Method of forming a containment system for an absorbent article

A method of forming a containment system for an absorbent article comprising a first containment flap and a second containment flap each including a stem, an inner flap projection extending away from the stem, and an outer flap projection extending away from the stern and the inner flap projection, the absorbent article including a body facing liner, a backsheet coupled to the body facing liner, and an absorbent body positioned between the body facing liner and the backsheet, the method comprising:

• providing a substrate having a first surface and a second surface, the first surface being opposite the second surface, the substrate including a first half and a second half divided by a centerline, the first half being on a first side of the centerline and the second half being on a second side of the centerline;
• attaching a first elastic member to the first surface in the first half of the substrate;
• attaching a second elastic member to the first surface in the second half of the substrate;
• folding a first portion of the first half of the substrate over the first elastic member towards the centerline;
• folding a first portion of the second half of the substrate over the second elastic member towards the centerline;
• folding a second portion of the first half of the substrate towards the centerline onto a third portion of the first half of the substrate such that the first portion of the first half of the substrate is folded onto the third portion of the first half of the substrate;
• bonding the folded first portion of the first half of the substrate to the third portion of the first half of the substrate to form the inner flap projection and the outer flap projection of the first containment flap;
• folding a second portion of the second half of the substrate towards the centerline onto a third portion of the second half of the substrate such that the first portion of the second half of the substrate is folded onto the third portion of the second half of the substrate;
• bonding the folded first portion of the second half of the substrate to the third portion of the second half of the substrate to form the inner flap projection and the outer flap projection of the second containment flap;
• slitting the substrate at the centerline to separate the first half of the substrate from the second half of the substrate;
• bonding the first half of the substrate to the absorbent article on a first side of a longitudinal axis of the article, the first half of the substrate forming the first containment flap, the first half of the substrate being bonded to the absorbent article such that the stem of the first containment flap is laterally inward from a first longitudinal side edge of the absorbent article on the first side of the longitudinal axis;
• bonding the second half of the substrate to the absorbent article on a second side of the longitudinal axis of the article, the second half of the substrate forming the second containment flap, the second half of the substrate being bonded to the absorbent article such that the stem of the second containment flap is laterally inward from a second longitudinal side edge of the absorbent article on the second side of the longitudinal axis;
• securing the first portion of the first half of the substrate that forms a part of the outer flap projection of the first containment flap to the third portion of the first half of the substrate in at least a portion of at least one of a front end region of the absorbent article and a rear end region of the absorbent article, but not in a crotch region of the absorbent article;
• and
• securing the first portion of the second half of the substrate that forms a part of the outer flap projection of the second containment flap to the third portion of the second half of the substrate in at least a portion of at least one of the front end region of the absorbent article and the rear end region of the absorbent article, but not in the crotch region of the absorbent article.

A method of forming a containment system for an absorbent article comprising a first containment flap and a second containment flap, the absorbent article including a body facing liner, a backsheet coupled to the body facing liner, an absorbent body positioned between the body facing liner and the backsheet, a first elasticized leg cuff, and a second elasticized leg cuff, the method comprising:

• providing a first substrate and a second substrate each having a first surface and a second surface, the first surface being opposite the second surface, the first substrate and the second substrate each having a proximal end and a distal end wherein the first substrate and the second substrate are joined together at a centerline at the proximal end of the first substrate and the proximal end of the second substrate as a single substrate, the first substrate being on a first side of the centerline and the second substrate being on a second side of the centerline;
• attaching a first elastic member to the first surface of the first substrate;
• attaching a second elastic member to the first surface of the second substrate;
• folding a first portion of the first substrate near the distal end of the first substrate over the first elastic member towards the proximal end of the first substrate;
• folding a first portion of the second substrate near the distal end of the second substrate over the second elastic member towards the proximal end of the second substrate;
• applying a first adhesive to the first substrate in a position to engage the first portion of the first substrate;
• applying a first intermittent adhesive to the first substrate in a position to engage the first portion of the first substrate near a first fold line created by folding the first portion of the first substrate over the first elastic member towards the proximal end of the first substrate;
• applying a second adhesive to the second substrate in a position to engage the first portion of the second substrate near a second fold line created by folding the first portion of the second substrate over the second elastic member towards the proximal end of the second substrate;
• applying a second intermittent adhesive to the second substrate in a position to engage the first portion of the second substrate near a fold line created by folding the first portion of the second substrate over the second elastic member towards the proximal end of the second substrate;
• folding a second portion of the first substrate towards the proximal end of the first substrate onto a third portion of the first substrate such that the first portion of the first substrate is bonded to the third portion of the first substrate at the first adhesive and the first portion of the first substrate is intermittently bonded to the third portion of the first substrate at the first intermittent adhesive;
• folding a second portion of the second substrate towards the proximal end of the second substrate onto a third portion of the second substrate such that the first portion of the second substrate is bonded to the third portion of the second substrate at the second adhesive and the first portion of the second substrate is intermittently bonded to the third portion of the second substrate at the second intermittent adhesive;
• slitting the single substrate to separate the first substrate and the second substrate;
• moving the first substrate from the first side of the centerline to the second side of the centerline after slitting the single substrate;
• moving the second substrate from the second side of the centerline to the first side of the centerline after slitting the substrate;
• bonding the first substrate to the absorbent article laterally inward from the first elasticized leg cuff to form the first containment flap;
• and
• bonding the second substrate to the absorbent article laterally inward from the second elasticized leg cuff to form the second containment flap;
• wherein the first intermittent adhesive and the second intermittent adhesive are registered and the first substrate and the second substrate are bonded to the absorbent article such that the first intermittent adhesive and the second intermittent adhesive are present in at least a portion of at least one of a front end region and a rear end region of the absorbent article and are not present in a crotch region of the absorbent article.