Abstract: Absorbent garments are made by applying a refastenable material to a continuous panel web, folding the panel web, cutting the folded panel web into discrete folded panels, and aligning the folded panels with perforations in a continuous elasticized waist web. Discrete folded patches are coupled to the elastic web via the refastenable material and the perforation cuts are broken to form a continuous waistband. Absorbent cores are coupled between the continuous waistband and a second continuous waistband, which are cut to form the absorbent garments. The manufacturing apparatus includes a perforation cutter that forms perforation cuts in a continuous waist web comprising elastic elements positioned between facing web layers, a panel applicator that cuts a folded panel web into discrete panels and attaches the discrete panels to the waist web about the perforation cut. A breakage system separates the waist web at the perforation cuts and unfolds the discrete panels.

Abstract: A method of manufacturing a face mask comprises coupling at least one tensioned elastic structure to at least one web material to form a continuous elastic strap, advancing the continuous elastic strap in a machine direction, coupling the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, and cutting the continuous face mask composite structure to define a plurality of discrete face masks. The multi-layer mask web comprises an inner web layer, an outer web layer, and a filter layer positioned therebetween.

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 web unwinding and splicing system includes a turret unwind having a turret arm with rotatable shafts at opposing ends thereof to unwind a running web of an expiring web material roll and unwind a waiting web of a new web material roll. A web splicing unit operable with the turret unwind includes a web deflection device that bumps the running web onto the waiting web to splice the running web with the waiting web and a cutting device that selectively severs the running web, thereby creating a leading portion of the running web that is spliced to the waiting web and a trailing portion of the running web that remains separate from the waiting web. A vacuum system is positioned proximate the running web to suction in the trailing portion of the running web left on the expiring web material roll.

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 in deposition of acquisition material, which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera, and an acquisition inverter can flip the material to a correct orientation.

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 in deposition of acquisition material, which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera, and an acquisition inverter can flip the material to a correct orientation.

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: An apparatus and method for manufacturing an elastic composite structure for an absorbent sanitary product includes a rotary anvil comprising a face surface, a plurality of non-linear ridges defined by a first plurality of grooves in the face surface, and a plurality of projections in each of the plurality of non-linear ridges. Each projection of the plurality of projections comprises a contact surface having parallel facing surfaces and parallel end surfaces.

Abstract: An elastic composite structure includes a plurality of tensioned elastic threads positioned between first and second web layers. A pattern of laminating bonds fuse the first and second web layers together within a deactivated zone of the elastic composite structure. A cut end of a first portion of a tensioned elastic thread and a cut end of a second portion of the tensioned elastic thread are positioned on opposing ends of the deactivated zone. A pattern of anchoring bonds fuses the first and second web layers together within an anchored zone bounding opposing ends of the deactivated zone. The anchored zone includes a first plurality of bonds that anchor the first portion of the tensioned elastic thread to the first and second web layers and a second plurality of bonds arranged that anchor the second portion of the tensioned elastic thread to the first and second web layers.

Abstract: Curved elastics are applied to both or either the front or rears of a pant type diaper extending near the leg and waist openings. An adhesive pattern is deposited onto a nonwoven sheet, and elastic strands are coupled to the nonwoven sheet. The elastic strands and nonwoven sheet are coupled to another web of ultrasonically bonded elastomeric material and nonwoven, and together the laminate is used as a front or rear portion of a diaper.

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: 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 method for reorienting discrete hygiene products for packaging includes providing discrete products traveling in a machine direction and all in a first orientation to a product turner and placer comprising a plurality of pucks rotatable about a central axis, with each puck also rotatable about a spin axis. The method also includes receiving a discrete product on each puck, transferring the discrete products via the pucks from a pick-up location to a drop-off location, and depositing the discrete products from the pucks onto a conveyor at the drop-off location, the discrete products deposited so as to be spaced apart on the conveyor. In transferring and depositing the discrete products, the rotation of each of the pucks is selectively controlled about its spin axis to reorient each of the discrete products for depositing onto the conveyor, with each of a direction and an amount of the rotation being selectively controlled.

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 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 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 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: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection in deposition of acquisition material, which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera, and an acquisition inverter can flip the material to a correct orientation.

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.