Method of manufacturing an absorbent article having fully encircling bodyside and garment-side waistband

1. A method for manufacturing absorbent articles, the method comprising:

delivering a continuous web assembly including a backsheet material, a liquid permeable bodyside liner material, and an absorbent structure interposed between the backsheet material and the bodyside liner material, the web assembly having a body-facing side and a garment-facing side;

attaching a discrete segment of first waist elastic material to the body-facing side of the web assembly;

attaching a discrete segment of second waist elastic material to the garment-facing side of the web assembly such that the web assembly is interposed between the discrete segments of first and second waist elastic materials;

attaching a discrete segment of third waist elastic material to the body-facing side of the web assembly;

attaching a discrete segment of fourth waist elastic material to the garment-facing side of the web assembly such that the web assembly is interposed between the discrete segments of third and fourth waist elastic materials; and

cutting the web assembly to form a plurality of absorbent articles.

2. The method as set forth in claim 1 wherein at least one of attaching the discrete segment of first waist elastic material and attaching the discrete segment of second waist elastic material comprises:

moving a web of waist elastic material;

cutting the web of waist elastic material into a plurality of discrete segments of waist elastic material;

orienting the discrete segments of waist elastic material in a cross-machine direction; and

attaching the discrete segments of waist elastic material to the web assembly in the cross-machine direction.

3. The method as set forth in claim 1 further comprising:

registering one of the discrete segments of first waist elastic material and second waist elastic material with the web assembly; and

registering the other of the discrete segments of first waist elastic material and second waist elastic material with the discrete segment of waist elastic material registered with the web assembly.

4. The method as set forth in claim 1 wherein the web assembly includes laterally opposing side edges, the discrete segment of second waist elastic material includes laterally opposing side edges, and attaching the discrete segment of second waist elastic material includes attaching the discrete segment of second waist elastic to the garment-facing side of the web assembly such that the side edges of the discrete segment are substantially aligned with the side edges of the web assembly.

5. The method as set forth in claim 1 wherein cutting the web assembly comprises cutting the discrete segment of first waist elastic material and the discrete segment of second waist elastic material along a mid-line to form two absorbent articles each having at least one bodyside waist elastic member and at least one garment-side waist elastic member.

6. The method as set forth in claim 1 wherein at least one of the discrete segment of first waist elastic material and the discrete segment of second waist elastic material are stretched in the cross-machine direction before being attached to the web assembly.

7. The method as set forth in claim 1 wherein the discrete segment of first waist elastic material is attached to the web assembly under a greater amount of elongation than the discrete segment of second waist elastic material.

8. The method as set forth in claim 1 wherein attaching at least one of the discrete segment of first waist elastic material and the discrete segment of second waist elastic material comprises at least one of thermal bonding, pressure bonding, adhesive bonding, and ultrasonic bonding.

9. The method as set forth in claim 1 wherein at least one of attaching the discrete segment of first waist elastic material and attaching the discrete segment of second waist elastic material comprises attaching the discrete segment of waist elastic material using an elastic construction adhesive.

10. The method as set forth in claim 1 wherein the backsheet material comprises a liquid impermeable material.

11. A method for manufacturing absorbent articles, the method comprising:

delivering a continuous web assembly including a backsheet material, a liquid permeable bodyside liner material, and an absorbent structure interposed between the backsheet material and the bodyside liner material, the web assembly having a body-facing side and a garment-facing side;

attaching a discrete segment of first waist elastic material to the body-facing side of the web assembly to define a bodyside front waist elastic member;

attaching a discrete segment of second waist elastic material to the garment-facing side of the web assembly to define a garment-side front waist elastic member such that the web assembly is interposed between the discrete segments of first and second waist elastic materials;

attaching a discrete segment of third waist elastic material to the body-facing side of the web assembly to define a bodyside rear waist elastic member;

attaching a discrete segment of fourth waist elastic material to the garment-facing side of the web assembly to define a garment-side rear waist elastic member such that the web assembly is interposed between the discrete segments of third and fourth waist elastic materials; and

cutting the web assembly to form a plurality of absorbent articles.

12. The method as set forth in claim 11 further comprising stretching the discrete segment of first waist elastic material before attaching the discrete segment of first waist elastic material to the body-facing side of the web assembly.

13. The method as set forth in claim 12 further comprising stretching the discrete segment of second waist elastic material before attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly.

14. The method as set forth in claim 13 wherein the discrete segment of first waist elastic material is stretched a greater amount than the discrete segment of second waist elastic material.

15. The method as set forth in claim 11 further comprising:

supplying a first continuous web of waist elastic material to a cutting station;

cutting the first continuous web of waist elastic material at the cutting station to define a plurality of the discrete segments of first waist elastic material;

supplying a second continuous web of waist elastic material to a cutting station; and

cutting the second continuous web of waist elastic material at the cutting station to define a plurality of the discrete segments of second waist elastic material.

16. The method as set forth in claim 11 further comprising registering the discrete segment of second waist elastic material in opposed relationship with the first waist elastic material before attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly.

17. The method as set forth in claim 16 wherein attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly comprises point bonding the discrete segment of second waist elastic material to the garment-facing side of the web assembly.

18. A method for manufacturing absorbent articles, the method comprising:

delivering a continuous web assembly including a backsheet material, a liquid permeable bodyside liner material, and an absorbent structure interposed between the backsheet material and the bodyside liner material, the web assembly having a body-facing side and a garment-facing side;

attaching a discrete segment of first waist elastic material to the body-facing side of the web assembly to define a bodyside rear waist elastic member;

attaching a discrete segment of second waist elastic material to the garment-facing side of the web assembly to define a garment-side rear waist elastic member such that the web assembly is interposed between the discrete segments of first and second waist elastic materials;

attaching a discrete segment of third waist elastic material to the body-facing side of the web assembly to define a bodyside front waist elastic member;

attaching a discrete segment of fourth waist elastic material to the garment-facing side of the web assembly to define a garment-side front waist elastic member such that the web assembly is interposed between the discrete segments of third and fourth waist elastic materials; and

cutting the web assembly to form a plurality of absorbent articles.

19. The method as set forth in claim 18 further comprising stretching the discrete segment of first waist elastic material before attaching the discrete segment of first waist elastic material to the body-facing side of the web assembly.

20. The method as set forth in claim 19 further comprising stretching the discrete segment of second waist elastic material before attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly.

21. The method as set forth in claim 20 wherein the discrete segment of first waist elastic material is stretched a greater amount than the discrete segment of second waist elastic material.

22. The method as set forth in claim 18 further comprising:

supplying a first continuous web of waist elastic material to a cutting station;

cutting the first continuous web of waist elastic material at the cutting station to define a plurality of the discrete segments of first waist elastic material;

supplying a second continuous web of waist elastic material to a cutting station; and

cutting the second continuous web of waist elastic material at the cutting station to define a plurality of the discrete segments of second waist elastic material.

23. The method as set forth in claim 18 further comprising registering the discrete segment of second waist elastic material in opposed relationship with the first waist elastic material before attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly.

24. The method as set forth in claim 23 wherein attaching the discrete segment of second waist elastic material to the garment-facing side of the web assembly comprises point bonding the discrete segment of second waist elastic material to the garment-facing side of the web assembly.