Abstract: An apparatus for applying elastics to a running web including a crank and arm, the arm arranged to reciprocate from side to side during use and having a laydown carriage carried on the arm, the laydown carriage including at least one eyelet arranged to support an elastic strand, the assembly further including a shoe guide.

Abstract: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection in deposition of acquisition material, which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera, and an acquisition inverter can flip the material to a correct orientation.

Abstract: A system and method for producing a disposable undergarment, with the lateral edges of the undergarment bonded by means of an ultrasonic horn. When a blank is formed for an individual undergarment, the lateral edges of opposing edges of the blank will form the seam. When the edges are sealed together, a seam is formed. The individual undergarments may be later separated along the seams.

Abstract: A pulpless core is provided with flexibility for superabsorbent expansion by using elastic strands stretched and coupled to a nonwoven layer, and then relaxed partially to create receiving valleys (puckers) and the puckers are provided with superabsorbent polymer, and then a layer of nonwoven or acquisition film can be coupled on top of nonwoven/elastic/sap carrier layers to create an absorbent core laminate. A tubular core can be created and placed into a product with or without additional absorbent material between adjacent tubular members. A printed back sheet corresponding to either the tubular core shape, or void spaces between tubular members can be provide. A forming drum pocket can be profiled to match tube or tube shaped zones and elastic placements between adjacent tubes, if desired.

Abstract: Systems and methods utilizing stationary and/or moveable cutting components provide limited interference with web processing operations, such as pad spin and pitch alteration. Heat, laser, fluid, or mechanical cutting operations may be used, including respectively, a heated element (e.g., wire, ribbon, bar, or embossing or perforating element) that may be triggered inductively, water or steam jets, or improved knife/anvil cooperation.

Abstract: A series of elastic break brakes are provided throughout a travel path of elastics in a machine operation. Elastic strands thread through each individual brake mechanism, and if an elastic strand breaks downstream, a natural snap back of the elastic, which ordinarily travels through the system under tension, drives an immediately upstream cam mechanism back, and holds the elastic thread in place at the elastic break brake immediately upstream of the break as to minimize rethreading required downstream of the elastic break brake.

Abstract: A web cutting system is provided for use with a single transfer insert placement mechanism having at least one puck for transferring a discrete web and a continuous web feeding mechanism for feeding a continuous web wherein first and second rollers having substantially parallel axes and being aligned with one another form a nip at their juncture, an anvil is attached to one roller, a die is attached to the other roller, a vacuum source is coupled to one of the rollers, a plurality of vacuum apertures is formed in the same roller. One of the rollers is positioned adjacent to the single transfer insert placement mechanism and to the continuous web feeding mechanism. The continuous web is applied to one roller and at least one discrete web is transferred from the puck to the same roller after which a die cutting process of the webs occurs at the nip.

Abstract: Several variations of core formation techniques and machines to produced cores are disclosed, including a large and small discrete core, formed on a screen and combined; a large and small continuous core, formed on a web; and two and three-dimensional cores, formed on a screen, and core formation on a non-woven web.

Abstract: Apparatus and methods are provided for folding discrete items such as diapers at high speeds. Discrete items are conveyed in a machine direction toward a pair of vacuum drums rotating in the machine direction and first carrying a top side of a leading edge of the discrete item away from the conveyor, and then carrying a bottom side of the leading edge with a second rotational vacuum drum back towards the conveyor. The diaper fold is created at a contact point with a folding finger which travels rotationally and straight in a fixed orientation about a pair of belts, into and out of contact with the diaper.

Abstract: Apparatus and methods are provided to allow for creation an elastic laminate. Non-stretched elastic can be laid at peaks over a nonwoven layer contained in valleys and atop peaks. Stretched elastic can be laid over tented nonwoven to create nonwoven tunnels when a second nonwoven is laid atop the first nonwoven and elastic, and the tunnels resist un-stretching of stretched elastic strands by frictional or obstruction forces. A laminated material comprising a first and second layer of material bonded at spaced apart bond sites is disclosed, with a plurality of elastic strands disposed in a non-linear manner between said first and second layer of material, so that said strands meander in a cross-machine direction and traverse a machine direction line, restraining movement of the strands by frictional forces between the strands and the non-woven layers.

Abstract: Continuous edge folds of a top sheet in disposable products prepare the top sheet for placement/attachment of discrete side panels to the folded-over portion of top-sheets oriented so that the side panels lay on top of the top-sheet without any further folding steps required. Later, a back sheet can be added and back sheet edges then folded over to cover edges of top-sheet/side panel sandwich.

Abstract: The present invention provides a method and apparatus for increasing the number of articles processed. over a distance traveled in the machine direction of an assembly line. In particular, the orientation of the long dimension of the article is provided transverse to the machine direction, thus process rug the articles side-by-side instead of end-to-end.

Abstract: 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.

Abstract: The present invention provides a method and apparatus for transporting a discrete element. A preferably rotatably driven vacuum commutation zone (or internal vacuum manifold), preferably internal to a preferably independently driven porous vacuum roll or drum is disclosed. The vacuum manifold applies vacuum through pores in the driven porous vacuum roll or puck in order to hold material against an external surface of the vacuum roll or puck. By independently controlling the vacuum commutation zone and the driven porous surface, unique motion profiles of the vacuum commutation zone relative to the driven porous surface can be provided. Micro vacuum commutation port structures are also disclosed.

Abstract: The present invention provides a method and apparatus for a transporting a discrete element, by activating a discrete vacuum zone on a puck at or before an acquisition, rotating the puck about an axis (and optionally twisting the puck), and deactivating the discrete vacuum zone at a deposition point, through tightly controlled piecewise vacuum porting particularly in applications where vacuum commutation length changes in radial direction.

Abstract: A system and method for producing a disposable undergarment, with the lateral edges of the undergarment bonded by means of an ultrasonic horn. When a blank is formed for an individual undergarment, the lateral edges of opposing edges of the blank will form the seam. When the edges are sealed together, a seam is formed. The individual undergarments may be later separated along the seams.

Abstract: A system and method for producing a disposable undergarment, with the lateral edges of the undergarment bonded by means of an ultrasonic horn. When a blank is formed for an individual undergarment, the lateral edges of opposing edges of the blank will form the seam. When the edges are sealed together, a seam is formed. The individual undergarments may be later separated along the seams.

Abstract: A method and apparatus for transporting a discrete element is disclosed. A preferably rotatably driven vacuum commutation zone (or internal vacuum manifold), preferably internal to a preferably independently driven porous vacuum roll or drum is disclosed. The vacuum manifold applies vacuum through pores in the driven porous vacuum roll or puck in order to hold material against an external surface of the vacuum roll or puck. By independently controlling the vacuum commutation zone and the driven porous surface, unique motion profiles of the vacuum commutation zone relative to the driven porous surface can be provided. Micro vacuum commutation port structures are also disclosed.

Abstract: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection both before and after application of component patches to a traveling web to create a product. Web defect detection may be provided by way of at least one visual inspection station located upstream from the patch applicator. Patch defect detection may be accomplished by way of a visual inspection station located proximate the patch applicator. If defects are detected in either the traveling web or the component patch prior to patch application, patch application may be prevented until both a satisfactory web and patch are provided. If defects are detected after patch application, the resulting product may be culled. Furthermore, the apparatus may be provided with diagnostic software to warn against extant or imminent machine complications.