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: 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: An apparatus and method for applying discrete segments to a continuous web includes feeding a first continuous web to a roller, the first continuous web comprising one or more layers, feeding a second continuous web to a vacuum anvil, cutting the first continuous web into a plurality of discrete segments via interaction of the roller with at least one cutting element selectively positionable adjacent the roller, transferring each of the plurality of discrete segments from the roller onto the second continuous web at a first location and via a vacuum pressure from the vacuum anvil, and bonding each of the plurality of discrete segments to the second continuous web at a second location downstream from the first location in a machine direction, each of the plurality of discrete segments bonded to the second continuous web via interaction of the vacuum anvil with a bonding device positioned at the second location.

Abstract: A web splicing apparatus is disclosed that includes a web unwinding unit configured to hold a running web material roll and a new web material roll and to unwind webbing from the running web material roll and a web splicing unit operable with the web unwinding unit to selectively splice the webbing of the running web material roll with webbing of the new web material roll. The web splicing unit further includes a cutting assembly configured to selectively sever the webbing of the running web material roll, a web deflection device, an actuator system configured to linearly translate the web deflection device in a first direction and a second direction opposite the first direction, and a locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection device in the first direction and the second direction.

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 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 of forming a disposable product includes feeding an incoming web of ear material, engaging the web with a rotating anvil, cutting ears from the web via the rotating anvil and interaction thereof with a corresponding die, so as to form pairs of ears having complimentary and nested ear shapes, and coupling the ears to at least one of a wing and a web of chassis material. In feeding the incoming web of ear material, the speed of the web is selectively varied between at least a first speed and a second speed, with the web being fed to the rotating die and anvil at the first speed to result in the cut ear shapes having a first height and the web being fed to the rotating die and anvil at the second speed to result in the cut ear shapes having a second height.

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: 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: 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: 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: 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 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 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.