Methods of making elastic belts for absorbent articles

Abstract

The present disclosure is directed to methods of manufacturing elastic belts for absorbent articles. The elastic belts may be used as waist bands, or portions thereof, in absorbent articles. The elastic belts may define a first nonwoven substrate, a second nonwoven substrate, and a plurality of elastic strands positioned intermediate the first and second nonwoven substrates. The elastic belts may define a plurality of apertures therethrough to create breathability in the elastic belts.

What is claimed is: 
     
         1 . A method of making a three-dimensional, apertured elastic belt for an absorbent article, the method comprising:
 conveying an elastic belt in a machine direction, wherein the elastic belt comprises a first nonwoven substrate, a second nonwoven substrate, and a plurality of elastic strands positioned intermediate the first nonwoven substrate and the second nonwoven substrate, wherein the elastic strands are strained in the machine direction, wherein the first nonwoven substrate has a first cross-directional width, wherein the second nonwoven substrate has a second cross-directional width, and wherein the first cross-directional width is greater than the second cross-directional width;   folding a portion of the first nonwoven substrate over a portion of the second nonwoven substrate;   providing a first roll having a first rotational axis;   providing a second roll having a second rotational axis, wherein the first rotational axis and the second rotational axis are positioned generally parallel to each other to form a nip between the first and second rolls;   rotating the first roll in a first direction about the first rotational axis;   rotating the second roll in a second, opposite direction about the second rotational axis;   using the first and second rolls to form apertures through the elastic belt in or proximate to the nip, wherein the apertures have an area in the range of about 0.5 mm 2  to about 3 mm 2 ;   using the first and second rolls to form three-dimensional elements in the elastic belt in or proximate to the nip in areas free of the apertures, wherein the three-dimensional elements are free of the apertures; and   using the first and second rolls to form compressed regions in the nip in the three-dimensional elements or around the apertures.   
     
     
         2 . The method of  claim 1 , wherein the first roll comprises:
 a first radial outer surface;   a first plurality of projections extending at least partially outwardly from the first radial outer surface, wherein the first plurality of projections are configured to form the apertures in the elastic belt;   a first plurality of recesses defined in the first radial outer surface;   first distal portions of at least some of the first plurality of projections forming elongated aperturing structures, wherein the elongated aperturing structures comprise side walls; and   first distal ends of the at least some of the first plurality of projections forming a point.   
     
     
         3 . The method of  claim 2 , wherein the second roll comprises:
 a second radial outer surface;   a second plurality of projections extending at least partially outwardly from the second radial outer surface, wherein the second plurality of projections are configured to form the three-dimensional elements in the elastic belt, and wherein the second plurality of projections comprise second distal portions and second distal ends; and   a second plurality of recesses defined in the second radial outer surface;   wherein at least some of the second distal portions comprise shoulders.   
     
     
         4 . The method of  claim 3 , comprising:
 intermeshingly engaging portions of the first plurality of projections with portions of the second plurality of recesses in the nip; and   intermeshingly engaging portions of the second plurality of projections with portions of the first plurality of recesses in the nip.   
     
     
         5 . The method of  claim 4 , comprising compressing the elastic belt intermediate the side walls of the elongated aperturing structures and the shoulders of the second distal portions to form the compressed regions. 
     
     
         6 . The method of  claim 1 , comprising heating the elastic belt prior to the elastic belt being conveyed through the nip. 
     
     
         7 . The method of  claim 1 , comprising heating the first roll and/or the second roll prior to the elastic belt being conveyed through the nip. 
     
     
         8 . The method of  claim 1 , wherein the elastic strands each comprise a plurality of filaments. 
     
     
         9 . The method of  claim 1 , comprising conveying the elastic belt toward the nip at an in-feed angle relative to a plane of the nip, wherein the in-feed angle is not zero, comprising conveying the elastic belt out of the nip at an out-feed angle relative to a plane of the nip, wherein the out-feed angle is not zero. 
     
     
         10 . The method of  claim 1 , wherein the folding occurs prior to the apertures being formed. 
     
     
         11 . A method of forming absorbent articles on an absorbent article manufacturing line, the method comprising:
 providing an elastic belt, wherein the elastic belt comprises a first nonwoven substrate, a second nonwoven substrate, and a plurality elastic strands positioned intermediate the first nonwoven substrate and the second nonwoven substrate, wherein the plurality of elastic strands are generally oriented in a machine direction, wherein the first nonwoven substrate has a first cross-directional width, wherein the second nonwoven substrate has a second cross-directional width, and wherein the first cross-directional width is greater than the second cross-directional width;   folding a portion of the first nonwoven substrate over a portion of the second nonwoven substrate;   conveying the elastic belt in the machine direction on the absorbent article manufacturing line, wherein the elastic strands are strained in the machine direction during the conveying;   forming apertures through the elastic belt;   forming three-dimensional elements in the elastic belt in areas free of the apertures, wherein the three-dimensional elements are free of the apertures;   using the first and second rolls to form compressed regions in the nip in the three-dimensional elements or around the apertures; and   attaching a portion of an absorbent article chassis to a portion of the second nonwoven substrate, wherein the absorbent article chassis comprises a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet.   
     
     
         12 . The method of  claim 11 , wherein the aperturing comprises:
 providing a first roll having a first rotational axis;   providing a second roll having a second rotational axis, wherein the first rotational axis and the second rotational axis are positioned generally parallel to each other to form a nip between the first and second rolls;   rotating the first roll in a first direction about the first rotational axis;   rotating the second roll in a second, opposite direction about the second rotational axis; and   forming the apertures and the three-dimensional elements in the elastic belt in or proximate to the nip.   
     
     
         13 . The method of  claim 12 , wherein the first roll comprises:
 a first radial outer surface;   a first plurality of projections extending at least partially outwardly from the first radial outer surface, wherein the first plurality of projections are configured to form the apertures in the elastic belt;   a first plurality of recesses defined in the first radial outer surface;   first distal portions of at least some of the first plurality of projections forming elongated aperturing structures, wherein the elongated aperturing structures comprise side walls; and   first distal ends of the at least some of the first plurality of projections forming a point.   
     
     
         14 . The method of  claim 13 , wherein the second roll comprises:
 a second radial outer surface;   a second plurality of projections extending at least partially outwardly from the second radial outer surface, wherein the second plurality of projections are configured to form the three-dimensional elements in the elastic belt, and wherein the second plurality of projections comprise second distal portions and second distal ends; and   a second plurality of recesses defined in the second radial outer surface;   wherein at least some of the second distal portions comprise shoulders.   
     
     
         15 . The method of  claim 14 , comprising:
 intermeshingly engaging portions of the first plurality of projections with portions of the second plurality of recesses in the nip; and   intermeshingly engaging portions of the second plurality of projections with portions of the first plurality of recesses in the nip.   
     
     
         16 . The method of  claim 11 , wherein the elastic strands each comprise a plurality of filaments. 
     
     
         17 . The method of  claim 11 , comprising heating the elastic belt prior to the elastic belt being conveyed through the nip. 
     
     
         18 . The method of  claim 11 , comprising heating the first roll and/or the second roll prior to the elastic belt being conveyed through the nip. 
     
     
         19 . The method of  claim 11 , comprising conveying the elastic belt toward the nip at an in-feed angle relative to a plane of the nip, wherein the in-feed angle is not zero, comprising conveying the elastic belt out of the nip at an out-feed angle relative to a plane of the nip, wherein the out-feed angle is not zero. 
     
     
         20 . The method of  claim 11 , wherein the folding occurs prior to the three-dimensional elements being formed.