Abstract: A vacuum roll has an inner cylinder defining an interior chamber. The interior chamber is fluidly connected to a vacuum source for applying a vacuum thereto. An outer cylinder is rotatable about the inner cylinder and has a plurality of apertures therein. An actuator is configured to move the inner cylinder between a first position and a second position. The vacuum roll has a first vacuum profile with the inner cylinder in the first position and a second vacuum profile with the inner cylinder in the second position.

Abstract: An apparatus for folding products has a conveying member configured to hold a first portion and a second portion of the product and to release the first portion while continuing to hold the second portion. The conveying member is configured to convey the product at a conveying speed. A folding assembly is disposed adjacent the conveying member. The folding assembly is configured to receive the first portion of the product from the conveying member while moving generally at the conveying speed, to decelerate relative to the conveying member while holding the first portion thereto thereby causing the product to fold about the fold axis, and to place the first portion of the product into contact with the second portion such that the first portion overlies the second portion.

Abstract: A boxer-style pant and methods of making a boxer-style pant having side seams and hanging legs. At least a portion of each of the hanging legs may be non-planar in an uncontracted state prior to formation of the side seams. The methods each involve providing at least one web. In some methods, a crotch panel is bonded to first and second regions of the web between two leg openings, and a distance between bonded regions of upper and lower edges of the crotch panel, measured parallel to a longitudinal axis of the pant, is shorter along a central region of the crotch panel and longer in distal regions of the crotch panel, such that the bonded region results in a bow-tie-shaped crotch panel. In some methods, a crotch region of the web is folded and stabilized along a longitudinal centerline of the web. In some methods, leg extensions are attached to at least a portion of each of two leg openings. Front and back regions may be joined together to form the side seams.

Abstract: A boxer-style pant and a method of making a boxer-style pant having side seams, a contracted crotch region, and hanging legs. A web is provided. The web may be a single pant assembly, or a continuous web of multiple pant assemblies connected to one another. The web may be folded against a support structure. In certain embodiments, a multi-lane production system may be used wherein the web is folded against multiple support structures each parallel to a direction in which the web is conveyed, with each lane or machine direction array of pant assemblies folded against just one support structure. The web is cut to define leg openings, and contracted in selected areas along the web between the leg openings. Front and back regions are then joined together to form the side seams. An absorbent structure may be attached to the web.

Abstract: A process for making a prefastened and refastenable pant includes providing a plurality of discrete articles having side panels and waist regions including an activatable retractive material. The side panels can be folded parallel to a longitudinal centerline to overlap at least portions of first and second fastening components. The fastening components are then engaged to form a prefastened and refastenable pant. The retractive material can be activated subsequent to engagement of the fastening components, or subsequent to obtaining position control of the side panels, to provide the pant with a waistband-to-hip circumference ratio of about 95 percent or less. The prefastened and refastenable pant and apparatus for its manufacture are also disclosed.

Abstract: A pant has a garment shell. The garment shell includes a front region, a back region, a contracted crotch region, side seams connecting the front region to the back region, two leg openings, and hanging legs. At least a portion of each of the front region, the back region, the contracted crotch region and the hanging legs include portions of a single flat web. The hanging legs include no elasticization around a full periphery of the leg openings and are adapted to hang loosely about a wearer's thigh.

Abstract: In a method and apparatus for mechanically fastening an absorbent undergarment during the initial manufacturing thereof, the undergarment is transported in a transport direction and folded longitudinally by a folding device such that first and second end regions of the undergarment are in generally opposed relationship with each other while transporting the partially assembled garment in the transport direction to fastenably engaged first and second fastening portions of the undergarment. A central region of the absorbent undergarment is held by a holding device, separate from the folding device, against bunching between the end regions of the undergarment during longitudinal folding of the undergarment. In another embodiment, the transverse position of the second fastening portion is adjusted relative to the first fastening portion to facilitate fastening engagement therebetween upon folding the absorbent garment longitudinally.

Abstract: A method of making a boxer-style pant having side seams, a contracted crotch region and hanging legs. A flat web is provided. Portions are removed from the flat web to define leg openings. The flat web is then contracted either elastically or inelastically in selected areas along the flat web between the leg openings. The flat web is cut into separate pieces, folded and side seams are formed. The pant may include an absorbent.

Abstract: New processes and apparatus for forming lap seams and making prefastened disposable absorbent articles are disclosed. The apparatus can include an interior folding mechanism adapted to position a first panel in an interior position and an exterior folding mechanism adapted to position a second panel in an exterior position relative to the interior position. The interior folding mechanism can include a mandrel defining a curved peripheral surface and an interior forming shoulder in proximity to the mandrel. A fluid pressure device can establish an air flow between the mandrel and the interior forming shoulder. The forming shoulder can modify the direction of the air flow as the first panel travels in a machine direction to increasingly fold the panel over the curved peripheral surface.

Abstract: A process and apparatus for registering a plurality of discrete components to a continuously moving first layer of material produces a disposable absorbent garment with improved alignment of the components on the first layer of material. The first layer has a plurality of reference marks positioned thereon. Various devices are used to compare distances between the reference marks to distances between corresponding components and synchronize a feed rate of the components to a feed rate of the first layer. After adhering the components to the first layer, the positions of the components relative to the reference marks are once again checked and, if necessary, the setpoint for the feed rate of the components is adjusted.

Abstract: A method of making a pant having a front-to-back crotch seam includes providing a flat web. The flat web can be cut into separate pieces or cut to provide interconnected pieces and the center portion of each separate piece is removed. Slits are cut in each separate piece or each interconnected piece and the remaining attached segments are drawn away from each other in opposite directions to bring first and second seam edges together for the purpose of forming a garment shell with a crotch seam. The method may be applied to a single piece of material representing a single garment or to an interconnected web of garments. After forming the crotch seam, the garment shell can be folded and side seams formed. The pant may include an absorbent structure.

Abstract: A process for making a prefastened and refastenable pant includes providing a plurality of discrete articles having side panels and waist regions including an activatable retractive material. The side panels can be folded parallel to a longitudinal centerline to overlap at least portions of first and second fastening components. The fastening components are then engaged to form a prefastened and refastenable pant. The retractive material can be activated subsequent to engagement of the fastening components, or subsequent to obtaining position control of the side panels, to provide the pant with a waistband-to-hip circumference ratio of about 95 percent or less. The prefastened and refastenable pant and apparatus for its manufacture are also disclosed.

Abstract: Efficient high speed methods for making garments with fastening components include positioning first fastening components on one surface of a product assemblage on opposite sides of a machine center line at selected first cross machine direction locations. In particular embodiments, second fastening components are positioned on another surface of the product assemblage on opposite sides of the machine center line at selected second cross machine direction locations. The product assemblage can be processed through bonding devices disposed at selected cross machine direction locations to bond the fastening components to opposite surfaces of the product assemblage. In other embodiments, the product assemblage can be processed through bonding devices subsequent to positioning the first fastening components.

Abstract: A method of making a boxer-style pant having side seams, a contracted crotch region and hanging legs. A flat web is provided. Portions are removed from the flat web to define leg openings. The flat web is then contracted either elastically or inelastically in selected areas along the flat web between the leg openings. The flat web is cut into separate pieces, folded and side seams are formed. The pant may include an absorbent.

Abstract: A method of making a pant having a front-to-back crotch seam includes providing a flat web. The flat web can be cut into separate pieces or cut to provide interconnected pieces and the center portion of each separate piece is removed. Slits are cut in each separate piece or each interconnected piece and the remaining attached segments are drawn away from each other in opposite directions to bring first and second seam edges together for the purpose of forming a garment shell with a crotch seam. The method may be applied to a single piece of material representing a single garment or to an interconnected web of garments. After forming the crotch seam, the garment shell can be folded and side seams formed. The pant may include an absorbent structure.

Abstract: A process and apparatus for registering a plurality of discrete components to a continuously moving first layer of material produces a disposable absorbent garment with improved alignment of the components on the first layer of material. The first layer has a plurality of reference marks positioned thereon. Various devices are used to compare distances between the reference marks to distances between corresponding components and synchronize a feed rate of the components to a feed rate of the first layer. After adhering the components to the first layer, the positions of the components relative to the reference marks are once again checked and, if necessary, the setpoint for the feed rate of the components is adjusted.

Abstract: A prefastened absorbent garment is manufactured with its longitudinal axis in the cross machine direction. A web of garment chassis material extending in the machine direction is overlaid within the garment chassis borders. The side panel webs are attached to the chassis web and have hook and loop fasteners thereon. The garment can be individuated from the combined chassis and side panel webs.

Abstract: A process and apparatus for registering a plurality of discrete components to a continuously moving first layer of material produces a disposable absorbent garment with improved alignment of the components on the first layer of material. The first layer has a plurality of reference marks positioned thereon. Various devices are used to compare distances between the reference marks to distances between corresponding components and synchronize a feed rate of the components to a feed rate of the first layer. After adhering the components to the first layer, the positions of the components relative to the reference marks are once again checked and, if necessary, the setpoint for the feed rate of the components is adjusted.

Abstract: New processes and apparatus for forming lap seams and making prefastened disposable absorbent articles are disclosed. The apparatus can include an interior folding mechanism adapted to position a first panel in an interior position and an exterior folding mechanism adapted to position a second panel in an exterior position relative to the interior position. The interior folding mechanism can include a mandrel defining a curved peripheral surface and an interior forming shoulder in proximity to the mandrel. A fluid pressure device can establish an air flow between the mandrel and the interior forming shoulder. The forming shoulder can modify the direction of the air flow as the first panel travels in a machine direction to increasingly fold the panel over the curved peripheral surface.

Abstract: A process and apparatus for making a three-dimensional garment. The process is carried out by loading an insert onto an expandable/retractable process loop fixture. A waist elastic member can be bonded to a waist area of the insert. A garment shell can be applied over the insert and the waist elastic member. A waist area of the garment shell can be attached to the waist elastic member and to the waist area of the insert.