An absorbent article with a fastening system with reduced waste and method of manufacturing such an absorbent article is disclosed. The method of manufacturing an absorbent article can include cutting a first web of ear tab material to provide a first ear tab that is registered and cutting a second web of ear tab material to provide a second ear tab that is registered. The method can also include providing a web of ear panel material, coupling the first and second ear tabs to the web of ear panel material, cutting the web of ear panel material to provide first and second ear panels to form first and second ears, and coupling the first and second ears to the absorbent assembly to form at least a portion of the fastening system for the absorbent article. The first and second ears can be configured to be different from one another.

An absorbent structure includes a first area of fibrous absorbent material and a second area of fibrous absorbent material. The first area has a greater basis weight than the second area. The second area includes a plurality of segments separated by vertical interfaces. Each of the vertical interfaces has a width less than 1 cm. Bridging of fibrous absorbent material extends across the vertical interfaces.

A disposable absorbent article having a topsheet; a backsheet; and an absorbent core disposed between the topsheet and the backsheet, is described. The disposable absorbent article includes a first side edge and an opposing second side edge; a first side flap and an opposing second side flap, each of the first and second side flaps forming at least a portion of the wearer-facing surface, each of the first and second side flaps having a first layer and a second layer. The first layer has a first layer proximal edge and the second layer has a second layer proximal edge. The second layer proximal edge is disposed laterally outboard from the first layer proximal edge.

A disposable absorbent article having a topsheet; a backsheet; and an absorbent core disposed between the topsheet and the backsheet, is described. The disposable absorbent article includes a first side edge and an opposing second side edge; a first side flap and an opposing second side flap, each of the first and second side flaps forming at least a portion of the wearer-facing surface, each of the first and second side flaps having a first layer and a second layer. The first layer has a first layer proximal edge and the second layer has a second layer proximal edge. The second layer proximal edge is disposed laterally outboard from the first layer proximal edge.

An absorbent article comprises a front waist region, a back waist region, a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. The absorbent core may comprise an absorbent material. The absorbent article may comprise a pair of back ears in the back waist region and a pair of front ears in the front waist region. The front ears may comprise a pattern. The pattern may comprise three-dimensional features and/or visually distinguishable zones.

A disposable absorbent article with a water-permeable covering sheet, a water-impermeable center sheet, and an absorbent core disposed therebetween is disclosed herein. The absorbent article includes a pair of side flaps comprising a first side flap and an opposing second side flap; each of the first and second side flaps being made from a distinct layer of material that is not an extension of the water-permeable covering sheet or the water-impermeable center sheet. The distinct layer of material is doubled over to form a first layer comprising a first layer proximal edge, and a second layer comprising a second layer proximal edge, wherein the first layer and the second layer enclose an elastic strand, and wherein the first layer is attached to the second layer.

A tape-type disposable diaper in which a lower edge of a non-connecting portion of a connecting tape has a shape in which a tangent angle θ decreases without having a critical point and an inflection point from a distal end far from a base portion of the connecting tape to a proximal end close to the base portion. A shorter one of a distance in a width direction between the proximal end of the lower edge of the non-connecting portion and the distal end of the lower edge of the non-connecting portion and a distance in a front-back direction between the proximal end of the lower edge of the non-connecting portion and the distal end of the lower edge of the non-connecting portion is set to r, the entire lower edge of the non-connecting portion exclusively includes a part having a radius of curvature of 0.8r or more.

An absorbent article with a fastening system with reduced waste and method of manufacturing such an absorbent article is disclosed. The method of manufacturing an absorbent article can include cutting a first web of ear tab material to provide a first ear tab that is registered and cutting a second web of ear tab material to provide a second ear tab that is registered. The method can also include providing a web of ear panel material, coupling the first and second ear tabs to the web of ear panel material, cutting the web of ear panel material to provide first and second ear panels to form first and second ears, and coupling the first and second ears to the absorbent assembly to form at least a portion of the fastening system for the absorbent article. The first and second ears can be configured to be different from one another.

An absorbent article with a fastening system with reduced waste and method of manufacturing such an absorbent article is disclosed. The method of manufacturing an absorbent article can include cutting a first web of ear tab material to provide a first ear tab that is registered and cutting a second web of ear tab material to provide a second ear tab that is registered. The method can also include providing a web of ear panel material, coupling the first and second ear tabs to the web of ear panel material, cutting the web of ear panel material to provide first and second ear panels to form first and second ears, and coupling the first and second ears to the absorbent assembly to form at least a portion of the fastening system for the absorbent article. The first and second ears can be configured to be different from one another.

The present invention provides a method of providing a disposable product with a contoured leg opening. In this method at least one chip is removed from at least one ear of a disposable product. The chip may be removed from an ear prior to attaching the ear to the chassis web. Alternatively, the chip may be removed from the ear after the ear is attached to the chassis web.