Zero scrap method for manufacturing side panels for absorbent articles

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal
• side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• c) separating said first panel from said second panel;
• d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• and
• e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• c) separating said first panel from said second panel;
• d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• and
• e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edge, the method comprising the steps of:

• a) providing a web of material in a machine direction said web having predetermined portions;
• b) activating said predetermined portions of said web of material to impart elasticity thereto;
• c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• d) separating said first panel from said second panel;
• e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• and
• f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article.
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) activating said predetermined portions of said web of material to impart elasticity thereto;
• c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• d) separating said first panel from said second panel;
• e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• g) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;
• h) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web;
• and
• i) joining said side panels along said longitudinal edges of said diaper web;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• c) separating said first panel from said second panel;
• d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• f) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;
• g) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web;
• and
• h) joining said side panels along said longitudinal edges of said diaper web;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• c) separating said first panel from said second panel;
• d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• f) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;
• g) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web;
• and
• h) joining said side panels along said longitudinal edges of said diaper web;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

• a) providing a web of material in a machine direction, said web having predetermined portions;
• b) activating said predetermined portions of said web of material to impart elasticity thereto
• c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;
• d) separating said first panel from said second panel;
• e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;
• f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;
• g) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;
• h) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web;
• and
• i) joining said side panels along said longitudinal edges of said diaper web;
• wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.