or ears that include a pre-folded portion prior to their attachment to topsheet 12. An embodiment where ears 16 include a pre-folded portion 32 is shown in FIGS. 4A-4C and 4A-A - 4D-D, which illustrate a process flow for forming an earweb assembly 10 similar to that shown in FIGS. 3A-3C and 3A-A - 3D-D. Pre-folded ears 16 are attached to topsheet 12 such that an outer edge 18 of each ear aligns with an edge 20 of topsheet 12. A continuous fold is performed on topsheet 12 along fold line 28 such that portion 30 of topsheet 12 and ears 16 are both folded, and backsheet 14 is then applied such that the folded portion 30 of topsheet 12 and ears 16 is sandwiched between the unfolded portion of topsheet 12 and backsheet 14. While only back ears 16b are depicted in FIGS. 4A-4C and 4A-A - 4D-D, it is contemplated that flat or pre-folded front ears (ears 16b shown in phantom in FIGS. 4A-4C) may be attached to topsheet 12 in a similar manner as described with respect to FIGS. 3A and 3B prior to forming the continuous edge fold along fold line 28.

[0037] According to yet another embodiment, the ear-web assembly 10 can also include elastics 34 as shown in FIGS. 6A-6C and 6A-A - 6D-D. The ear-web assembly 10 of FIGS. 6A-6C includes many common elements previously described with respect to the embodiment of FIGS. 3A-3C and common part numbers are used as appropriate. In addition to the common elements, the embodiment of FIGS. 6A-6C includes one or more elastic strands 34 that are coupled to the top surface 15 of topsheet 12 prior to attaching ears 16. In the illustrated embodiment, a single elastic strand 34 is positioned adjacent each of the top and bottom edges 20 of topsheet 12. Multiple elastic strands 34 may be positioned adjacent each edge 20 in alternative embodiments. Upon folding of ear-web assembly 10 along fold line 28, the elastic strands 34 are therefore placed within the folded portion 30 so as to be contained by the folded ear-web assembly 10.

[0038] In an alternative embodiment shown in FIGS. 7A-7C and 7A-A - 7D-D, elastic strands 34 are positioned on the bottom surface 13 of the topsheet 12 after the ears 16 are attached to the top surface 15 of the topsheet 12. A single strand 34 may be positioned adjacent each edge 20 of the topsheet 12 as shown in FIG. 7A, or multiple strands 34 may be included in alternative embodiments. The elastic strands 34 are contained within the folded portion 30 of topsheet 12 following the continuous edge folding step. Manufacture continues in the same manner as previously described by attaching backsheet 14 as shown in FIGS. 7C, 7C-C and 7D-D.

[0039] FIGS. 8 and 8-8 depict yet another embodiment of the invention in which the front and back ears are formed from a common web of ear material 16 that is coupled to topsheet 12. Discrete front and back ear portions are formed when a final knife unit 72 (FIG. 9) cuts the completed continuous diaper composite along cut line 74. The common web of ear material 16 may be rectangular, as shown, or provided having angled or curved side edges to form shaped ears in alternative embodiments. The additional processing of the ear-web assembly 10 of FIG. 8 will continue in the same manner as described with respect to FIGS. 3B and 3C.

[0040] The ear-web assembly 10 formed by any of the process flows shown in FIGS. 3A-3C, 4A-4C, 5A-5C, 6A-6C, 7A-7C, and 8 desirably includes a “soft” folded edge topsheet construction having pleasing aesthetic and tactile properties. That is, the soft edge in ear-web assembly 10 formed by the continuous fold of topsheet 12 is similar to a clothing seam, as compared to a prior art ear-web assembly where only ears are folded (over topsheet 12). This soft edge construction of ear-web assembly 10 can thus eliminate rough spots that might be present when only ears 16 are folded over the topsheet 12, as done according to known prior art methods.

[0041] Referring now to FIG. 9, an exemplary manufacturing line 40 for producing a disposable diaper 42 that includes an ear-web assembly 10 as previously described is illustrated according to an embodiment of the invention. To form the diaper 42, an ear web 44 is first provided that is used to form back ears 16a on the diaper 42. The ear web 44 may be provided as a single web or as two separate webs of equal size, according to embodiments. When provided as a single web input, as illustrated in FIG. 9, the ear web 44 is provided to a web slitter 46 that cuts the web into two separate lanes of ear web material 44a, 44b. While ear web 44 is described hereafter as being a single material web that is processed to form discrete ears, it is recognized that back ear panels could instead be formed of multiple materials and/or multiple panels or sections joined together, such as an ear panel coupled to an extension panel, for example. [0042] As shown in FIG. 9, each of the lanes 44a, 44b of the ear web is provided to an ear cut and re-pitch apparatus 48 that cuts the continuous ear web lanes 44a, 44b into discrete back ears 16a and re-pitches the discrete ears for application onto topsheet 12 running in a machine direction 49. Each ear cut and re-pitch apparatus 48 may be comprised of a cylindrical rotating vacuum anvil 50 and a rotating knife roll 52. Each lane of ear web material 44a, 44b may be fed at a relatively low speed along the vacuum face of a respective rotating anvil 50, which is moving at a relatively higher surface speed and upon which the incoming ear web 44a, 44b is allowed to “slip.” A knife-edge (not shown), mounted on the rotating knife roll 52, cuts off a segment of the incoming ear web 44a, 44b against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the anvil's surface. Once cut, the web segment (i.e. , a discrete back ear 16a) is held by vacuum drawn through holes on face of the anvil 50 as it is carried at the anvil's speed downstream to a transfer roll 54 or other suitable transfer device. The transfer roll 54 may be a high vacuum drum that grabs ears 16a from both of the ear cut and re-pitch apparatuses 48 and retains the ears 16a thereon on left and ride sides of the transfer roll 54 until reaching a transfer point 56, with the rotational speed of transfer roll 54 matching the speed of topsheet 12.

[0043] At the transfer point 56, a combining roll 58 interacts with the transfer roll 54 (collectively forming a transfer and combining unit 59) to cause the back ears 16a to transfer onto each of opposing edges 20 of the running topsheet 12. According to one embodiment, the combining roll 58 may be configured as a bump roll unit that bumps the topsheet 12 into contact with the back ears 16a on transfer roll 54. In such an embodiment, the back ears 16a may be secured to the topsheet 12 via an adhesive applied by an adhesive applicator 60, where the adhesive is applied to topsheet 12 upstream from the transfer point 56. The adhesive is applied in a pattern that matches the locations at which back ears 16a are to be applied to the topsheet 12, and the combining roll 58 (bump roll unit) bumps the adhesive on topsheet 12 into contact with the ears 16a to attach them to the topsheet 12. In alternative embodiments, back ears 16a may be mechanically, thermally, or ultrasonically bonded to topsheet 12, with the bonding operation occurring at the transfer point 56 or at a point downstream therefrom via use of a bonding unit 61 (shown in phantom), such as the interaction of a horn and anvil, as known in the art. In yet other embodiments, adhesive may be applied to the ear web 44a, 44b via adhesive applicators 63 located upstream of the ear cut and re-pitch apparatuses 48.

[0044] Referring still to FIG. 9, and with reference back to FIGS. 3A-3C, the back ears 16a attached to topsheet 12 are positioned such that an outer edge 18 of each ear 16a is aligned with an edge 20 of topsheet 12. That is, the back ears 16a are positioned on topsheet 12 such that an outer edge 18 of each ear is flush (or nearly flush) with edge 20 of topsheet 12. The outer edge 18 of each back ear 16a is bonded to topsheet 12 at these locations via one of the bonding techniques described above (adhesive, ultrasonic, heat/pressure, etc.).

[0045] It is recognized that, in addition to attaching back ears 16a to topsheet 12, front ears 16b (FIG. 3A) may also be attached to topsheet 12, according to an embodiment. The formation and attachment of front ears 16b would be similar to that of back ears 16a, with lanes of ear web material 44 being provided to ear cut and repitch apparatuses and a transfer roll (not shown) that collectively function to form discrete front ears 16b and re-pitch the discrete ears for application onto topsheet 12. Alternatively, lanes 44a and 44b could be fed into a single ear cut and re-pitch apparatus 48 or slip cut unit that cuts both back ears 16a side by side and applies them to the transfer roll 54.

[0046] As shown in FIG. 9, upon attachment of ears (back ears 16a and, optionally, front ears 16b) to topsheet 12, an edge fold of the ear-web assembly 10 is performed by a folding apparatus 62. The folding apparatus 62 operates to form a continuous edge fold of the topsheet 12 as the topsheet is pulled therethrough, with a fold being formed on each of opposing edges 20 (FIG. 3B) of the topsheet 12, as shown in FIGS. 3B and 3C, for example. Each of ears 16 is folded along with topsheet 12 as part of the continuous edge fold, such that the folding of individual ears 16 is not required. The folding apparatus 62 forms a folded portion 30 on each edge 20 of topsheet 12 of a desired width, such that the width of the folded portions 30 may be controlled as well as an overall width of the resulting folded topsheet 12. The folding apparatus 62 may include any known folding device(s), such as one or more plow folding devices, one or more folding boards, or one or more roller edge folding devices, as non-limiting examples. [0047] Additional processing steps are performed downstream of folding apparatus 62, as illustrated in FIG. 9. According to one embodiment, the additional processing steps include the addition of elastics 34, core 64, backsheet 14, and waistband 66 at combining point 68. Elastics 34 and core 64 may be applied in a known manner, while backsheet 14 is applied to topsheet 12 such that the folded portion 30 of ear-web assembly 10 is sandwiched between the unfolded portion of topsheet 12 and backsheet 14 (FIGS. 3A-3C). The backsheet 14 is bonded to the topsheet 12 via a bonding unit 69 positioned at or downstream of the combining point 68, with the bonding unit 69 bonding backsheet 14 and topsheet 12 via adhesive bonding, ultrasonic bonding, thermal bonding, mechanical bonding, or another known bonding technique. A continuous formed assembly 70 output from the combining point 68 (and bonding unit 69) is then cut into discrete diapers 42 at knife unit 72, with the discrete diapers 42 then subsequently folded and packaged (as indicated at 76 and 78, respectively) according to one embodiment.

[0048] In an alternative embodiment, and as shown in phantom in FIG. 9, elastic strands 34 may be added prior to the edge folding of ear-web assembly 10 by folding apparatus 62. The elastic strands 34 are coupled to the bottom surface of topsheet 12 adjacent edges 20 thereof, in the area that is to become the folded portion 30. Upon folding ear-web assembly 10, the elastics 34 are positioned within the folded portion 30. This addition of elastic strands 34 prior to the continuous folding of ear-web assembly 10 can reduce congestion in the manufacturing line 40 by allowing for removal of the step of introducing elastic strands 34 at a combining point 68 with the core (not shown) and backsheet 14.

[0049] Beneficially, embodiments of the invention thus provide a system and method for attaching and folding ears on a running web during fabrication of an absorbent article, so as to produce an article with desirable aesthetic and tactile characteristics. An edge of each ear is aligned with an edge of the running web and the edges of the running web are continuously folded, such that the edges of the ears are folded along with the topsheet edges. The resulting article thus includes a soft folded edge topsheet construction similar to a clothing seam that is both cosmetically appealing and comfortable to wear. [0050] Therefore, according to one embodiment of the invention, a laminate for use in an absorbent article includes a topsheet comprising a first surface and a second surface, a backsheet positioned facing the second surface of the topsheet, and a plurality of ears positioned on the first surface of the topsheet to form an ear-web assembly, with a first ear of the plurality of ears having an outer edge aligned with a first edge of the topsheet and a second ear of the plurality of ears having an outer edge aligned with a second edge of the topsheet opposite from the first edge. The earweb assembly comprises a continuous edge folded portion adjacent each of the first and second edges thereof extending a length of the topsheet, wherein a portion of each of the plurality of ears is folded within the continuous edge folded portion.

[0051] In accordance with another embodiment of the invention, a method of manufacturing a laminate for use in an absorbent article is provided. The method includes providing a topsheet running in a machine direction, attaching a plurality of ears onto the topsheet on a top surface thereof such that an outer edge of each of the plurality of ears is aligned with one of a first edge and a second edge of the topsheet, and continuously folding each of the first edge and the second edge of the topsheet away from the top surface and onto a back surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to the continuous folding of the first and second edges. The method also includes attaching a backsheet to the back surface of the topsheet. The continuous folding of the first edge and the second edge of the topsheet, and the accompanying folding of each of the plurality of ears, forms a pair of folded portions positioned between the backsheet and an unfolded portion of the topsheet.

[0052] In accordance with another embodiment of the invention, a machine for manufacturing an absorbent article includes a means for attaching a plurality of ears onto a top surface of a running topsheet such that an outer edge of each of the plurality of ears is generally aligned with one of a first edge and a second edge of the topsheet, and a means for continuously folding each of the first edge and the second edge of the topsheet away from the top surface and onto a bottom surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to the continuous folding of the first and second edges, so as to form a pair of folded portions. The machine also includes a means for attaching a backsheet to the bottom surface of the topsheet such that the pair of folded portions is positioned between the backsheet and an unfolded portion of the topsheet.

[0053] In accordance with yet another embodiment of the invention, a machine for manufacturing an absorbent article includes a first cut and re-pitch apparatus configured to cut a first continuous ear web into discrete first ears and re-pitch the discrete first ears, a second cut and re-pitch apparatus configured to cut a second continuous ear web into discrete second ears and re-pitch the discrete second ears, and a transfer and combining unit configured to transfer the first discrete ears and the second discrete ears from the first cut and re-pitch apparatus and the second cut and re-pitch apparatus, respectively, onto a top surface of a running topsheet, the transfer and combining unit attaching the first discrete ears and the second discrete ears onto the top surface of the running topsheet such that an outer edge of each of the discrete first ears is generally aligned with a first edge of the topsheet and an outer edge of each of the discrete second ears is generally aligned with a second edge of the topsheet. The machine also includes a folding apparatus configured to continuously fold each of the first edge and the second edge of the topsheet away from the top surface and onto a bottom surface of the topsheet, with each of the plurality of ears being folded along with the topsheet responsive to folding of the first and second edges, so as to form a pair of folded portions. The machine further includes a bonding unit configured to attach a backsheet to the bottom surface of the topsheet such that the pair of folded portions is positioned between the backsheet and an unfolded portion of the topsheet.

[0054] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description but is only limited by the scope of the appended claims.