Abstract: A method of making a prefastened refastenable diaper or other undergarment includes the steps of forming a web of diaper material, cutting holes in the center of the web as precursor leg cutouts and, placing a fastening system divided between front and back waist sections onto each diaper section of the web to prepare inchoate diapers having their long axes in the cross machine direction of the web. Then the web is cut to define the web into individual diapers. The diapers are then folded in half at the crotch section, placing the fastening system section in lapping alignment and fastening the system together. The diapers are then removed by the leg holes to bundle and place the diapers in point of sale containers. The method lends itself to simple in-line process machinery for accomplishing the manufacture of the diapers.

Abstract: The present invention provides a distinctive process and apparatus (20) for forming an article. The technique of the invention includes a providing of a first panel layer (22), and a positioning of a second panel layer (28) onto the first panel layer (22). An inboard portion (24) of the first panel layer (22) is attached to an inboard portion (30) of the second panel layer (28), and a side region (36) of a tab web (34) is attached to the inboard portion (24, 30) of at least one of the first and second panel layers (22, 28) to provide a first assembly web (48). A fastening mechanism (40) is attached to the tab web (34), and an outboard portion (26, 32) of at least one of the first and second panel layers (22, 28) is folded to provide a folded layer (44) and a protruding layer (46). A protruding layer portion (56) of a panel assembly (50) is attached to a first waistband portion (62) of an article segment (60), and the article segment (60) is transversely folded to provide a folded article segment.

Abstract: The present invention provides a process and apparatus for applying a web component (42) to a moving substrate (44). The process aspect includes a delivering of the web component (42) to a rotatable applicator wheel (58). The applicator wheel has an entry surface-region (114), an exit surface-region (116), a transport surface-region (118), and an applicator wheel diameter (112). The web component (42) is contacted onto the entry surface-region (114) of the applicator wheel (58), and the applicator wheel is rotated to move the web component along a substantially circumferential, applicator path along the transport surface-region (118) of the applicator wheel. The applicator wheel (58) is oscillated about a pivot axis (102) which is spaced from the moving substrate (44) by a pivot distance (100), and the web component (42) is operatively applied from the exit surface-region (116) of the applicator wheel (58) onto the moving substrate (44) to provide a desired curved web configuration.

Abstract: A method and apparatus (20) for changing the speed of discrete components (22) can include a first rotatable drive member (32), and at least a second rotatable drive member (42) which is substantially coaxial with the first drive member (32). A first servo motor (34) is connected to rotate the first drive member (32), and at least a second servo motor (34) is connected to rotate the second drive member (42). A first transfer puck (36) is driven by the first rotatable drive member (32), and at least a second transfer puck (46) is driven by the second rotatable drive member (42). A first electronic drive (38) is connected to the first servo motor (34), and is configured to selectively move the first transfer puck (36) at a first, pick up speed (V1) and at least a second, deposit speed (V2). At least a second electronic drive (48) is connected to the second servo motor (44), and is configured to selectively move the second transfer puck (46) at the first pick up speed and at the second deposit speed (V2).

Abstract: A disposable absorbent article includes an absorbent chassis, at least one fit panel, a pair a primary fasteners and an integral waist size adjustment mechanism. The fit panel is located in one of the waist regions of the absorbent chassis and defines a waist edge, a pair of laterally opposed outboard edges which are located laterally beyond the side edges of the absorbent chassis, and an inward edge which is located longitudinally inward from the waist edge. The pair of primary fasteners are located on the laterally opposed outboard edges of the fit panel and are configured to releasably engage the opposite waist region of the absorbent chassis to provide the disposable absorbent article. The waist size adjustment mechanism may include a secondary fastener tab which is integral with the fit panel.

Abstract: A prefastened, refastenable, disposable absorbent article includes an absorbent chassis, at least one stretch panel, and a pair a primary fasteners. The absorbent chassis defines a pair of longitudinally opposed end edges and a pair of laterally opposed side edges. The stretch panel is located in one of the waist regions and defines a waist edge, a pair of laterally opposed outboard edges which are located laterally beyond the side edges of the absorbent chassis, and an inward edge which is located longitudinally inward from the waist edge. The pair of primary fasteners are located on the laterally opposed outboard edges of the stretch panel and are releasably prefastened to an opposite waist region of the absorbent chassis to releasably engage a front waist region to a rear waist region to provide the prefastened disposable absorbent article.

Abstract: A prefastened, refastenable, disposable absorbent article includes an absorbent chassis, at least one stretch panel, and a pair a primary fasteners. The absorbent chassis defines a pair of longitudinally opposed end edges and a pair of laterally opposed side edges. The stretch panel is located in one of the waist regions and defines a waist edge, a pair of laterally opposed outboard edges which are located laterally beyond the side edges of the absorbent chassis, and an inward edge which is located longitudinally inward from the waist edge. The pair of primary fasteners are located on the laterally opposed outboard edges of the stretch panel and are releasably prefastened to an opposite waist region of the absorbent chassis to releasably engage a front waist region to a rear waist region to provide the prefastened disposable absorbent article.

Abstract: There is provided an apparatus for dividing logs of substrate into rolls and a method of using this apparatus. The apparatus may include a distribution sprocket, a pocket for holding the log, a cutting device, and a device for collecting the rolls. Logs may be transported, divided, and distributed without the need for secondary clamping devices.

Abstract: The present invention provides a distinctive process and apparatus (20) for forming an article. The technique of the invention includes a providing of a first panel layer (22), and a positioning of a second panel layer (28) onto the first panel layer (22). An inboard portion (24) of the first panel layer (22) is attached to an inboard portion (30) of the second panel layer (28), and a side region (36) of a tab web (34) is attached to the inboard portion (24, 30) of at least one of the first and second panel layers (22, 28) to provide a first assembly web (48). A fastening mechanism (40) is attached to the tab web (34), and an outboard portion (26, 32) of at least one of the first and second panel layers (22, 28) is folded to provide a folded layer (44) and a protruding layer (46). A protruding layer portion (56) of a panel assembly (50) is attached to a first waistband portion (62) of an article segment (60), and the article segment (60) is transversely folded to provide a folded article segment.

Abstract: There is provided an apparatus for dividing logs of substrate into rolls and a method of using this apparatus. The apparatus may include a distribution sprocket, a pocket for holding the log, a cutting device, and a device for collecting the rolls. Logs may be transported, divided, and distributed without the need for secondary clamping devices.

Abstract: Methods and apparatus for applying elastic material in a curvilinear pattern on a continuously moving substrate. The method moves a substrate along a substrate path, supplies the elastic material to an oscillation unit first roll mounted for pivoting and rolling engagement with a transfer roll, oscillates the oscillation unit in a path generally transverse to the substrate path, applies the elastic material from the first roll to the transfer roll in the desired curvilinear path configuration, then applies the elastic material from the transfer roll to the substrate and bonds the elastic material to the substrate. Optionally the first roll may apply the elastic material directly to the substrate.

Abstract: Methods and apparatus for applying elastic material in a curvilinear pattern on a continuously moving substrate. The method moves a substrate along a substrate path, supplies the elastic material to an oscillation unit first roll mounted for pivoting and rolling engagement with a transfer roll, oscillates the oscillation unit in a path generally transverse to the substrate path, applies the elastic material from the first roll to the transfer roll in the desired curvilinear path configuration, then applies the elastic material from the transfer roll to the substrate and bonds the elastic material to the substrate. Optionally the first roll may apply the elastic material directly to the substrate.

Abstract: The present invention provides a combination roller, a machine and process for cutting workpieces from a web moving at a first speed and depositing them on and bonding them to a substrate web moving at a second speed with the functions of cutting, transferring, and bonding all carried out on a single roller. The reduction in roller mass achieved by this roller and machine design permits driving the combination roller at variable speeds by means of a servomotor and servomotor controller. The resulting machine permits electronic rather than machine grade changes as the machine and process are used to produce products having different configurations.