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: 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 machine for producing disposable products anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. An integrated production facility layout automatically orders and stocks raw material based on production plans, and commands a production machine to produce specific products of differing configurations, and automatically loads appropriately sized raw materials into the process.

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.

Abstract: The present invention provides machinery used to create products (for instance disposable products). The machinery is operated at high speed, with the machine occupying a small footprint. Materials can be fed into the manufacturing process vertically (from above or below), using assembly stations to feed completed components into the system at appropriate stations. Additionally, restocking of raw components can be accomplished by robotic means of transferring the raw material from staging areas into infeeding or splicing stations, without the need for human operators.

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: An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval. The web material can be cut to different insert lengths and the placement location varied.

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: 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: 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. A cut/slip operation is performed on an incoming web carried by a transfer drum, and the cut/slip pieces are further divided and next separated by a second transfer drum and bonded to incoming webs.

Abstract: Using electrostatic means, such as plasma, webs can be cut, and webs can be bonded together. A plasma is created and directed at an intervening poly or a nonwoven to sever the fabric, either continuously or intermittently, or to bond and sever two more material layers together.

Abstract: An apparatus is disclosed for severing a continuous web into discrete pieces, and re-orienting the discrete pieces by turning and placing the discrete pieces onto a moving conveyor for further processing as desired.

Abstract: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. A first non-elastomeric layer is bonded with an elastomeric layer, and to a second non-elastomeric layer. The apparatus and methods provide defect detection in the elastomeric layer and triggers an unthreading/rethreading sequence. Web defect detection may be provided by way of at least one visual inspection station. If defects are detected in the elastic layer, the resulting products may be culled.

Abstract: A corrosion protected knife and anvil system is disclosed. A source of lubricating fluid is provided to a lubricating fluid distribution mechanism, coupled to both a knife blade and a salt bridge and an associated sacrificial anode. The sacrificial anode is consumed in order to protect corrosion on a rotating knife blade, which intermittently contacts both an associated anvil in order to cut material used in making disposable products, and the source of lubricating fluid. A knife holder holds a knife which is corrosion protected by an impressed current anode.

Abstract: Discrete items are conveyed, preferably by a vacuum conveyor, in a machine direction toward a pair of rotating blades. A first intended target of folding, for instance a right portion of front and back panels of a diaper, travels up a ramp, raising the level of the intended target. A rotating blade passes under the intended target of folding, and folds the right portion of front and back panels of a diaper over. If desired, a second intended target of folding, for instance a left portion of front and back panels of a diaper, travels up a second ramp, raising the level of the intended target. A rotating blade passes under the second intended target of folding, and folds the left portion of front and back panels of a diaper over. The folded diaper then exits the folding system and travels downstream for further processing as desired.

Abstract: A core forming unit feeds a core to a cutting unit, where a core is wrapped with a core topsheet and backsheet. The core insert is folded and a front wing web and a back wing web are coupled to the folded core. If a pant type diaper is desired, side seams of the front wing web and back wing web are bonded together at side seam regions. Next, portions of the front wing web and back wing web are folded over to create a compact product for packaging and shipment.

Abstract: Ventilated vacuum structures such as pucks and rings are disclosed for carrying portions of disposable products during manufacturing. Air flow enters vacuum commutation ports on an article carrying structure from vents nearby, the vents receiving air from a side, a top or an underside of the article carrying structure.

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: A pulpless core is provided with flexibility for superabsorbsnt 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.