Methods and apparatus for application of nested zero waste ear to traveling web

[0001] This patent application claims priority over the provisional U.S. Patent Application No. 61/500 519, filed June 23, 2011, and U.S. Provisional Patent Application No. 61/509 438, filed on July 19, 2011, which are temporary U.S. U.S. Patent Applications Patent Application No. 12/925 033, filed October 12, 2010, which is a partial continuation of U.S. Patent Application No. 12/798 520, filed on April 5, 2010, which is currently U.S. Patent No. 8,172,977, which in turn reserves the benefit of U.S. Patent Application No. 61/212 011, filed April 6, 2009, Provisional US Patent Application No. 61/212 619, filed April 14, 2009, and US Patent Application Number 12 / 151.667, filed May 8, 2008, which is currently US Patent No. 8,016 972, which reserves the benefit of U.S. Provisional Patent Application No. 60 / 928,305, filed May 9, 2007, and is a partial continuation of U.S. Patent Application No. 12 / 806,891, filed August 24, 2010, which is a continuation of U.S. Patent Application No. 11 / 436.274, filed May 18, 2006, which is currently US Patent No. 7,780 052.

Background of the Invention [0002] The present invention relates to disposable hygiene products, and in particular to methods and apparatus for processing disposable hygiene products. In particular, the invention relates to cutting and applying segments of one fabric that are combined with a disposable diaper.

[0003] The invention disclosed herein also relates to apparatus and methods for reducing waste. Typically, diapers contain an absorbent pad or pad and a support structure that, when wearing the diaper, holds the pad close to the wearer's body. In addition, diapers may contain various other inserts, for example tape inserts, reusable fasteners, and the like. The raw materials used to form the representative insert are usually cellulose pulp, tissue paper, non-woven absorbent material, and an elastic element, although specific application materials are sometimes used. Usually, most of the raw materials for the inserts are in the form of bales, and the material is unwound and applied in the same way as on the assembly line. As with many manufacturing operations, waste minimization is the goal in fabric processing applications, as products with pleated raw materials cannot be sold to users. In fact, because of the speed at which fabric processing machines work, even minimal losses can cause large scale inefficiency.

[0004] In current systems, waste materials are recycled. However, the task of collecting recycling materials from a defective product is labor intensive. That is, recycling materials are only collected after identifying the rejected product at the end or end of the process. As a result, the materials to be recycled are mixed and collection requires an additional step of separating the waste elements. Thus, it is preferable to use all incoming bales so that part of the incoming bales do not become waste. This object is achieved by the present invention.

[0005] In the production of hygiene products, e.g. baby diapers, adult diapers, disposable underwear, products used in the case of uncontrolled physiological functions, sanitary towels and the like, a commonly used method of applying separate pieces of one fabric to another is to use a type applicator sliding / cutting. The extension / cutting type applicator usually consists of a cylindrical rotary vacuum cutting device, rotary cutterblock and a transfer device. In typical applications, the incoming fabric is fed at a relatively low speed along the surface with the negative pressure of a rotary cutting device that moves at a relatively high surface speed and where the incoming fabric can "slide out". The knife blade, mounted on a rotating knife shaft, cuts off a segment of incoming fabric on the surface of the cutting device. This knife blade preferably moves at a surface speed similar to the surface speed of the cutting device. After cutting, the fabric segment is held by vacuum applied through holes on the surface of the cutting device when it is transferred at the speed of the cutting device further to the transfer point, where the fabric segment is transferred to the moving fabric.

[0006] Continuous improvements and competitive pressure have gradually increased the operating speeds of disposable diaper processing devices. Depending on the increase in speed, the mechanical integrity and operational capabilities of the applicators had to be improved.

Summary of the Invention [0007] The present invention allows the application of square and non-square, and preferably trapezoidal, ear fabric to the moving fabric with zero or minimized losses occurring in the entering ear fabric. Zero material losses are achieved due to the geometry of the selected ear pattern and its further processing.

[0008] The ear is a component of the diaper which is gripped and clamped around the wearer's waist. Usually, the ears are attached to the diaper at the first end, and the other free end is usually provided with a fastening means, e.g. a pressure-sensitive adhesive, or a hook-and-loop material. When the user grips and pulls the ear, the elasticity around the waist area of ​​the diaper allows the free end to tightly fit around the user's waist, and connects to the diaper. The ears may be rectangular or may have irregular shapes.

[0009] The present invention provides a process in which a rotary knife or die, with one or more cutting edges, rotates towards and in coordination with the corresponding cylinder, preferably forming trapezoidal ears. The ear material is cut into two stripes, one for the left side of the diaper and the other for the right side of the diaper. Attachment straps are applied to both the right and left ear fabric. The ear material is then die cut into a nested pattern on a synchronized vacuum cutting device.

[0010] However, due to the trapezoidal ear pattern, the resulting separate ear elements alternate with the correct orientation and the incorrect (inverted) orientation. The inverted ear must be rotated 180 ° to the correct orientation so that the ears and the associated tape form the left ear and the right ear on the diaper.

[0011] To achieve ear pattern reversal, separate ear pieces are selected with a nested ear module by means of an ear rotating assembly that expands to a sufficiently large module for the ears that are to be not nested and allows slack for every other ear to be rotated . The rotated ears are therefore not nested and have the correct orientation.

[0012] Two ear pivoting assemblies can be used to rotate every other ear applied to the right side of the product and every other ear applied to the left side of the product. In this way, for a single product, one of the two eyes will be rotated 180 °.

[0013] The application of the ear to the fabric of the support structure can be carried out by means of the impact method (described later) by discontinuous application of the adhesive to the fabric of the support structure, or it can be carried out by means of a vacuum transfer.

[0014] The present invention also allows the attachment of two side panel assemblies, including attachment mechanisms, to two lugs, the side panel assemblies being attached in a pre-assembled state. Two more ears can be combined with the supporting fabric to create a front lobe to be worn around the wearer's waist.

[0015] The present invention also allows the removal of scraps of material from the ears to create contoured leg openings in the diaper. In one embodiment, scraps can be removed from the ears before attaching the ears to the supporting structure fabric. In another embodiment, the scraps can be removed from the ears after the ears are attached to the supporting structure fabric. In another embodiment, scraps can be removed from the eyes and the removed portion of the support structure fabric after the ears have been attached to the support structure fabric.

Brief description of the figures [0016]

Fig. 1 is a schematic side view of a prior art process;

Fig. 2 is a plan view of the disposable diaper product having a pair of ears;

Fig. 3 is an elevational view of the ear forming fabric comprising a single ear separated from the fabric;

Fig. 4 is a front view of a cutting device roll carrying two ear fabrics; Fig. 5 is a simplified view of the nested rear waste applicator with zero waste and methods of the present invention;

Fig. 5a is a simplified view of the nested zero-waste rear ear applicator and methods of the present invention with an alternating fabric path configuration;

Fig. 6 shows an alternating ear pattern and size of the alternating ear;

Figures 7A, 7B, 7C, 7D, 7E and 7F are top views of ear fabrics, where Figure 7A shows non-rotated, staggered, die-cut ear fabrics, and Figure 7B shows rotated, staggered, die-cut ear fabrics, and the figures 7C, 7D, 7E and 7F show alternating ear configurations;

Fig. 8 is a simplified perspective view of the nested zero-waste rear ear applicator device and methods of the present invention;

Fig. 8a is a simplified perspective view of a nested zero-waste rear ear applicator device and methods of the present invention with an alternating fabric path configuration;

Fig. 9 is a side view of an ear rotating assembly device used to rotate alternating ears;

Fig. 10a is a front view of an ear rotating device device used to rotate alternating ears;

Fig. 10b is a front view of the ear rotating assembly device used to rotate the alternating ears, illustrating alternate embodiments of the drawing pulley adapted to fit in shape and size with opposing ear patterns;

Fig. 11 is a perspective view of two devices of the ear rotating assembly used to rotate the alternating ears on the left and right ear fabric;

Fig. 12 is a side view of an ear rotating assembly device used to rotate alternating ears;

Fig. 13 is a front view of two devices of the ear rotating assembly used to rotate the alternating ears on the left and right ear fabric;

Fig. 14 is a side view of an ear rotating device device used to rotate alternating ears;

Fig. 15 is a cross-sectional view of the ear turning device device used to rotate the alternating ears shown in Fig. 10;

Fig. 16 is a front view of the cutting device, ultrasonic joining ring, and vacuum model used to change the ear module from a slow moving fabric and applying and joining the ear to a faster moving fabric of the support structure;

Fig. 17 is a simplified view of the nested device of the zero-waste rear ear applicator and methods of the present invention, shown by an alternative embodiment of the means for applying the ear to the fabric of the support structure.

Figs. 18-28 are simplified views and plan views of implementations of nested application of rear ears with zero waste, including the multi-component part of the ear.

Fig. 18 is an elevational view of the material forming the ear tab (or wing, nonwoven fabric);

Fig. 19 is a plan view of the material forming the ear tab after incision and spread;

Fig. 19a is a simplified view of forming a side lobe assembly;

Fig. 20 is a plan view of the side lobe assembly connected to the ear-tab forming material;

Fig. 21 is a plan view of the side lobe assembly attached to the ear-tab forming material after the side lobe assembly has been assembled;

Figs. 22 and 23 are elevational views of the side panel assembly connected to the ear tab forming material after the side panel assembly has been assembled and during and after re-chamfering the side panel and wing assembly;

Fig. 24 is a plan view of the side panel and wing assembly, die-cut, re-beveled and inverted;

Fig. 25 is a plan view of the side panel and wing assembly after cutting, beveling, and turning;

Fig. 26 is a plan view of a side panel and flap assembly connected to the support structure assembly;

Fig. 27 is a plan view of a side panel and flap assembly connected to the support structure assembly and assembled into the shape of the support structure assembly;

Fig. 28 is an elevational view of an innovative disposable product in use made using the methods of the present invention.

Figs. 29-42 are simplified views and plan views of how to assemble a disposable product, including creating a nested ear with zero waste, on the nested wing portion with zero waste, joining the ear and wing portion to the top sheet of the support structure, and folding the product to form a folded diaper .

Fig. 29 is an elevational view of the material forming the ear tab (or wing, nonwoven fabric);

Fig. 30 is an elevation view of the material forming the ear tab after cutting and spreading; Figures 30-32 are a simplified view of forming an ear assembly subjected to cutting, spreading, adding tape and ear punching, beveling and rotation again;

Figures 33-34 show the formation of cut and stretched wing fabric;

Fig. 35 shows an ear connected to the wing fabric;

Fig. 36 shows the ear during folding and temporary attachment to the wing; Figures 37-38 show die cutting, beveling and rotation of the wing assembly while moving the ear assembly;

Fig. 39 is a plan view of a side panel and flap assembly connected to the support structure assembly;

Fig. 40 is a plan view of a side panel and flap assembly connected to the support structure assembly and assembled into the shape of the support structure assembly;

Fig. 41 is a plan view of an innovative disposable product in use made with the methods of the present invention; Fig. 42 is a cross-sectional view of an innovative disposable product made with the methods of the present invention;

Figures 43-60 are simplified views and plan views of assembly methods of a disposable product;

Fig. 61 is a plan view of the wing assemblies connected to the support structure assemblies, with sections removed from the wing assemblies;

Fig. 62 is a plan view of the wing assemblies connected to the support structure assembly, with sections removed from the wing and support structure assemblies; Fig. 63 is a perspective view of the scrap removal system of the present invention, with the supporting fabric fabric being fed and the scrap to be removed therefrom;

Fig. 64 is a two-dimensional representation of the scrap removal system of Fig. 63;

Fig. 65 is a cross-sectional view of the scrap removal system;

Fig. 66 is a simplified view of a section removal system receiving an article from a transfer roller in the initial position of the section connection;

Fig. 67 is a simplified view of a scrap removal system separating the first product from the second product;

Fig. 68 is a simplified view of a scrap removal system separating the scrap from the first product;

Fig. 69 is a simplified view of a scrap removal system;

Fig. 70 is a simplified view of a scrap removal system returning to its initial scrap linking position;

Fig. 71 is a simplified view of a scrap removal system after returning to its initial scrap linking position;

Figs. 72-75 are elevational views of the position of the section relative to the fabric, showing the tearing effects of the present invention;

Fig. 76 is an elevational view of the fabric of the wing assemblies, with scraps removed from each of the wing assemblies;

Fig. 77 is a plan view of the blade assemblies, with sections removed from selected blade assemblies;

Fig. 78 is an elevational view of the wing assemblies connected to the support structure assembly, with the sections removed from the wing assemblies and support structure assembly. Fig. 79 is a plan view of a product variation showing the protruding front ear extending / cutting, alternating rotation of the rear ears and extension lobes extending from the rear ears;

Fig. 80 is a plan view of a product variation showing the protruding front ear extending / cutting, alternately rotating back ears and extension lobes extending from the rear ears, and a die cut support structure;

Fig. 81 is a plan view of a product variation showing the protruding front ear extending / cutting, alternately rotating rear ears and extension lobes extending from the rear ears, die cut front and rear ear parts, and die cut support structure;

Fig. 82 is a plan view of a product variation showing alternately rotated front ears, alternating rotated rear ears, and extension panels extending from the rear ears;

Fig. 83 is a plan view of a product variation showing alternately rotated front ears, alternately rotated rear ears, extension lobes extending from the rear ears, and a die cut support structure;

Fig. 84 is a plan view of a product variation showing alternately rotated front ears, alternately rotated rear ears, extension lobes extending from the rear ears, a die cut support structure, and die cut ears;

Fig. 85 is a plan view of a product variant showing the front ear protrusion / cut method and alternately rotated rear ear;

Fig. 86 is a plan view of a product variant showing the front ear / extensions applied and alternately rotated rear ears and a die cut support structure;

Fig. 87 is an elevation view of a product variation showing the protruding / extending front ear and alternately rotated rear ear, die cut support structure and die cut ear;

Fig. 88 is an elevation view of a product variation showing alternately rotatable overlayed front ears and alternately rotated rear ears;

Fig. 89 is a plan view of a product variation showing alternately rotatable overlayed front ears and alternately rotated rear ears and a die cut support structure;

Fig. 90 is a plan view of a product variation showing alternately rotatable overlayed front ears and alternately rotated rear ears, die cut support structure, and die cut ears.

Fig. 91 is a simplified elevational view of a non-woven fabric extension panel receiving tapes that are folded. A stretch laminate fabric was used that receives cut and spread extension sheets of the nonwoven extension sheet, and the combination of stretch laminate fabric combined with extension sheets holding folded ears is cut and spread apart;

Fig. 92 is a non-woven side panel fabric with scrap portions;

Fig. 93 is a non-woven fabric of the side panel after receiving (preferably by ejection / cutting methods) separate pieces of a cut and spread combination of a stretch laminate fabric combined with extension panels holding folded ears;

Fig. 94 is a non-woven fabric of a side panel after receiving (preferably by ejecting / cutting methods) separate pieces of a cut and spread of a stretch laminate fabric combination, combined with extension sheets holding folded ears, with separate pieces of a cut and spread of a stretch laminate fabric combined with extending lobes keeping folded ears;

Fig. 95 shows the components of Fig. 94 cut and spread;

Fig. 96 shows the cut and spread components of Fig. 95, with scrap removal;

Fig. 97 shows the chopped and spread components of Fig. 96 after scrap removal, with the components unfolded;

Fig. 98 shows the components of Fig. 98 applied to a fabric of a support structure; Fig. 99 is an elevation view of a finished diaper with an open position;

Fig. 100 shows an alternating section pattern for use in the structure of Fig. 9199.

Fig. 101 shows a device for placing lugs on a fabric of a support structure, with zero waste, from a single incoming strip.

Fig. 102 is a side perspective view of the embodiment shown in Fig. 101;

Fig. 103 is a side view of the embodiment shown in Fig. 101.

Fig. 104 are additional symmetrical ear patterns that can be formed from a single incoming fabric.

Description of the Preferred Embodiment [0017] Although this disclosure is detailed and accurate to enable those skilled in the art to implement the invention in practice, the physical embodiments disclosed herein only illustrate the invention that can be implemented in other specific structures. Although a preferred embodiment has been described, the details can be changed without departing from the invention, which is defined by the claims.

[0018] Referring to the drawing, figure 1 is a schematic illustration of a prior art process for applying patches to fabrics in a diaper making process, resulting in the intermediate article shown in figure 2. The present invention can use this prior art method to attach segments 12 to the fabric 10, by means of another cutting device, described later in the new cutting device 114. The fabric 10 is a composite material used for making diapers, which is usually formed of different layers of material, for example plastic bottom panels, absorbent pads and nonwoven top panels. A series of eyes 12 are applied to the fabric 10. In the illustrated process of Fig. 1, a rotary vacuum cutting device 14 is used to feed the eyes 12 to the fabric 10. The cutting device 14 has an internally reduced air pressure or underpressure (not shown), and there are a plurality of holes 24 on its surface 24 to allow the segments 12 of the tabs to be sucked to the surface of the cutting device 14. The fabric of the material 16 forming the ear tab is fed through rollers 20 and 22 to the surface 14 of the cutting device, where it is cut into segments by means of a rotary knife 18.

[0019] The surface of the roll 14 of the cutting device may have vacuum holes 24 on its smooth surface. In the typical configuration of the extension / cutting type applicator, there is a pattern of vacuum holes 24 distributed to evenly pull in the incoming fabric on the surface of the cutting device 14, and thus to the cutting point where the edge 18 of the knife connects to the cutting device 14.

[0020] It can be seen from Fig. 1 that in the prior art the feeding of the material 16 forming the ear tab may take place at a first speed (with the individual ears 12 spaced apart), after which the individual ears increase the speed to the speed of the cutting device 14. Typical feeding speeds they can be 120 mm / product for feeding, while the cutting device speeds can be 450 mm / product on the cutting device. This transition from the lower first speed to the higher second speed takes place at the cutting point, with the material 16 forming the ear tab extending on the cutting device 14 to cut it. However, directly at point 18 the transition of the cut from a lower speed to a higher speed, it is required to apply a vacuum to the ear due to the fact that the centrifugal force will try to detach the ear from the vacuum cutting device 14.

[0021] The ear fabrics 16 may consist of two parts, 12a and 12b, as shown in Fig. 3. The segment 12a is in particular called the lap section of the ear 12, the segment 12b is the segment of the ear ribbon 12.

[0022] Alternatively, the ears may have a trapezoidal shape, as shown in Figs. 6, 7A and 7B, as will be described later. The trapezoidal shape of Figures 7A and 7B is particularly advantageous for zero waste applications where a reduction or elimination of raw material ejection is required. In another zero-waste method, two parallel series of alternating ear fabrics 16 with ribbon ear sections 12 can be formed by mirroring the fabric 16, as shown in Figure 3, and placing the reflected mirror fabric along the entire / half of the length of the ear (not shown) .

[0023] Referring now to Fig. 4, the shaded area is a front view of the roll 114 of the cutting apparatus carrying the ear-forming material 16 (and then, individual ears 12) in outline. The cutting tool roller 114 is preferably formed of two vacuum parts 116 separated by a central groove section 118. The vacuum portions 116 are preferably their mirror images. The cutting tool roller 114 is symmetrical about a median plane along its circumference. Each vacuum portion 116 includes several circumferential rows of circular vacuum holes 24. Each vacuum portion 116 may also include a circumferential groove 120 with an additional circumferential row of vacuum holes 24 located in the circumferential groove 120.

[0024] Still referring to Figure 4, two diametrically opposed pockets of the cutting device 122 and two diametrically opposed pairs of ear retaining parts 124 are shown. The ear support parts can be formed as inserts using various vacuum patterns that the user deems necessary. Each pocket 122 of the cutting device is a groove extending over the face of the entire roll 114 of the cutting device. One ear holding part 124 is located on each vacuum portion 116. Each ear holding portion 124 has a pattern of ear vacuum holes 126, consisting of a plurality of vacuum holes 24 located on or near the surface of the cutting apparatus roller 144. Multiple rows of vacuum holes 24 may be used, each row having multiple vacuum holes 24, although more or less configurations or shapes may be used than those shown.

[0025] Referring now to Fig. 5, a simplified view of a nested ear applicator with zero waste and methods of the present invention is shown. The components of this ear applicator include a fabric cutter 210, which processes the incoming ear fabric material 16 into two parallel paths (not shown in this view). After cutting, the fabric material of the ear is processed by a tape applicator 220 that can add tape to the ear to attach the ear 12 around the user's waist.

[0026] After cutting and applying the tape to the ear fabric 16, an ear matrix is ​​used to cut the ear fabric 16 to the shape shown in Fig. 7A. The ear material 16 is die cut with a nested shape on a synchronized vacuum connected cutting device / die, 230/232, and transferred by rotating or otherwise to the ear rotating assembly 200.

[0027] Referring still to Fig. 5, the cutting edges of the ear dies 230 pivot to and in coordination with the respective cutting device 232 to form preferably trapezoidal ears. It should be noted that, as shown in Figure 6, ears 12 having different heights, H1 and H2, can be produced in this configuration by increasing or decreasing the feed speed of material 16 to the combined cutting device / matrix, 230/232. In this way, before cutting, the material 16 is subjected to a larger or smaller extension, which results in longer or shorter ears.

[0028] Since the ear material 16 has already been cut into two strips, one for the left side of the diaper and the other for the right side of the diaper, it should be noted that two parallel ear dies 230 are used to form the shape shown in Fig. 7A , for cutting fabric 16, but because of the side view of Fig. 5a, only one of the strips is visible if more than one is required.

[0029] However, the individual ear pieces obtained, due to the trapezoidal shape of the ears shown in Fig. 7A, alternate in the correct orientation A and the incorrect (inverted) orientation B. It is required to rotate 180 ° inverted ear B to the correct orientation A, so that the ears and the associated tape represent the left ear and right ear on the diaper, such as that shown in Fig. 7B. In the correct orientation A, as shown in Fig. 7B, the shorter of the parallel sides of the trapezoid will face outwards, left to the left and right to the right. Such geometry is desirable to fit the user's legs when the ears 12 are wrapped around the user's waist.

[0030] To achieve an inversion of the ear pattern, separate ear elements are selected with a nested ear module by means of the ear rotating assembly 200 (see Figures 5 and 8), which has a series of pucks 234 moving radially from the minimum radius R1 (and therefore the minimum tangential velocity) to the maximum radius R2 (and therefore the maximum tangential velocity) at the deposition site. The difference between R1 and R2 is that individual feed pulleys 235 may be non-nested and allow slack (in radial direction from adjacent feed pulleys 234) for every second ear to be rotated, which will be described hereinafter with reference to Fig. 10a and 10b. The rotated ears are then not nested in the correct orientation, and brought to the appropriate deposition speed either on an additional vacuum drum (as shown in Fig. 5a) followed by fabric 10 or a high vacuum drum 250.

[0031] Referring to Fig. 7A, two ear strips 12, 16A and 16B are shown, representing the right and left ears intended for the article. The longest side of the ear 12 is intended to attach to the fabric 10, so because trapezoids are desirable, every second trapeze in each strap will need to be rotated 180 ° to allow the desired side to be attached to the fabric 10 (e.g., the longest side ) ear 12. All of the ears 12 marked with the letter "B" on material 16A will be rotated 180 ° to position A. All of the ears 12 marked with the letter "B" on material 16B will be rotated 180 ° to orientation A to achieve the desired seating orientation shown in fig 7B.

[0032] It should be noted that the ear configurations may vary as shown in Figs. 7C-7F. In Figures 7C and 7D, wavy or curved ear patterns are shown. In Fig. 7E, a square shape is shown. In Fig. 7F, the trapezoidal shape is shown. Scraps can be cut in any shape of the ear pattern, for example as in Fig. 7F. Scraps can be of any shape or size and can be placed either on the edges of the ears or on the inside of the ears.

[0033] Referring now to Fig. 5, after rotating each ear 12 designated "B", each ear is seated on the vacuum drum 240, rotated and received by the high vacuum drum 250. The vacuum drum 240 is a size change shaft that fits the scale. The vacuum drum 240 can also be used as a roller, in conjunction with the roller or to replace the roller 260, Fig. 16.

[0034] Because the ears 12 need to be accelerated to match the speed of the fabric 10 of the support structure, the rotation speed of the high vacuum drum 250 is greater than the rotation speed of the vacuum drum 240. The high vacuum in the drum 250 relative to the drum 240 allows to catch or gripping the ear 12 at the higher rotational speed present in the drum 250.

[0035] Referring now to Fig. 5a, a simplified view of a nested applicator device of the zero-waste rear ears and the methods of the present invention with alternating configuration of the fabric path is shown.

[0036] Referring now to Fig. 8, a simplified perspective view of a nested zero waste rear applicator device is shown and methods of the present invention. As shown, two assemblies 200R (right) and 200L (left) rotating the ear are used to rotate every other ear 12 applied to the right side of the fabric 10 of the support structure and every other ear 12 applied to the left side of the fabric 10 of the support structure. In this way, for one product, one of the two eyes will be rotated 180 °. As shown in Figure 8, two types of feed pulleys, non-rotating feed pulleys 234A and rotating feed pulleys 234B were used. Non-rotating pucks 234A carry ears "A" shown in Fig. 7A or ears that do not need to be turned. The rotating pucks 234B carry the "B" ears shown in Fig. 7A. When the ear rotating assemblies 200R and 200L rotate, the ears 12 are picked up from the die / cutting station 230/232 and rotate around the rotatable member 200, while each of the rotatable feed pulley 234B also rotates radially during the rotational movement of the rotary member 200, which will described later.

[0037] The ears 12 are then mounted on the fabric 10 of the supporting structure and connected to it, for example by means of an ultrasonic joining ring 252, and the resulting product is sent further for further processing.

[0038] Referring now to Fig. 8a, a simplified perspective view of a nested zero-waste rear applicator device is shown and methods of the present invention with an alternating fabric path configuration. This is the preferred embodiment of the vacuum drum / ring 250/252 for ultrasonic joining with respect to the vacuum drum 240. In this configuration, the ears are ultrasonically bonded to the support fabric 10 between the vacuum drum / ultrasonic coupling ring 250/252 and the vacuum drum 240 when the support structure fabric 10, as shown, moves from right to left.

[0039] Referring now to Fig. 9, a side view of an ear rotating assembly device 200 is shown. The ear turning device 200, used to rotate the alternating ears, again with the whole device 200, rotates about the central axis, and each pull disc 234 moves radially from the minimum radius R1 to the maximum radius R2, at the location of the deposition during rotation. then back to the minimum radius R1. The difference between R1 and R2 is that individual feed pulleys 235 may not be nested and allow clearance for every other ear to be rotated. When turning from position R1 to position R2, the rotating pucks 234B are not only increased in radius, but also rotated 180 ° about an axis perpendicular to the central axis. This can preferably be done by means of a screw (letter reference S, Fig. 12). When turning from position R2 back to position R1, the rotating feed pulleys 234B rotate back by rotating them 180 °, reaching their initial position using a Yankee bolt that is capable of both moving forward and retracting the rollers 234B, and turning the 234B, after moving the Yankee shaft radially inward and outward.

[0040] Referring now to Fig. 10a, a front view of the ear rotating assembly device 200 used to rotate the alternating ears is shown. As shown, the pulleys 234 are provided with vacuum holes 236 through which a vacuum is applied, stopping the ears on the rotation member 200 by rotating them (rotating radially for each ear, rotating radially and axially for every other ear) until they are seated. As shown, the feed pulleys 234 may be approximately trapezoidal in shape to roughly match the shape of the ears 12. In this view, it can also be seen that the non-rotating feed pulleys 234A remain in their radial inverted position relative to the rotating feed pulleys 234B, which rotate from its initial position, nested between two non-rotating feeder discs 234A, and back again.

[0041] Referring now to Fig. 10B, the alternating shape of the pulleys 234 is shown. In Fig. 10A, the pulleys 234 are adapted to receive the wavy ears as described previously. In Fig. 10B, the pucks 234 are adapted to receive trapezoidal shaped ears, as previously described. It is preferred to configure the pulleys 234 to match the desired ear shape.

[0042] Referring now to Fig. 11, a perspective view of two devices, 200R and 200L, of rotating ears is shown. Vacuum collectors used to apply vacuum to the feed rollers 234 are also shown. In this sense, the rotational movement of the pull rollers 234 is described in US Patent Application No. 11/244 387 currently under consideration. A front view of this configuration is shown in Figure 13 and a side view in Fig. 14.

[0043] Referring now to Fig. 12, a mechanism for turning the feed rollers 234b is shown. It can be seen that the screws 236 are used so that the movement of the pulley 234B away from the central axis simultaneously causes the pulley 234B to rotate. A radially moving connector 238 connects the feed pulley to the screw 236, and when the thread turns of the screw engage radially with the moving connector 238, rotation is induced.

[0044] Fig. 15 is a cross-sectional view of the ear turning assembly device 200 used to rotate the alternating ears along the line shown in Fig. 12. Particularly, the screws 236 are operatively connected to the pulleys or swivel units 234. By turning the screw 236, the pulleys 234 are moved along a radial line with respect to the shaft rotating device 246. A vacuum manifold 244 was used to provide vacuum to the feed pulleys 234, and ultimately to hold the ears 12 in place. Cam 242 of the ear rotating device is used for rotating purposes.

[0045] Referring now to Fig. 16, a front view of a rotary vacuum wheel 114, an ultrasonic joining ring 252 and a vacuum pattern 124 used for the bias changing the slower fabric and applying and joining the ears 12 located between the roller 260 and cutting device 114 for a faster moving fabric of the support structure.

[0046] In this embodiment, the clear vacuum pattern 124 on the high vacuum drum 250 will withdraw the ears 12 from the vacuum drum 240. This step follows the rotational movement of the ear "B" as described above. The fabric 10 of the support structure is fed between the roller 260 and the high vacuum drum 250. An ultrasonic bonding ring 252 connects the ears 12 to the fabric 10 of the support structure (see Fig. 5).

[0047] Referring now to Fig. 17, a simplified view of a nested zero-waste rear ear applicator device 200 is shown in an alternative embodiment of the means for applying the ear 12 to the fabric 10 of the support structure. Instead of the slit underpressure system described above, the rotary member 274 with projections is pressed against the fabric 10 of the support structure as disclosed in US Patent No. 6,475,325. The disclosure in US Patent No. 6,475,325 is referred to as the "shock transfer" method. In this embodiment at the stand 270, the adhesive 10 is applied to the fabric of the supporting structure. The adhesive is applied in points at intervals to make contact with the ears 12 carried by the rotary element 200. The protrusion of the element 274 pushes the fabric 10 of the supporting structure towards the eye 12 carried by the feed roller 234. When the eye 12 is connected to the fabric of the support structure, the connected material is processed by the end joint station 272, after which the ear / support structure combination is forwarded for further processing as required.

[0048] Referring generally to Figs. 18-28, diagrams and plan views of a novel disposable underwear configuration using methods of nested application of a rear ear with zero waste, including multi-component ear assembly, assembly and assembly, are shown. The embodiments of Figs. 18-28 are particularly well adapted to the production of an article called an adult size diaper in the industry.

[0049] One problem with an adult-size diaper is overall size. The products are required to be fairly voluminous (e.g., 32 "wide in the unstretched state) in the waist section to fit around the adult waist. However, adult-size products are usually shipped in about 8" wide packaging, so the products require folding, especially in the waist area, where the product is the widest, for compact packaging and shipping.

[0050] To adjust the waist strap to size, Z-folded ears are often used in the prior art. For example, the ears 12 applied to the fabric 10 shown in Fig. 2 would have to be folded so that they do not go far beyond the fabric profile 10 of the supporting structure. This helps both in the processing of the fabric, as it avoids loose parts, but also helps in packaging and transporting the material.

[0051] The embodiments of Figs. 18-28 illustrate an ear segment structure that can be formed of multiple pieces, as opposed to prior art single-piece ears (see, for example, ears 12 of Fig. 2). This allows both the contoured multi-element ear segment and the assembly of at least a portion of the ear segment in a pre-folded state to be produced. [0052] Referring now to Fig. 18, an elevational view of the material 316 forming the ear tab entering the system, disposed similarly to the material 16 shown in FIGS. 8 or 8a. Preferably, the material 316 forming the ear tab (or wing) is a nonwoven continuous fabric that is finally formed into ear shaped parts 312. Ear shaped parts 312, as described with reference to Fig. 7a-7f, may take different shapes and may have the correct original orientation, or orientation requiring re-chamfering or rotation, as described above [0053] In a preferred embodiment, the ear parts 312 of the present invention have a side lobe assembly adopting the ear part configurations 312a and 312d rather than adopting the 312b and 312c configurations of the ear portion, as will be described later.

[0054] Referring to Fig. 19, the ear strap forming material 316 is cut and stretched, for example as shown in Fig. 8, at station 210. The strips 316a and 316b of the chopped and spreaded ear strap forming material 316 receive the lateral lobe assemblies described in Fig. 19a and eventually become the left and right ear segments on the disposable product.

[0055] Referring now to Fig. 19a, a simplified view of forming the side panel assemblies 320 is shown. The formation of side flap assemblies 320 begins with the outer nonwoven fabric material 318, which is cut and spread in separate parts 318a, 318b, 318c and 318d of the nonwoven fabric, each of the nonwoven fabric parts also preferably being cut to a favorable size in the transverse direction of the machine .

[0056] One or more attachment mechanisms 322 are applied to each of the separate portions 318a, 318b, 318c and 318d of the nonwoven fabric. The attachment mechanisms 322 may be strips of tape, covered with strips of tape, strips of hook-loop material, continuous hook-type material - loop, hook and loop material inserts and the like. The fastening mechanisms 322 will be removable and re-fastened around the waist to tighten disposable underwear around the waist.

[0057] Next, the nonwoven fabrics 318 containing the attachment mechanisms 322 are folded to form the folded fabric 318 and the complex attachment mechanisms 322 '. This combines the nonwoven fabric 318 and the fastening mechanisms 322 to be narrower than the separate parts 318a, 318b, 318c and 318d of the nonwoven fabric. It should be noted that the complex fastening mechanisms 322 'of the fabric portions 318a and 318b will have opposing fastening mechanisms 322' because they will be right and left fastening mechanisms of the thigh waist portion, respectively, when positioned around the user's waist (shown later in the process).

[0058] In addition to separate portions 318a, 318b, 318c and 318d of the nonwoven fabric, stretch laminate fabric 324 is also used. It is also cut and spread in separate parts 324a, 324b, 324c and 324d of stretch laminate fabric.

[0059] Next, the nonwoven fabric parts 318a, 318b, 318c and 318d, including their respective fastening mechanisms 322 ', are combined with the parts 324a, 324b, 324c and 324d of the stretch laminate fabric, respectively, to form side flap assemblies 320 in four different strips , 318a + 324a, 318b + 324b, 318c + 324c and 318d + 324d. The nonwoven fabric parts 318a, 318b, 318c and 318d can be connected to the parts 324a, 324b, 324c and 324d of the stretch laminate fabric in any way, e.g. by ultrasonic joining, using a mechanism such as shown in Fig. 16, with overlapping seams , with adhesives, welded seams, and the like.

[0060] The stretch laminate parts 324a, 324b, 324c and 324d can also be folded if required, or all the stretch laminate parts 324a, 324b, 324c and 324d in combination with the nonwoven fabric parts 318a, 318b, 318c and 318d can be folded together and again. [0061] Referring now to Fig. 20, an elevational view of the lateral lobe assembly 320 coupled to the ear-tab material is shown. In a preferred embodiment, the side flap assembly 320, and especially the flap 320 having the 318a + 324a configuration (of Figure 19), is cut by the extension-cut method on top of the belt 316a, and particularly cut by the extension-cut method and combined with the configuration 312a ear.

[0062] Similarly, the side panel assembly 320, and especially the panel 320 having the 318b + 324b configuration (of Figure 19), is cut by the extension-cut method on the bottom of the belt 316a, and particularly cut by the extension-cut method and combined with the configuration 312d of the part ear.

[0063] In strip 316b, the side panel assembly 320, and particularly the panel 320 having the 318c + 324c configuration (of Figure 19), is cut by the extension-cut method on top of the belt 316b, and in particular cut by extension-cutting method and combined with the configuration 312d parts of the ear.

[0064] Similarly, the side panel assembly 320, and especially the panel 320 having the 318d + 324d configuration (of Figure 19), is cut by the extension-cut method at the bottom of the belt 316b, and especially cut by the extension-cut method and combined with the configuration 312a ear.

[0065] The lobes 320 can be combined with the cut and spread material 316 forming the ear tab in any manner. Preferred methods may include ultrasonic bonding, non-adhesive bond, thermal bonding, and the like. The connection between the lobes 320 and the ear strap forming material 316 may also be included in or be part of a larger laminate including other materials and fasteners.

[0066] Next, now referring to Fig. 21, the side lobe assemblies 320 have been folded over (or below) the ear tab forming material 316 to conform, and preferably be narrower than the ear portions 312 of strips 316a and 316.

[0067] It is desirable to process the combination of side panel assemblies 320 temporarily stacked on top of one another with the material 316 forming the ear tab, so that the components are not caught in the machine during processing. It is also desirable that packaging takes place in an orderly and even manner. Preferably, the side panel assemblies 320 are temporarily stacked on top of each other with the material 316 forming the ear flap. Temporary stacking can be done, for example but not limited to, by applying a thin layer of glue, by light pressure, by light pressure supported by slight penetration of the convex elements through the layers, by means of light ultrasonic joining, or other types of temporary and light bonds can be used.

[0068] Referring now to Figs. 22-25, after the side lobe assembly 320 has been joined to the ear tab forming material 316 and after the side lobe assembly 320 has been assembled, the side lobe assembly 320 + 316 is machined as if the ear 12 were machined with reference to Figs. 1-17. For example, the lateral lobe assembly 320 and ear tab 316 may be beveled again (Fig. 2223), then die cut, beveled and inverted again (Figs. 24-25).

[0069] In particular, the configurations of the ear portions 312c and 312d can be cut together by an ejection / cut method with a unit as shown in Figs. 8 or 8a, on the machine shown in Fig. 9, which dies, bevels and turns again a second wing assembly as shown in Fig. 24.

[0070] Belt 316a will be machined by one of the ear (200R) (right) or 200L (left) assemblies, and Figure 316b will be machined by the other of the ear inverting 200R or 200L assemblies.

[0071] As a result, and as shown in Fig. 25, every other part of the 312c and 312d configurations of the ears will be rotated 180 ° and re-chamfered so that the 312a / 312b configurations of the ear parts will be identical to the rotated 312c / 312d configurations of the parts ears, and stripes 316a and 316b will be their mirror images.

[0072] Referring now to Fig. 26, ears 312 and side lobes 320 have been properly oriented and re-chamfered so that the right front ear 312b (front of the product, without attached side lobe 320) and its associated right rear ear 312d (back of the product, with side lobe 320 attached and folded in) are a mirror image of the left front ear 312c (front of the product, without attached side lobe 320) and the associated left rear ear 312d (back of the product, with side lobe 320 attached and folded in). These lugs 312 and side panels 320 are introduced into and connected to the fabric 10 (or top sheet of the support structure), usually the composite material used to make the diaper, which is usually formed of different layers of material, for example plastic back panels, absorbent pads 340 and top nonwoven sheets (shown in Figs. 27 and 28).

[0073] Referring now to Fig. 27, the next step is to fold the ears 312b and 312c and 312a and 312d and their associated side panels 320 overlapped so that first one of the stripes 316a and 316b is folded down and then folded is the second one. As shown, the ears 312b and 312c and 312a and 312d and the associated side panels 320 are folded at, and narrower than, the width of the support structure assembly 10 in the transverse direction of the machine.

[0074] Fig. 28 is an elevational view of an innovative disposable product in use made using the methods of the present invention. As shown, the ears 312a and 312d are connected to the associated side lobes 320 that have previously been deposited on the ears 312. The user can place the absorbent pad 340 in the crotch area and connect the attachment mechanisms 322 of the side panels 320 around the waist to reach the front of the ear 312b and 312c, and attach the disposable product.

[0075] Referring now to Figs. 29-42, simplified views and elevational views of assembly methods of a disposable product, including forming a nested ear with zero waste, in the nested wing portion with zero waste, fixing the ear portion and wing portion to the top sheet are shown. supporting structure and folding the product to form a folded diaper. Generally, the product shown in Fig. 29-42 is formed by cutting (preferably matrix cutting) a fabric (preferably stretchable laminate or nonwoven) to form an ear, alternately rotating and attaching the ear to the wing, folding and stacking the ears on the wing, matrix cutting of the wings, alternately turning and fastening the assembly ears and wings for the load-bearing structure, folding and stacking the wings on the fabric of the load-bearing structure.

[0076] Referring to Fig. 29, the process begins with a fabric portion 1000 (preferably a nonwoven) introduced into the system which, as shown in Fig. 30, is separated and spread over four strips of nonwoven fabric 1002, 1004, 1006 and 1008 similar to those previously described with reference to Fig. 19a. Instead of rectangular blanks formed from separate parts 318a, 318b, 318c and 318d of the non-woven fabric of Fig. 19a, ears 1012 shown when forming the ear of Fig. 29-32 can be punched out of the trapezoidal zero waste configuration as shown, or from other rectangular or non-rectangular zero waste configurations (such as in Figs. 7a-7f).

[0077] As shown in Fig. 31, tapes 1022 are applied to the nonwoven (similar to 322 and 322 'of Fig. 19a) and folded. Then, referring to Fig. 32, the ears 1012 are die cut, beveled again and rotated, as shown, for example using the machine shown in Figs. 11-14. The final orientations show tapes 1022 folded in line with the ears 1012, and the ear orientations after folding result in four different ear orientations, 1012a, 1012b, 1012c and 1012d.

[0078] In orientation 1012a, the strips 1022 are on the upper edge, the long edge (opposite the upper edge) being on the lower edge. In orientation 1012b, the strips 1022 are on the bottom edge, the long edge (opposite the bottom edge) being on the top edge. Similar rotation and resulting orientations are shown with reference to 1012c and 1012d.

[0079] Referring to Figs. 33 and 34, a flap fabric 1040, preferably nonwoven, for receiving folded straps 1022 connected to the ears 1012, with the flap fabric 1040 cut and spread as in Figs. 18 and 19, is shown, while the ear after cutting, beveling and turning again is introduced into the fabric of the wings as shown in Fig. 35 (similar to Fig. 20 above).

[0080] As shown in Fig. 35, folded straps 1022 connected to the ears 1012 are introduced as shown, wherein the strip fabric material strip 1042 receives folded straps 1022 connected to the ears 1012 in orientation 1012a connected to the wing fabric portion 1042b, such that the short side of the trapezoid in the transverse direction of the machine (from left to right) adopts the long side of the ear 1012 from orientation 1012a. The short side of the wing fabric portion 1042a in the transverse direction of the machine adopts the long side of ear 1012 in orientation 1012b. The resulting configuration is shown in Fig. 35, also regarding the strip 1044 of the flap fabric material, with short sections of the portion 1040a in the transverse direction of the receiving machine 1012 in orientation 1012c on the long side of the orientation 1012c in the transverse direction of the machine, and similarly with oriented receiving parts 1044b ear 1012d as shown.

[0081] All of the ears are then folded as shown in Fig. 36, so that parts 1042a and 1042b hold the ears 1012, while parts 1042c and 1042d do not fit the ears. Portions 1044a and 1044b contain portions 1012 of ears arranged in orientations 1012c and 1012d, respectively. In Figs. 36-40, the process continues as shown, similar to the process described above with reference to Figs. 21-27. A representative product is thus formed, as shown in Fig. 41 and its cross section is shown in fig. 42.

[0082] Referring to Fig. 37, it can be seen that every second pair of elements from belt 1042 are rotated. Elements 1042d and adjacent 1042a are not rotated, while 1042b and adjacent 1044c are rotated 180 ° in turn. Similarly, with respect to belt 1044, elements 1044c and 1044b are rotated sequentially, while elements 1044a and 1044d are not rotated in orientation relative to the machine direction.

[0083] In Fig. 38 it can be seen that the elements have been positioned correctly for seating on the fabric of the supporting structure (preferably pre-formed from the elements, for example the absorbent core, the top sheet and the bottom sheet as shown but not marked in the other figures). All folding of the ear parts 1012 with the wing parts 104s overlaps the top of the strap 1042 and the bottom of the strap 1044, so that when a portion of the supporting structure is connected between the straps 1042 and 1044, as shown in Figure 39, the wings 1042a holding the ears 1012d and 1044a may form two parts waist wrapping. The space between elements 1042a and 1042c forms parts for the left leg, and the space between elements 1044a and 1044c forms parts for the right leg.

[0084] Referring now to Fig. 40, items 1042a (including ear 1012a), 1042b (containing ear 1012b), 1042c and 1042d, as well as 1044a (containing ear 1012d), 1044b (containing ear 1012c), 1044c and 1044d are folded up, to be leveled with the fabric of the supporting structure. [0085] Referring now to Figs. 43-60, an additional embodiment was created using the procedure set out herein.

[0086] Referring to Fig. 43, a laminate after cutting and stretching (501-504) is shown, and four strips of hook material 505 are shown below. In Fig. 44, hooks 505 attached to stretch laminate fabrics 501-504 are shown, while additional sliced ​​nonwoven fabric 510 and 512 are introduced and, as shown in fig. 45, stretch laminate fabrics 501504 are connected to outer nonwoven fabrics 510 and 512 as shown, for example, by ultrasonic joining methods. Then, as shown in Fig. 46, the laminate side panel is folded as shown. The laminate side panel is cut, as shown in Fig. 47, forming the 501 / 501a, 502 / 501b, 503 / 501c and 504 / 501d side panel assemblies, respectively.

[0087] Next, fabrics 610a, 610b of the rear lugs (preferably nonwoven) are introduced, as shown in the state formed in Fig. 51 and cut in Fig. 52, preferably by sliding / cutting, into and combined with the units 501 / 501a, 502 / 501b, 503 / 501c and 504 / 501d of the lateral lobe, as shown in Fig. 48.

[0088] The side panel assemblies 501 / 501a, 502 / 501b, 503 / 501c and 504 / 501d are then folded and preferably stacked temporarily, as shown in Fig. 49.

[0089] Next, the side lobe assemblies 501 / 510a, 502 / 510b, 503 / 510c and 504 / 510d, connected to the corresponding parts 610a1, 610a2, 610a3 and 610a4 and 610b1, 610b2, 610b3 and 610b4 of the rear ear fabric are cut out of the die , beveled again and rotated according to Fig. 50a, which results in the final orientation shown in Fig. 50b, where every second of 610a1, 610a2, 610a3 and 610a4 has been rotated 180 degrees, and every second of 610b1, 610b2, 610b3 and 610b4 has also been rotated 180 degrees and re-chamfered, which results in matching right and complex sets left.

[0090] Figs. 53 and 54 show molded and cut nonwoven fabric 702/704 of the front ear, particularly parts 702a, 702b, 702c and 702d and 704a, 704b, 704c and 704d, which are then die cut, beveled and rotated again as shown in figures 55-56.

[0091] As shown in Fig. 57, the nonwoven fabric parts 702a, 702b, 702c and 702d and 704a, 704b, 704c and 704d of the front lugs are inserted into and connected around the opposite edges of the fabric 10 of the supporting structure, and the corresponding parts 610a1, 610a2, 610a3 and 610a4 of the fabric of the rear lugs, correct alignment, and the corresponding parts 610b1, 610b2, 610b3 and 610b4 of the rear lugs, also after correct alignment, are in the same way inserted into and connected around the opposite edges of the fabric 10 of the supporting structure, as shown in Fig. 58, staggered with portions of the front lugs, as shown.

[0092] All parts 702a, 702b, 702c and 702d and 704a, 704b, 704c and 704d of the front ears; and parts 610a1, 610a2, 610a3 and 610a4; and 610b1, 610b2, 610b3 and 610b4 fabric of the rear ears; they are all folded to accommodate (slightly larger, equal, or slightly smaller than) the width of the support structure 10 in the transverse direction of the machine, as shown in Fig. 59.

[0093] A product having the configuration shown in Fig. 60 is produced.

[0094] It is believed that it may be desirable to provide the disposable product with a contoured or curved leg opening 1200 by cutting a portion of the bonded fabric 1202 after placing the wings 1042a-1042d, 1044a-1044d on the fabric 10 of the supporting structure as shown in Fig. 61 and 62. For illustrative purposes, Figures 61 and 62 show combined fabric 1202 and resulting disposable underwear 1204 in Figs. 39-41, however, it should be understood that the methods described herein can be used on any combined fabric. Preferably, the bonded fabric 1202 comprises a fabric 10 of the support structure, a plurality of wings 1042a, 1042b, 1044a, 1044b comprising ears and wings 1042c, 1042d, 1044c, 1044d not including ears, as shown in Fig. 39.

[0095] Preferably, a portion of the wings 1042a, 1042b, 1044a, 1044b containing the ears and the wings 1042c, 1042d, 1044c, 1044d not including the ears on each side of the garment 1204 can be removed to form a contoured shape as shown in Fig. 61. However, it is also believed that the fabric portion 10 of the supporting structure between the ear wing 1042a, 1042b, 1044a, 1044b and the non-ear wing 1042c, 1042d, 1044c, 1044d can also be removed to form a contoured shape as shown in Fig. 62 For example, as shown in Fig. 61, the fabric portion of the support structure between the first non-ear wing portion 1042d and the first non-ear wing portion 1042b has been removed.

[0096] It is believed that any means known in the art can be used to remove the desired portions of the wings 1042a-1042d, 1044a-1044d and, if required, the fabric 10 of the support structure to form a contoured leg opening 1200. For example, and not limiting, a cutterblock can be used to cut a leg hole 1200 in the desired contour in the underwear. In this arrangement, a profiled knife roller with a cutting edge adapted to the size and shape will be used to cut the leg hole 1200 into the desired shape. It is believed that at the same time both the left 1200a and right 1200b can be cut at the leg hole, for example with a knife roller with two cutting surfaces, or that a pair of knife rollers can be used, one for the left leg hole 1200a and one for right leg hole 1200b. Each knife roller is provided with a associated cutting device as is known in the art. In use, the cutting device and the knife roller rotate, with the fabric 1202 to be cut connected, between the surface of the knife roller and the cutting device. When the knife shaft rotates, the cutting edge cuts the connected fabric 1202 on the cutting device.

[0097] It is further believed that the scrap removal system 1210, as shown in Fig. 63, can be used to remove cut pieces from the combined fabric 1202. Fig. 63 shows the fed fabric 1202 and the scrap or scraps 1230 to be therefrom deleted. Transfer roller 1214 and associated trimming blade or trimming blades 1212 receive the combined fabric 1202 and scraps 1230. Preferably, trimming blades 1212 have a complementary shape with scraps 1230. Vacuum ports 1216 are disposed on transfer roller 1214 and trim blades 1212 to hold the combined fabric 1202 and scraps 1230 in direct contact with transfer roller 1214 and trim blades 1212. It should be noted that to make the products of the present invention in addition to the specific removal system 1210 scraps, other ways of cutting fabric can be used. It should also be noted that the illustrated scrap removal system 1210 is adapted to cut two scraps 1230 from the incoming fabric 1202 in the outer parts of the incoming fabric 1202. Different configurations of 1212 blades may be used to cut off scraps 1230 of different size and / or shape, e.g., scraps 1230 which need to be removed from the subsequent rear ears 1042a and 1042b as shown in Fig. 76, or scraps 1230 from between successive front lugs 1042c and 1042d, as shown in Fig. 76, if required. Compare Fig. 76 showing sections removed between successive front ears 1042c and 1042d and Fig. 77, without any sections between front ears 1042c and 1042d.

[0098] The inner axle 1218 and the outer axle 1220 are connected to the transfer roller 1214 (or hub 1222) and trim blades 1212, respectively. The inner axis 1218 and the outer axis 1220 can operate at different speeds relative to each other, driven by an actuator (not shown). This speed difference allows the trimming blades 1212 to rotate faster or slower relative to the transfer roller 1214, as required. In use, as will be described later, this speed difference produces a burst effect by first pulling the attached fabric 1202 away from the scrap 30 when the transfer roller 1214 rotates faster than the blade 1212, then by pulling the scrap 1230 away from the connected fabric 1202 when the blade 1212 rotates faster than the transfer roller 1214.

[0099] Referring now to Fig. 64, a two-dimensional representation of the trimming blade 1212 and the transfer roller 1214 of Fig. 63 is shown. As shown, the vacuum channels 1217 are connected to the vacuum ports 1216 on both the trimming blade 1212 and the transfer roller 1214 to maintain control of scrap 1230 and the combined fabric 1202. From this point of view, it can be seen that the different rotational speeds of trimmer blade 1212 and transfer roller 1214 have a tearing effect by first pulling fabric 1202 away from the scrap 1230, when transfer roller 1214 rotates faster than blade 1212, and then pulling the scrap away 1230 away from the bonded fabric 1202 when the blade 1212 rotates faster than the transfer roller 1214.

[0100] Fig. 65 is a cross-sectional view of the trimming blade 1212 and the transfer rollers 1214 according to the present invention. As shown, vacuum is applied to ports 1216 through channels 1217 that are connected to a vacuum source (not shown). The rotational movement of the outer axis 1220, which is connected to the blade 1212, causes the rotational movement of the blade 1212. The inner axis 1218 is preferably connected to the hub 1222 and to the transfer roller 1214.

[0101] Referring now to Figs. 66-71, the sequence of the scrap removal system 1210, removing scrap 1230 and unloading them, is shown, and then the system 1210 returns to its initial position to remove more scrap 1230 from the next fabric segment 1202. Fig. 72 - 75 are plan views of the positions of sections 1230 relative to fabric 1202, in positions associated with Figs. 66-68 respectively, showing the tearing effects of the present invention.

[0102] Referring now to Fig. 66, a simplified view of a fabric receiving system 1210 is shown. This figure shows a matrix and cutting device system 1226 rotating to connect to the fabric 1202 and cutting out sections from it 1230 (not visible in this view ), which is well known in the art. Unfortunately, the matrix of the matrix system and cutting device 1226 is susceptible to wear and tear and needs to be replaced when the matrix becomes blunt to an unacceptable condition.

[0103] In this view, the trimming blade 1212 can be seen in the initial position of receiving the scrap, aligned to receive the scrap 1230 of fabric 1202 on the blade 1212, which, as previously described, will be pressed against the surface of the blade 1212 by vacuum ports 1216. It can be seen that the blade trim 1212 rotates around the outer axis 1220. In this view, unload chute 1228 is shown for final collection of waste scrap 1230, and discharge conveyor 1240 is used to collect fabric 1202 with scrap 1230 removed, for further processing and manufacturing steps in assembling disposable garments as required.

[0104] The inner axis 1218 preferably operates at a first continuous speed, the rotating hub 1222 and the transfer roller 1214 at a continuous speed consistent with the feed speed of fabric 1202. In this initial scrap take-up position shown in Fig. 66, the outer axis 1220 and associated with the blades 1212 are rotated at the same speed as the inner axis 1218.

[0105] The position of the scrap piece 1230 relative to the fabric 1202 is shown in Fig. 72 for the initial scratch receiving position. In this position, the cutting device and matrix 1226 form a separating device, but scrap 1230 and fabric 1202 may remain somewhat connected, depending on the sharpness of matrix 1226. The separation method shown in the figures, particularly the strip removal system 1210 is just one method for producing the novel products of the present invention, with other methods of cutting off / removing scrap.

[0106] Referring now to Fig. 67, the outer axis 1220 and associated blades 1212 are switched more slowly than the inner axis 1218 to allow detachment of the fabric from the scrap 1230 on the leading edge of the scrap 1230 towards the machine. It is clear in this view that the distance between the end edge of the blade 1212 and the leading edge of the transfer roller 1214 becomes shorter. This peeling is caused by peeling the main fabric 1202 away from the scrap 1230 at the leading edge of the scrap 1230, as shown in connection with Fig. 73.

[0107] Referring now to Fig. 68, the outer axis 1220 is switched at the same speed and then faster than the inner axis 1218 to allow tearing off scrap 1230 from fabric 1202 at the leading edge of scrap 30, as shown in connection with Fig. 74. At this stage of the process, the scrap 1230 will be removed from the fabric 1202 by first tearing the main fabric 1202 away from the scrap 1230 at the leading edge of the scrap 1230, and then by peeling the leading edge of the scrap 1230 from fabric 1202.

[0108] The discharge conveyor 1240 was used to receive fabric 1202 with scrap 1230, as shown in Fig. 75, for further processing and manufacturing steps in the disposable garment assembly as required. The vacuum of the transfer roller 1214 can be turned off at this stage to allow fabric 1202 to be released from the conveyor, for example according to patent application No. 11/141 552 entitled "High Speed ​​Vacuum Porting".

[0109] Referring now to Fig. 69, scrap 1230 has been unloaded into the discharge chute 1228, which is preferably vacuum assisted, although other receiving means will successfully accomplish the task of collecting waste scrap 1230. It should be noted that vacuum can be turned off from blades 1212 enable the release of 1230 scraps into the 1228 unloading chute. Alternatively, you can simply apply a vacuum to the discharge chute 1228 which will be greater than the vacuum applied to blades 1212.

[0110] The rotation speed of the blades 1212 and the outer axis 1220, which first worked at a speed approximately equal to the speed of the inner axis 1218, the rotating hub 1222 and the transfer roller 1214, initially decreases or delays, as shown by comparing Fig. 66 of Fig. 67.

[0111] Then, the rotation speed of the blades 1212 and the outer axis 1220 increased or sharply increased relative to the speed of the inner axis 1218, the rotating hub 1222 and the transfer roller 1214.

[0112] In order to return to the initial position of the scrap connection, the rotation speed of the blades 1212 and the external axis 1220 must again decrease or decelerate relative to the internal speed of axis 1218, rotating hub 1222 and transfer roller 1214. This delay is evident by comparing Fig. 68 of Figs. 69, 70 and 71. Finally, in Fig. 71, by one turn, system 1210 removed and unloaded scraps 1230, unloaded fabric 1202 for further processing, and blades 1212 were moved back to their initial position to remove more scraps 1230 from subsequent fabric segments 1202.

[0113] It is believed that the matrix of the matrix system 1226 and the cutting device in the above-mentioned scrap removal device can be replaced by a perforating device. The perforating device preferably forms scraps 1230 on fabric 1202, but does not completely separate scraps 1230 from fabric 1202. Perforated scraps 1230 can then be removed from fabric 1202 in the same manner as described previously. The perforating device may take any form known in the art including, but not limited to, a perforating matrix roller.

[0114] It is further believed that scraps can be removed from the wings 1042a-1042d, 1044a-1044d before the wings 1042a-1042d, 1044a-1044d are attached to the fabric 10 of the support structure. Scraps can be removed from wings 1042a-1042d, 1044a-1044d, by any means known in the art. For example, the blade fabric 1042, 1044 can be fed between the cutting device and the cutterblock, the cutterblade having a cutting edge adapted to the size and shape to cut the desired scraps from the blades 1042a-1042d, 1044a-1044d.

[0115] Although the illustrated embodiments of Figures 61, 62 and 76 show the specific configuration or shape of the section removed from the wings 1042a-1042d, 1044a-1044d and fabric 10, the sections removed from the wings 1042a-1042d, 1044a-1044d are believed to be they can take any desired shape to provide a contoured leg opening 1200.

[0116] It is further believed that if required, scraps can only be removed from wings 1042a, 1042b, 1044a, 1044b containing ears or wings 1042c, 1042d, 1044c, 1044d not including ears. For example, Fig. 77 shows a section removed only from the wings 1042a, 1042b, 1044a, 1044b containing the ears. Scraps can be cut from desired wings 1042a-1042d, 1044a-1044d using any means known in the art, including those described above.

[0117] It is further believed that the sections can be removed from the wings 1042a-1042d, 1044a-1044d and the support structure 10 in separate steps, as shown in Fig. 78. For example, the sections can be cut from the wings 1042a-1042d, 1044a-1044d in first stage and then they are cut from the fabric 10 in the second stage, or vice versa. The sections can be cut off from the wings 1042a-1042d, 1044a-1044d and fabric 10 using any means known in the art, including those described above.

[0118] Referring now to Figs. 79-90, using the principles of the invention, several variations of product configuration are shown. For example, it is possible to pre-apply either the front 1042 (c or d) or 1044 (c or d) or the rear 1042 (a or b) or 1044 (a or b) eyelets to the fabric of the supporting structure using previously known methods of extending / cutting ( for example, ears 1144 applied by the protrusion / cut method shown in Fig. 79) followed by the alternating rotation method according to the invention to assemble a novel product configuration (see, for example, Fig. 79). Similarly, it is possible to apply laterally to the fabric of the supporting structure or the front or rear lugs using the previously known extension / cutting methods, after applying the alternating rotation method according to the invention to assemble a novel product configuration, resulting in the configuration, for example, from Fig. 79 . In this method, the protrusion / cutting method was used for, for example, applying each front ear 1144 (both the left and right front ear 1144, Fig. 79), and the alternating rotation technique described earlier was used to apply each rear ear (on Examples 1042b and 1044b, Figure 79).

[0119] Furthermore, it can be seen that the extension flaps 1012 may or may not be applied if required (compare Fig. 79 with the extension flaps 1012 and Fig. 85 without the extension flaps 1012) on parts 1044 of the rear ears, if required, and that these extension flaps 1012 can be paired with rear lugs 1044 with extension flaps 1012 in a pre-folded (or unfolded) state, if required (e.g., Fig. 79 shows unfolded, with folding lines). In addition, parts of the front lugs 1144 can be brought to the support fabric fabric in a pre-folded state (e.g., Fig. 79 is shown unfolded, with folding lines) if a wider portion 1144 of the front ear is required. These configurations can also be combined with the scrap removal method discussed earlier (or with any other scrap removal or die cutting or ear fabric forming method) in which curved parts of either one or both of ears 1144, 1044, or 1042, or foot part 1200a and 1200b of the support structure, or any combination thereof (see, e.g., Figures 80 and 81), product configurations of Figures 79-90 can be obtained.

[0120] Referring to Fig. 79, there is shown an elevation view of a product variant showing the protruding / extending front ear 1144 applied, alternately rotated rear ears 1042, 1044 and extension lobes 1012 extending from rear ears 1042, 1044.

[0121] Referring to Fig. 80, the embodiment of Fig. 79 is shown, with the additional product feature that the foot portions 1200a and 1200b of the support structure are removed from the support structure for a fit around the user's leg.

[0122] Referring to Fig. 81, the embodiment of Fig. 80 is shown, with the additional product feature that scraps 1230 are removed from both the front and back of the product, for example using a separation and removal pattern sections from Fig. 76.

[0123] Referring to Fig. 82, an elevational view of a product variant is shown showing alternately rotated front and rear ears using the techniques described above (for example, using the construction technique of the embodiment as shown in Fig. 28 and / or Fig. 60 above).

[0124] Referring to Fig. 83, the embodiment of Fig. 82 is shown, with an additional product feature in that the foot portions 1200a and 1200b of the support structure are removed from the support structure for a fit around the user's leg.

[0125] Referring to Fig. 84, the embodiment of Fig. 83 is shown, with the additional feature of the product that scraps 1230 are removed from both the front and back of the product, for example using a scrap separation and removal pattern of Fig. 76.

[0126] Referring to Fig. 85, an elevational view of a product variation is shown, showing the method of extending / cutting the front ears 1144 and alternating rotation of the rear ears. [0127] Referring to Fig. 86, the embodiment of Fig. 85 is shown, with the additional product feature that the foot portions 1200a and 1200b of the support structure are removed from the support structure for a fit around the user's leg.

[0128] Referring to Fig. 87, the embodiment of Fig. 86 is shown, with the additional feature of the product that scraps 1230 are removed from both the front and back of the product, for example using a scrap separation and removal pattern from Fig. 76.

[0129] Referring to Fig. 88, an elevational view of a product variation is shown showing alternately rotatable overlayed front ears and alternately rotated back ears using the previously described methods, for example the method used to construct the configuration of the product shown in Fig. 28, with this except that in the embodiment shown in Fig. 88 there is no extension piece.

[0130] Referring to Fig. 89, the embodiment of Fig. 88 is shown, with the additional product feature that the foot portions 1200a and 1200b of the support structure are removed from the support structure for a fit around the user's leg.

[0131] Referring to Fig. 90, the embodiment of Fig. 89 is shown, with the additional product feature that scraps 1230 are removed from both the front and back of the product, for example using a scrap separation and removal pattern of Fig. 76.

[0132] Referring to Fig. 91 is a simplified elevational view of a nonwoven fabric 801/802 of an extension panel, receiving tapes 805, which are then folded onto a nonwoven fabric 801/802 of an extension panel. A stretch laminate fabric 810a / 810b was used that receives cut and spread extension sheets 801/802 of the nonwoven extension sheet and a combination of stretch laminate fabric 810a / 810b combined with extension sheets 801/802 holding the folded ears 805 is cut and spread.

[0133] Referring now to Fig. 92, the non-woven fabric of the side panel is provided with section parts 911 for later removal. As shown in Fig. 93, the non-woven fabric 910A / 910B of the side panel receives (preferably by ejection / cutting methods) separate pieces of a combination of stretch laminate fabric 810a / 810b combined with extension panels 801/802 holding the folded ears 805. The combination of stretch laminate fabric 810a / 810b connected to extension lugs 801/802 holding folded ears 805 is then folded up as shown in Fig. 94, sliced ​​and spreaded as shown in Fig. 95. Then, scraps 911 are removed as shown in fig. 96. Then, separate combinations of stretch laminate fabric 810a / 810b connected to extension panels 801/802 holding folded ears 805 carried by portions of nonwoven fabric 910A / 910B are then cut off and connected to the fabric of the supporting structure, as shown in Fig. 98. Then, to Separating individual diapers uses the die punching assembly shown in Fig. 99, which shows a plan view of the finished diaper in an open, unfolded position. The separation takes place between the desired parts of the combination of stretch laminate fabric 810a / 810b, connected to extension panels 801/802, holding folded ears 805 carried by nonwoven fabric 910A / 910B, producing a separate article.

[0134] Referring now to Fig. 100, an alternating shape of 911 'sections is shown for use in the structure of Figs. 91-99. This shape allows a great deal of flexibility in placing the separation device for producing separate diapers.

[0135] Referring now to Fig. 101, there is shown a device for placing lugs 12 on fabric 10 of a support structure, with zero waste, from a single incoming strip 16. This embodiment is useful if it is required to avoid rotational movement of the lugs, as previously described , around two different rotary axes.

[0136] In Fig. 101, a method of joining ears to a fabric is disclosed, the method comprising providing an incoming ear fabric 16 forming the left ear shape 12 and the complementary shape of the right ear 12 (for examples, see Fig. 104) from the incoming ear fabric 16 . Then, the shape of the left ear is separated from the shape of the right ear 12 by the assembly 1120r rotating and spreading the asymmetrical right ears and the assembly 1120l rotating and spreading the asymmetrical left ears, said assembly 1120r rotating and spreading the asymmetrical right ears is equipped with a series of pullers 1126r for transferring the mentioned shapes 12 right ears, and said assembly 1120l that rotates and extends the asymmetrical left ears is equipped with a series of pucks 1126l for carrying said shapes of the left ears 12. The incoming fabric 10 of the support structure receives the left ear 12 on the first portion of the edge of said incoming fabric 10 of the support structure from said rotating and spreading assembly of the asymmetrical left ear 1120l (or, alternatively, from the secondary rotary element 1122l, which will be described later), and the right the ears 12 are embedded in a similar manner. The assembly 1120R and 1120L rotating and spreading asymmetrical right and left ears rotates faster than the incoming fabric 10, thereby accelerating individual ear pieces 12 when they are sliced ​​and received by the assembly 1120R and 1120L rotating and spreading asymmetrical right and left ears.

[0137] The device allows cutting through a synchronized cutting device / matrix 1110 of the incoming fabric 16 into desired, preferably symmetrical, ear shapes 12, such as those shown in Figs. 7A-7E, or shown in Fig. 104. The assembly 1120R and 1120L rotating and spreading unsymmetrical right and asymmetrical left ears receives individually cut out ears 12 (for example, by extension / cutting methods), which are transferred, for example, on 1126R and 1126L feed rollers, for example vacuum assisted, shown as feed rollers 234 on Figures 10a and 10B. Unsymmetrical spreading assemblies ensure displacement of the ears 12 in the transverse direction of the machine, so that the ears can be simultaneously extended and accelerated to be positioned as required, with the rotational movement of the ear 12 around only a single axis, the axis rotating the assembly rotating and spreading the asymmetrical right and asymmetrical left ears 1120R and 1120L, but asymmetrical feeder pulleys, relative to the rotary axis, allow correct orientation when selecting and placing ears 12.

[0138] In a preferred embodiment of this device, there is no axial rotation of the ears 12, so that the shape of the ear 12 can be provided symmetrical with respect to the right and left ears, with zero waste of incoming fabric.

[0139] The rotating and spreading assemblies 1120R and 1120L are preferably equipped with a vacuum system to keep the ears 12 while rotating, and then releasing the ears for the secondary clockwise rotation assembly 1122R and the secondary counterclockwise rotation assembly 1122L, which further spreads the ear 12 and more accelerates the ear 12 to the deposition speed of the fabric 10 of the support structure. Preferably, the secondary anti-clockwise assembly 1122R and the secondary anti-clockwise assembly 1122L also rotate the ear 12 about a rotational axis, but it is not required to rotate the ear about an ear axis. The secondary clockwise rotation assembly 1122R and the counterclockwise rotation secondary assembly 1122L are also preferably vacuum assisted to control the ears 12, and likewise include the pulleys 1128R and 1128L, again similar to the pulleys 234 of Figures 10a and 10B.

[0140] The clockwise rotation assembly 1120R extends the right ear and accelerates the right ear from the entry speed to the deposition speed of the fabric of the support structure. The left-turning assembly 1120L extends the left ear and accelerates the left ear from entry speed to deposition fabric 10 of the support structure. It should be noted that the left or right ear can be positioned vertically distant from its intended point of attachment, and then only one left or right ear will require the lateral displacement of the machine to seat.

[0141] As shown in a side perspective view of Figs. 102 and 103, the embodiment shown in Figs. 101; the pulleys 1126L and 1126L are nested so that they catch the ears 12 coming in succession. Also preferably, the feed pulleys are inclined at a certain angle with respect to their rotational movement, so that the receiving and mounting locations of the eyes 12 are relatively horizontal with respect to the machine direction. The feed rollers 1126L and 1126L are matched to the rotatable feed rollers 1128R and 1128L, respectively, to seat the ears prior to seating on the fabric of the support structure.

[0142] A low speed mismatch is preferred between the feed rollers 1128R and 1128L, respectively, for matching pickup and placement of the product.

[0143] The above description is considered to illustrate only the principles of the invention. In addition, since modifications and changes may seem obvious to a person skilled in the art, it is not required that the invention be limited to the precise constructions and operation described and described. Although preferred embodiments have been described, the details may be varied without departing from the scope of the invention, which is defined by the claims.