Abstract: The present invention provides a method of providing a disposable product with zero waste ear formation and attaching the ears to a running chassis web.

Abstract: A variable interference anvil and knife combination is provided to selectively sever elastics in a laminate and preferably not sever the nonwoven portions of the laminate. The distance between the anvil and the knife can be programmatically altered to provide for smaller or larger gaps as processing speeds are changed.

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: 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: A method for manufacturing and folding a gown which increases manufacturing efficiency and consistency and decreases the time to manufacture. Additionally, the method includes folding a gown for packaging which will allow a person to don the gown with minimal contact with the outer portions of the gown.

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 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: 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: Methods and apparatus for transporting either an entire web or discrete components of disposable products such as diaper components down the machine using mechanical forces to grip the nonwoven web and transfer it from one belt or roll to another without or reducing added vacuum. There is a carrier nonwoven web that goes down the length of the machine and other substrates are added on top of this layer, and the machine provides sufficient gripping to allow transport of diaper components through the fabrication process. Securing and releasing forces are supplied so that the components can be retained at some points and released at others.

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: 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: Methods and apparatus for transporting either an entire web or discrete components of disposable products such as diaper components down the machine using mechanical forces to grip the nonwoven web and transfer it from one belt or roll to another without or reducing added vacuum. There is a carrier nonwoven web that goes down the length of the machine and other substrates are added on top of this layer, and the machine provides sufficient gripping to allow transport of diaper components through the fabrication process. Securing and releasing forces are supplied so that the components can be retained at some points and released at others.

Abstract: Individual fibers of a material layer are pinched within adjacent coils of a spring in the present invention by a spring-like surface carried by a moving object such as a conveyor belt, rotating drum or rotating puck. The spring coils are slightly opened to accept the individual fibers. Next the spring coils are closed to carry and transport the web of fibers. At a deposition point, the coil springs, carried by a moving object such as a conveyor belt, rotating drum or rotating puck, are opened slightly, releasing fibers and depositing the web at a desired location.

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: 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: 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: 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.