Method for making a disposable garment having softer waist and leg cuffs

A method of making an absorbent personal care product comprising, the steps, in the order stated, of:

• a) creating a retention-barrier composite web on a first component line by:
• i) wrapping a fluff pad in tissue forming a continuous retention web;
• ii) feeding an extendible, vapor-permeable, liquid barrier sheet material into the first component line;
• iii) adhering a spacer layer on the barrier sheet;
• iv) laminating the retention web to the spacer layer thereby creating a retention-barrier composite web;
• v) cutting leg openings in the retention-barrier composite web;
• and
• vi) cutting the retention-barrier composite web to individual garment lengths;
• b) creating a precursor product web on a conversion line by:
• i) feeding a soft and flexible backsheet (elastic or extensible) into the conversion line;
• ii) adding soft and flexible waist elastics to the backsheet;
• iii) adding soft and flexible leg elastics to the backsheet;
• iv) coating the construction of steps i)-iii) with adhesive and adhering the retention-barrier composite web thereto;
• v) adhering a fluid distribution layer over and within the central portion of the retention-barrier composite web;
• vi) adhering a soft and flexible topsheet (elastic and extensible) over the whole construction of steps i)-v);
• vii) cutting leg holes in the backsheet and the topsheet and leaving said leg elastics adjacent the leg holes;
• and
• viii) cutting the precursor product web into individual absorbent personal care products.

An absorbent personal care product consisting of:

• a) a retention-barrier composite web having an absorbent material adhered to an extendible vapor-permeable, liquid barrier sheet and cut to individual product lengths;
• b) an extendible soft and flexible backsheet having soft and flexible waist elastics adhered to the backsheet and tensioned soft and flexible leg elastics adhered to the backsheet;
• c) the retention-barrier composite web adhered to the backsheet in an area between the waist elastics and the leg elastics;
• d) a fluid distribution layer adhered over and within the central portion of the retention-barrier composite web;
• and
• e) an extendible soft and flexible topsheet adhered to the soft and flexible backsheet and covering the retention-barrier composite web, the fluid distribution layer, the waist elastics and the leg elastics.