Process for cutting of discrete components of a multi-component workpiece and depositing them with registration on a moving web of material

A process for manufacturing a multi-component product comprising at least two components cut from respective first and second moving webs of material, registering the components with respect to one another, and depositing the registered components on a third moving web of material, said components having respective leading and trailing edges, lengths between said leading and trailing edges, a longitudinal center line, and a longitudinal center defined by a point midway on said longitudinal center line between said leading and trailing edges, said process comprising the steps of:

• a) cutting on a first die cut and transfer apparatus a first workpiece component from a web of first material moving at a first speed;
• b) directly transferring the cut first workpiece component from a first die cut and transfer apparatus overlay a web of a second material on a second die cut and transfer apparatus positioned adjacent the first die cut and transfer apparatus and moving at a second speed;
• c) registering the cut first workpiece component with respect to the web of second material such that when the second workpiece component is cut from the second web of material, the longitudinal centers of the first and said second workpiece components substantially coincide;
• d) cutting the second workpiece component from the second web while incorporating the overlying cut first workpiece component wholly within the cut boundaries of the second workpiece component;
• and
• e) transferring the cut first and second workpiece components to a third web of material moving at a third speed.

A process for manufacturing a multi-component product comprising at least two components cut from moving webs of material, registering the components with respect to one another, and depositing the registered components on a web of moving material, said components having respective leading and trailing edges, a longitudinal center line, and a longitudinal center defined by a point midway on said longitudinal center line between said leading and trailing edges, said process comprising the steps of

• a) cutting on a first die cut and transfer apparatus a first workpiece component from a first web of material moving at first speed;
• b) directly transferring the cut first workpiece component from the first die cut and transfer apparatus to overly a web of a second material on a second die cut and transfer apparatus positioned adjacent the first die cut and transfer apparatus and moving at a second speed;
• c) adjusting the longitudinal center of said cut first workpiece component with respect to the longitudinal center of said second workpiece component prior to cutting said second workpiece component from said second web of material;
• d) cutting on the second die cut roller a second workpiece component from the second web so that the first cut component overlies the cut second component;
• and
• e) transferring the cut first and second workpiece components to a third web of material moving at a third speed.

A process for producing a sanitary napkin comprising a cover layer permeable to body fluids, a body fluid distribution layer component lying next adjacent the cover layer, and a body fluid transfer delay layer component lying next adjacent the distribution layer component, the process comprising the steps of:

• a) cutting on a first die cut and transfer apparatus the body fluid distribution component from a first web of material moving at a first speed;
• b) directly transferring the body fluid distribution component from a first die cut and transfer apparatus to overlay a web of body fluid transfer delay material on a second die cut and transfer apparatus positioned adjacent the first die cut and transfer apparatus and moving at a second speed;
• c) cutting the body fluid transfer delay component from the web of body fluid transfer delay material while the body fluid distribution component overlies the body fluid transfer delay component;
• and
• d) transferring the cut body fluid distribution component and body fluid transfer delay component to a web of cover material moving at a third speed.