Methods and Apparatus for Assembling Refastenable Absorbent Articles

A method for assembling refastenable absorbent articles, each absorbent article comprises a chassis having a topsheet, backsheet, and an absorbent core disposed between the topsheet and the backsheet, wherein the chassis defines a first waist region longitudinally opposed to a second waist region, and having a longitudinal axis and a lateral axis, each absorbent article further comprising a first waist belt connected with the first waist region and a second waist belt connected with the second waist region, wherein a first discrete fastener component joins first end regions of the first and second waist belts and a second discrete fastener component joins second end regions of the first and second waist belts, wherein the first and second discrete fastener components are refastenably connected with the first waist belt and permanently connected with the second waist belt, the method comprising the steps of:

• advancing a continuous length of chassis assemblies in a machine direction;
• cutting the continuous length of chassis assemblies into discrete chassis;
• advancing the discrete chassis in the machine direction onto a carrier apparatus, wherein the carrier apparatus comprises a frame rotatable about an axis of rotation, and a transfer member connected with the frame, wherein the transfer member is rotatable about a second axis of rotation that is orthogonal to the first axis of rotation, wherein the transfer member has a first portion and a second portion, wherein the topsheet of the discrete chassis contacts the first portion of the transfer member;
• advancing a continuous length of fastener assemblies in the machine direction;
• cutting the continuous length of fastener assemblies into discrete fastener components, wherein each discrete fastener component define a first surface and a second surface, each discrete fastener component comprising a first end region and an opposing second end region separated by a central region;
• advancing the discrete fastener components in the machine direction onto the carrier apparatus, wherein the second surface of the discrete fastener component contacts the second member of the transfer member, wherein the discrete fastener component is positioned adjacent to the chassis;
• advancing a first waist belt web in the machine direction, wherein the first waist belt web defines a first surface and a second surface;
• advancing a second waist belt web in the machine direction, wherein the second waist belt web defines a first surface and a second surface;
• reorienting the discrete chassis such that the lateral axis is parallel with the machine direction by rotating the transfer member about the second axis of rotation;
• combining the first waist region of the chassis intermittently along the first surface of the first waist belt web, the second waist region of the chassis intermittently along the first surface of the second waist belt;
• combining the first surface of the discrete fastener component to the first surface of the second waist belt web;
• folding the chassis to position the first waist region of the chassis into a face-to-face relationship with the second waist region of the chassis using a folding apparatus, wherein the second surface of the discrete fastener component is in a face-to-face relationship with the folding apparatus;
• bonding the second surface of the discrete fastener component with the first waist belt web;
• and
• cutting the first and second waist belt webs in a cross direction along the central region of the discrete fastener component to form a first absorbent article having a first discrete fastener component and a second absorbent article having a second discrete fastener component.

An apparatus for forming a refastenable absorbent article, the apparatus comprising:

• a frame rotatable about an axis of rotation;
• a transfer member connected with the frame and extending radially outward from the frame, wherein:
• the transfer member is rotatable about a second axis of rotation that is orthogonal to the first axis of rotation;
• the transfer member comprises a first portion and a second portion, wherein the portion defines a first end region and a second end region separated by a central region, wherein the second portion comprises a proximal region and a distal region, wherein the proximal region of the second portion is connected with the first end region of the first portion such that the second portion forms an arm extending from the first portion of the transfer member, and
• the transfer member defines an outer surface located at the farthest radially outward surface of the transfer member, wherein the first and second portions each have an outer surface that forms the outer surface of the transfer member.