U.S. patent application number 10/314915 was filed with the patent office on 2004-06-10 for process to make boxer shorts having a contracted crotch region.
Invention is credited to Coenen, Joseph Daniel, Mortell, Heather Schenck, Popp, Robert Lee.
Application Number | 20040107481 10/314915 |
Document ID | / |
Family ID | 32468595 |
Filed Date | 2004-06-10 |
United States Patent
Application |
20040107481 |
Kind Code |
A1 |
Mortell, Heather Schenck ;
et al. |
June 10, 2004 |
Process to make boxer shorts having a contracted crotch region
Abstract
A method of making a boxer-style pant having side seams, a
contracted crotch region and hanging legs. A flat web is provided.
Portions are removed from the flat web to define leg openings. The
flat web is then contracted either elastically or inelastically in
selected areas along the flat web between the leg openings. The
flat web is cut into separate pieces, folded and side seams are
formed. The pant may include an absorbent.
Inventors: |
Mortell, Heather Schenck;
(Neenah, WI) ; Coenen, Joseph Daniel; (Neenah,
WI) ; Popp, Robert Lee; (Hortonville, WI) |
Correspondence
Address: |
PAULEY PETERSEN KINNE & ERICKSON
2800 WEST HIGGINS ROAD
SUITE 365
HOFFMAN ESTATES
IL
60195
US
|
Family ID: |
32468595 |
Appl. No.: |
10/314915 |
Filed: |
December 9, 2002 |
Current U.S.
Class: |
2/400 |
Current CPC
Class: |
A61F 13/496 20130101;
A61F 13/15593 20130101; A61F 13/15723 20130101; Y10T 156/1085
20150115; A41B 9/001 20130101; Y10T 156/1062 20150115; A61F 13/4963
20130101; Y10T 156/1092 20150115; A61F 13/49017 20130101; Y10T
156/1057 20150115; Y10T 156/1051 20150115; A41B 2400/52
20130101 |
Class at
Publication: |
002/400 |
International
Class: |
A41B 009/00 |
Claims
What is claimed is:
1. A method of making a pant having side seams and hanging legs,
comprising: providing a flat web; removing at least one portion of
the flat web to define two leg openings; contracting the flat web
in at least one selected area to define at least one contracted
area, a first region and a second region; and attaching the first
region and the second region together to form the side seams.
2. The method of claim 1, further including applying a strip in the
at least one selected area.
3. The method of claim 2, wherein contracting the flat web in the
at least one selected area comprises contracting the strip.
4. The method of claim 2, wherein the strip comprises a delayed
retraction material.
5. The method of claim 1, wherein contracting the flat web in the
at least one selected area comprises corrugating the flat web.
6. The method of claim 5, wherein corrugations are bonded
together.
7. The method of claim 1, further comprising attaching at least one
waist elastic to the flat web.
8. The method of claim 1, further comprising folding the flat
web.
9. The method of claim 1, wherein the pant is made using a machine
direction assembly.
10. The method of claim 1, wherein the pant is made using a
cross-machine direction assembly.
11. The method of claim 1, further comprising cutting the flat web
into separate pieces.
12. The method of claim 11, wherein the contracting occurs before
the cutting.
13. The method of claim 11, wherein the contracting occurs after
the cutting.
14. The method of claim 1, wherein the flat web comprises an
integral elastic zone.
15. A method of making an absorbent pant having side seams and
hanging legs, comprising: providing a flat web; removing at least
one portion of the flat web to define two leg openings; contracting
the flat web in at least one selected area to define at least one
contracted area, a first region and a second region; attaching an
absorbent structure to the flat web; and attaching the first region
and the second region together to form the side seams.
16. The method of claim 15, further including applying a strip in
the at least one selected area.
17. The method of claim 15, wherein contracting the flat web in the
at least one selected area comprises contracting the strip.
18. The method of claim 15, wherein the strip comprises a delayed
retraction material.
19. The method of claim 15, wherein contracting the flat web in the
at least one selected area comprises corrugating the flat web.
20. The method of claim 19, wherein corrugations are bonded
together.
21. The method of claim 15, further comprising attaching at least
one waist elastic to the flat web.
22. The method of claim 15, further comprising folding the flat
web.
23. The method of claim 15, wherein the pant is made using a
machine direction assembly.
24. The method of claim 15, wherein the pant is made using a
cross-machine direction assembly.
25. The method of claim 15, further comprising cutting the flat web
into separate pieces
26. The method of claim 25, wherein the contracting occurs before
the cutting.
27. The method of claim 25, wherein the contracting occurs after
the cutting.
28. The method of claim 15, wherein the flat web comprises an
integral elastic zone.
29. A pant made from a single flat web, the pant comprising: a
garment shell, the garment shell including a front region, a back
region, a contracted crotch region, side seams connecting the front
region to the back region, and hanging legs, at least a portion of
each of the front region, the back region, the contracted crotch
region and the hanging legs comprising portions of the single flat
web.
30. The pant of claim 29, further comprising a waist elastic
extending along at least a portion of at least one of a front waist
edge of the front region and a back waist edge of the back
region.
31. The pant of claim 29, further comprising an absorbent structure
attached to the garment shell in at least one of the front region,
the back region and the crotch region.
32. The pant of claim 31 wherein the absorbent structure is
attached to the garment shell by one of ultrasonic bonding and
adhesive bonding.
33. The pant of claim 31, wherein the absorbent structure comprises
a stretchable material.
34. The pant of claim 29, wherein a ratio of a take up to twice an
inseam length is in a range from about 1:1 to about 1.5:1.
35. A method of making a pant having side seams and hanging legs,
comprising: providing a flat web; removing at least one portion of
the flat web to define two openings; applying at least one strip to
the flat web; contracting the strip to provide at least one
contracted area, a first region and a second region; attaching the
first region to the second region.
Description
BACKGROUND OF INVENTION
[0001] The present invention pertains to methods of making pants
having side seams and a contracted crotch region. More
particularly, the present invention pertains to methods of making
boxer shorts having side seams and a contracted crotch region. The
boxer shorts may be absorbent or non-absorbent.
[0002] Pant-like garments have numerous applications including
disposable clothing, training pants, feminine care products, adult
incontinence products, disposable swimwear, or the like. Pant-like
disposable garments are typically three-dimensional products with
closed sides so that the product has a unitary waist opening and
two leg openings. The wearer raises and lowers the garment to apply
the product. Three-dimensional, boxer shorts-like products are
particularly appealing because the boxer shorts look more like
conventional articles of clothes.
[0003] Many disposable pants are formed as composite structures in
which several components are combined to form a product
specifically suited to its intended purpose. For example,
disposable pants often include one or more absorbent materials
intended to absorb various bodily exudates such as urine, menstrual
fluid, and/or sweat. Such products may include a liquid permeable
bodyside liner and a liquid impermeable outer cover, and can
include other materials and features such as elastic materials and
containment structures.
[0004] However, many disposable pants are aesthetically
unappealing. Existing disposable absorbent pants can be overly
bulky and often resemble disposable baby diapers. Various attempts
have been made to provide disposable pants having an improved, more
clothing-like appearance. However, disposable pants, particularly
disposable absorbent boxer shorts, present many manufacturing
challenges. In part, this is due to the high speed that is
necessary to economically produce relatively low-cost disposable
absorbent products. Product design is often compromised by cost and
manufacturing constraints, resulting in disposable pants that lack
aesthetic appeal and product function. In addition, crotch depth is
required for a good fit, but difficult to achieve in a garment like
boxer-shorts with hanging legs when using conventional
manufacturing processes.
[0005] Thus, what is lacking and needed in the art are
garment-like, aesthetically appealing boxer shorts, as well as
methods of efficiently manufacturing such boxer shorts.
SUMMARY OF THE INVENTION
[0006] In response to the above-referenced unfulfilled need in the
art, new pants, and methods for manufacturing such pants, have been
invented. The material for the garment shell of the pant is handled
as a flat web throughout assembly until seaming in order to
streamline the assembly. The pants can include an absorbent
assembly and can be made in either the machine direction or the
cross-machine direction.
[0007] One aspect of the invention pertains to a method of making a
pant having side seams and hanging legs. One embodiment of the
method comprises: providing a flat web; removing at least one
portion of the flat web to define at least one leg opening;
contracting the flat web in selected areas, and attaching a first
region and a second region together to form the side seams.
[0008] Another aspect of the invention pertains to a method of
making an absorbent pant having side seams and hanging legs. One
embodiment of the method comprises: providing a flat web; removing
at least one portion of the flat web to define at least one leg
opening; contracting the flat web in selected areas, attaching an
absorbent structure to the flat web, and attaching a first region
and a second region together to form the side seams.
[0009] Another aspect of the present invention pertains to a pant
made from a single flat web. One embodiment of the pant comprises:
a garment shell, the garment shell including a front region, a back
region and a contracted crotch region, side seams connecting the
front region to the back region, and hanging legs. The pant may
also include an absorbent structure. At least a portion of each of
the front region, the back region, the contracted crotch region and
the hanging legs include portions of the single flat web.
[0010] The present invention relates to a wide variety of absorbent
and non-absorbent pants, including training pants, swim pants,
diaper pants, incontinence garments, feminine care products, health
care garments, apparel for institutional, industrial and consumer
use, or other garments. Disposable absorbent pants are adapted to
be worn adjacent the body of a wearer to absorb and contain various
exudates discharged from the body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front view of one embodiment of a pant according
to the present invention;
[0012] FIGS. 1A and 1B illustrate dimensions described with respect
to Tables 1 and 2.
[0013] FIG. 2A is a perspective cut-away view of one embodiment of
a pant according to the present invention;
[0014] FIG. 2B is a perspective cut-away view of one embodiment of
a pant according to the present invention;
[0015] FIG. 3A is a plan view of the garment shown in FIG. 2A,
showing the side facing the wearer;
[0016] FIG. 3B is a plan view of the garment shown in FIG. 2B,
showing the side facing the wearer;
[0017] FIG. 3C is a plan view of the garment shown in FIG. 2A,
showing the side facing the wearer without an absorbent
structure;
[0018] FIG. 4 is a top view of a flat web;
[0019] FIG. 5 is a top view of the flat web of FIG. 4 including leg
openings and strips applied to the flat web for assembling pants
according to one embodiment of the invention in the machine
direction;
[0020] FIGS. 5A and 5B illustrate dimensions described with respect
to Tables 1 and 2;
[0021] FIG. 6 is a top view of the flat web of FIG. 5 after
contraction of the flat web;
[0022] FIG. 7 is a side view of a looper drum for applying an
elastic strip to the flat web;
[0023] FIG. 8 is a side view of a process for applying a strip to
the flat web;
[0024] FIG. 9 is a side view of a corrugating drum for corrugating
the flat web of FIG. 5;
[0025] FIG. 10 is a top view of the flat web of FIG. 4 including
leg openings and strips applied to the flat web for assembling
pants according to one embodiment of the invention in the
cross-machine direction;
[0026] FIG. 11 is a top view of the flat web of FIG. 10 after
contraction of the flat web;
[0027] FIG. 12 is a side view of the flat web of FIG. 10 passing
through corrugating rollers for corrugating the flat web of FIG.
10.
DEFINITIONS
[0028] Within the context of this specification, each term or
phrase below will include the following meaning or meanings.
[0029] "Attached" refers to the joining, adhering, connecting,
bonding, or the like, of two elements. Two elements will be
considered to be attached together when they are attached directly
to one another or indirectly to one another, such as when each is
directly attached to intermediate elements.
[0030] "Bonded" refers to the joining, adhering, connecting,
attaching, or the like, of two elements. Two elements will be
considered to be bonded together when they are bonded directly to
one another or indirectly to one another, such as when each is
directly bonded to intermediate elements.
[0031] "Boxer shorts" refers to a garment having hanging legs.
[0032] "Comprising" is inclusive or open-ended and does not exclude
additional, unrecited elements or method steps.
[0033] "Connected" refers to the joining, adhering, bonding,
attaching, or the like, of two elements. Two elements will be
considered to be connected together when they are connected
directly to one another or indirectly to one another, such as when
each is directly connected to intermediate elements.
[0034] "Corrugated" refers to the condition of a material which has
been gathered into pleats or regular rugosites or folds, the
material being shortened thereby.
[0035] "Disposable" refers to articles which are designed to be
discarded after a limited use rather than being laundered or
otherwise restored for reuse.
[0036] "Elastic," "elasticized" and "elasticity" mean that property
of a material or composite by virtue of which it tends to recover
its original size and shape after removal of a force causing a
deformation.
[0037] "Elastomeric" refers to a material or composite which can be
elongated by at least 25 percent of its relaxed length and which
will recover, upon release of the applied force, at least 10
percent of its elongation. It is generally preferred that the
elastomeric material or composite be capable of being elongated by
at least 100 percent, more preferably by at least 300 percent, of
its relaxed length and recover, upon release of an applied force,
at least 50 percent of its elongation.
[0038] "Fabrics" is used to refer to all woven, knitted and
nonwoven fibrous webs.
[0039] "Flat web" comprises any material used for making garments
that can be provided and processed in a substantially open,
unfolded state; while the web can possess ripples or areas that do
not lie exactly within an overall plane of the web, all points of
the web should be reasonably identifiable as constituents in either
an upper or a lower surface of the web. No portions of a flat web
are enclosed or fixed into a loop or tunnel-like, or
three-dimensional configuration.
[0040] "Garment shell" refers to an outer cover or outer layer of a
garment. In a single-ply garment, the single layer of the garment
is the garment shell.
[0041] "Garment insert" refers to an inner layer of a garment. The
garment insert provides a close-to-the-body fit about a wearer's
lower torso, thereby serving as a form of built-in underwear within
the garment.
[0042] "Hanging legs" refers to the portions of a garment which
extend from the crotch region downward to the leg openings.
"Downward" refers to a direction toward the ground when the garment
is positioned on a standing wearer.
[0043] "Hydrophilic" describes fibers or the surfaces of fibers
which are wetted by the aqueous liquids in contact with the fibers.
The degree of wetting of the materials can, in turn, be described
in terms of the contact angles and the surface tensions of the
liquids and materials involved. Equipment and techniques suitable
for measuring the wettability of particular fiber materials or
blends of fiber materials can be provided by a Cahn SFA-222 Surface
Force Analyzer System, or a substantially equivalent system. When
measured with this system, fibers having contact angles less than
90 are designated "wettable" or hydrophilic, while fibers having
contact angles greater than 90 are designated "nonwettable" or
hydrophobic.
[0044] "Integral" is used to refer to various portions of a single
unitary element rather than separate structures bonded to or placed
with or placed near one another.
[0045] "Layer" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0046] "Liquid impermeable", when used in describing a layer or
multi-layer laminate, means that a liquid, such as urine, will not
pass through the layer or laminate, under ordinary use conditions,
in a direction generally perpendicular to the plane of the layer or
laminate at the point of liquid contact. Liquid, or urine, may
spread or be transported parallel to the plane of the liquid
impermeable layer or laminate, but this is not considered to be
within the meaning of "liquid impermeable" when used herein.
[0047] "Machine direction" refers to the length of a fabric in the
direction in which it is produced, as opposed to "cross-machine
direction" which refers to the width of a fabric in a direction
generally perpendicular to the machine direction.
[0048] The term "machine direction assembly" refers to a
manufacturing process in which disposable products travel in an
end-to-end or waist-to-waist orientation, in the longitudinal
direction shown by arrow 48 in FIG. 5. A process utilizing a
machine direction assembly entails products traveling through a
converting machine parallel to the direction of arrow 102, as
opposed to "cross-machine direction assembly" in which the products
travel in a side-by-side orientation such as that shown by arrow 49
in FIG. 10.
[0049] "Member" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0050] "Nonwoven" and "nonwoven web" and "web" refer to materials
and webs of material which are formed without the aid of a textile
weaving or knitting process.
[0051] "Operatively joined," with reference to the attachment of an
elastic member to another element, means that the elastic member
when attached to or connected to the element, or treated with heat
or chemicals, by stretching, or the like, gives the element elastic
properties; and with reference to the attachment of a non-elastic
member to another element, means that the member and element can be
attached in any suitable manner that permits or allows them to
perform the intended or described function of the joinder. The
joining, attaching, connecting or the like can be either directly,
such as joining either member directly to an element, or can be
indirectly by means of another member disposed between the first
member and the first element.
[0052] The term "spunbonded fibers" refers to small diameter fibers
which are formed by extruding molten thermoplastic material as
filaments from a plurality of fine capillaries of a spinnerette
having a circular or other configuration, with the diameter of the
extruded filaments then being rapidly reduced as by, for example,
in U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618
to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al.,
U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No.
3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Petersen, and U.S.
Pat. No. 3,542,615 to Dobo et al. Spunbond fibers are quenched and
generally not tacky on the surface when they enter the draw unit,
or when they are deposited onto a collecting surface. Spunbond
fibers are generally continuous and may have average diameters
larger than 7 microns, often between about 10 and 30 microns.
[0053] "Stretchable" means that a material can be stretched,
without breaking, by at least 50% (to 150% of its initial
(unstretched) length) in at least one direction, suitably by at
least 100% (to 200% of its initial length), desirably by at least
150% (to at least 250% of its initial length).
[0054] "Surface" includes any layer, film, woven, nonwoven,
laminate, composite, or the like, whether pervious or impervious to
air, gas, and/or liquids.
[0055] "Three-dimensional garment" refers to a garment that cannot
be laid flat with all of its seams in one plane.
[0056] These terms may be defined with additional language in the
remaining portions of the specification.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0057] As representatively illustrated in FIGS. 1, 2A and 2B, an
embodiment of a pant 10 of the present invention includes a garment
shell 64. The garment shell 64 can include a front region 22, a
back region 24, a contracted crotch region 26, an inner surface 28
which is configured to contact the wearer, and an outer surface 30
opposite the inner surface 28 which is configured to contact the
wearer's clothing. The pant 10 also defines a pair of
longitudinally opposed waist edges, which are designated front
waist edge 38 and back waist edge 39. The front region 22 is
contiguous with the front waist edge 38, and the back region 24 is
contiguous with the back waist edge 39. The front region 22
includes the portion of the pant 10 which, when worn, is positioned
on the front of the wearer while the back region 24 includes the
portion of the pant 10 which, when worn, is positioned on the back
of the wearer. The contracted crotch region 26 of the pant 10
includes the portion of the pant which, when worn, is positioned
between the legs of the wearer and covers the lower torso of the
wearer. As illustrated in FIGS. 1, 2A and 2B the front and back
regions 22 and 24 are joined together at side seams 54 to define a
three-dimensional pant configuration having a waist opening 50 and
a pair of leg openings 52. In particular embodiments, the pant 10
can include an absorbent structure 60. Various embodiments of these
and other features will now be described.
[0058] The garment shell 64 includes a contracted crotch region 26.
As described more fully below, the contraction of the contracted
crotch region 26 can be accomplished either elastically or
inelastically. The contracted crotch region 26 provides crotch
depth that provides a good fit through the contracted crotch region
26. The garment shell 64 can also include hanging legs 23 which
extend from the contracted crotch region 26 downward to the leg
openings 52 (FIGS. 1, 2A and 2B).
[0059] The pant 10 also includes side seams 54 which connect the
front region 22 to the back region 24 to create the pant 10. The
side seams 54 can take any number of forms, including both
refastenable and non-refastenable seams as is known in the art. The
provision of the side seams 54 can be accomplished in the manner
described in U.S. Pat. No. 5,046,272, issued Sep. 10, 1991 to Vogt
et al., which is incorporated herein by reference, or in the manner
described in PCT Publications WO 01/87562 by Tomsovic, et al., WO
01/87217 by Durrance, et al., WO 01/87753 by Hietpas, and or WO
01/87218 by Vogt, et al., all of which which are incorporated
herein by reference. As is known in the art, the side seams 54 can
be inward or outward fin seams or lap seams (not shown).
[0060] The pant 10 can also have a waist elastic member 58
extending along at least a portion of the front waist edge 38
and/or the back waist edge 39. The waist elastic member 58 can be
formed of any suitable elastic material. As is well known to those
skilled in the art, suitable elastic materials include sheets,
strands or ribbons of natural rubber, synthetic rubber, or
thermoplastic elastomeric polymers. The elastic materials can be
stretched and adhered to a substrate, adhered to a gathered
substrate, or adhered to a substrate and then elasticized or
shrunk, for example with the application of heat, such that elastic
constrictive forces are imparted to the substrate. In one
particular embodiment, for example, the waist elastic member 58
includes a plurality of dry-spun coalesced multifilament spandex
elastomeric threads sold under the trade name LYCRA.RTM. and
available from E.I. du Pont de Nemours and Company, Wilmington,
Del., U.S.A. Alternatively, multiple strands of 310 decitex
LYCRA.RTM. (may be also laminated at 250% elongation between
spunbond facings in addition to an adhesive.
[0061] As another alternative, the waist elastic member 58 can be a
material exhibiting delayed retraction, or can in fact be
non-elastic. Delayed retraction materials may include those
designed to retract relatively slowly following compression, such
as "temporarily inhibited" elastic materials. "Temporarily
inhibited" materials are described, for example, in U.S. Pat. No.
5,545,158 issued Aug. 13, 1996, to Jessup, U.S. Pat. No. 5,669,996
issued Sep. 23, 1997, to Jessup, and U.S. Pat. No. 5,500,063 issued
Mar. 19, 1996, to Jessup, all of which are herein incorporated by
reference, and references cited therein. Alternatively, a delayed
retraction material may be designed to resist retraction until an
activation process occurs, such as so-called "latent elastic"
materials. Suitable retractive materials for use as a delayed
retraction material can alternatively comprise any material adapted
to retract upon activation, whether immediately upon activation or
subsequently thereto. The retractive material can comprise
elastomeric or nonelastomeric materials. Suitable nonelastomeric
retractive materials can comprise without limitation polyether
block amides (PEBAX.RTM.) or the like, and laminates thereof.
Suitable elastromeric retractive materials can comprise without
limitation LYCRA.RTM. materials, elastomeric materials including
latex or rubber or synthetic urethanes, or the like, and laminates
thereof. In particular embodiments, the retractive material can
comprise an elastomeric material having an unstable state relative
to some other stable and elastic state. In such embodiments, the
retractive material can, but need not, have elastomeric properties
in the unstable state. Other examples include heat-shrinkable
elastic materials such as described in U.S. Pat. No. 4,816,094
issued Mar. 28, 1989 to Pomplun et al., U.S. Pat. No. 4,665,306
issued May 12, 1987 to Roland et al., and U.S. Pat. No. 4,663,106
issued May 5, 1987 to Pomplun et al., all of which are herein
incorporated by reference.
[0062] A pant of this type can be designed to fit wearers in a wide
range of sizes, by adjusting the pant dimensions based on the
anthropometric features of an intended wearer. Ratios of wearer
dimensions to pant dimensions for a suitable boxer-style pant have
been determined and are shown in Table 1. In addition, stylistic
variations such as hip-hugging (low rise), relatively more closely
or loosely fitted shorts, and other styles, may be provided by
varying the ratios listed in Table 1 within (or even beyond) the
ranges shown. Moreover, the use of elastomeric or extensible
material to form the garment shell may provide additional
adaptability to fit a wider range of wearer sizes.
[0063] Since the pant dimensions are determined by the dimensions
of the intended wearer, the ratios shown are based upon five
measurements of an intended wearer, abbreviated as follows:
[0064] A: waist circumference (FIG. 1A)
[0065] B: hip circumference (FIG. 1A)
[0066] C: thigh circumference (measured in crotch region,
horizontally; see FIG. 1A)
[0067] D: crotch depth (measured in crotch region, viewed 18 inches
from the wearer's side; see FIG. 1B)
[0068] E: center front waist to center back waist through crotch;
see FIG. 1B
[0069] Table 2 shows how garment shell dimensions shown in FIGS. 5A
and 5B are determined using body measurements A-E and ratios in
Table 1. Table 2 also shows how the ratios in Table 1 have been
applied to create shorts for two different size wearers, one a
mannequin of a child (Wearer #1) weighing approximately 32 to 40
pounds (15-18 Kg), the other an adult female (Wearer #2) weighing
approximately 125 pounds (57 Kg).
1TABLE 1 PANT DIMENSIONS DETAILS and RATIOS EXEMPLARY RANGES
Garment inseam I Selected based on garment 1-5 inches, or more
(FIG. 5A, dimension "I") style. There is not a seam at this
location; this is simply the location where an "inseam" measurement
is generally taken. After contraction, this dimension "I" provides
the "hanging legs" feature of the pant. Width of garment shell
Ratio of 2x Width (i.e., From about 1.2:1 to about (FIG. 5A,
dimension "w") garment circumference) to 2:1, such as about 1.7,
e.g. the larger of wearer's Hip or 2w = 1.2A or 1.2B Waist
circumference 2w:[B or A] Length of base of arc (FIG. Ratio of Arc
base length to From about 1:1 to about 5A, dimension "b") Wearer
crotch depth 1.5:1, such as about 1.25:1 b:D Circumference of leg
Ratio of Leg opening to From about 1.1:1 to about opening (FIG. 5A,
Wearer thigh circumference 1.5:1, such as about 1.25:1 dimension
"c") c:C Takeup (shortening) of Ratio of Takeup to 2x From about
1:1 to about garment shell on gathering Garment inseam length I
1.6:1, such as about 1.3:1 of crotch (FIG. 5B, s:2I dimension "s")
Length of garment shell Ratio of Length after This can vary widely
after gathering (FIG. 5B, gathering to Wearer F to B depending on
the desired dimension "l") waist thru crotch short style, but for a
1:E standard fit, from about 1.1:1 to about 1.4:1, such as about
1.25:1, e.g. 1 = 1.4E Length of garment shell Sum of Takeup and
Length before gathering (FIG. 5A, of shell after gathering
dimension "L") s + 1 Arc height (FIG. 5A, (Width of garment shell -
2x dimension"a") Garment inseam I)/2 (w - 2I)/2
[0070]
2 TABLE 2 Wearer #1 Short #1 Wearer #2 Short #2 A 50 cm 78 cm B 54
cm 96 cm C 29 cm 55 cm D 10 cm 16.5 cm E 41 cm 61 cm I 6 cm 8 cm w
45 cm 67 cm b 12.5 cm 20.5 cm c 36 cm 68 cm s 15.5 cm 21 cm l 50.5
cm 75 cm L 66 cm 96 cm a 15 cm 25 cm
[0071] The pant 10 can also include an absorbent structure 60. The
absorbent structure 60 can be attached to the garment shell 64 at
the front waist edge 38 and back waist edge 39, or at some point
below the front waist edge 38 and back waist edge 39 on the front
region 22 and back region 24. (FIGS. 2A and 2B). Alternatively, the
absorbent structure 60 can be attached to the garment shell 64 in
the contracted crotch region 26.
[0072] The absorbent structure 60 can be any structure which is
generally compressible, conformable, non-irritating to the skin,
and capable of absorbing and retaining liquids and certain body
wastes. The absorbent structure 60 can be manufactured in a wide
variety of sizes and shapes, from a wide variety of liquid
absorbent materials commonly used in the art, and may be
stretchable, non-stretchable, or elastic. For example, the
absorbent structure 60 can suitably include a matrix of hydrophilic
fibers, such as a web of cellulosic fluff, mixed with particles of
a high-absorbency material commonly known as superabsorbent
material. In a particular embodiment, the absorbent structure 60
includes a matrix of cellulosic fluff, such as wood pulp fluff, and
superabsorbent hydrogel-forming particles. The wood pulp fluff can
be exchanged with synthetic, polymeric, meltblown fibers or short
cut homofil bicomponent synthetic fibers and natural fibers. The
superabsorbent particles can be substantially homogeneously mixed
with the hydrophilic fibers or can be nonuniformly mixed. The fluff
and superabsorbent particles can also be selectively placed into
desired zones of the absorbent structure 60 to better contain and
absorb body exudates. The concentration of the superabsorbent
particles can also vary through the thickness of the absorbent
structure 60. Alternatively, the absorbent structure 60 can include
a laminate of fibrous webs and superabsorbent material or other
suitable means of maintaining a superabsorbent material in a
localized area.
[0073] Suitable superabsorbent materials can be selected from
natural, synthetic, and modified natural polymers and materials.
The superabsorbent materials can be inorganic materials, such as
silica gels, or organic compounds, such as crosslinked polymers,
for example, sodium neutralized polyacrylic acid. Suitable
superabsorbent materials are available from various commercial
vendors, such as Dow Chemical Company located in Midland, Mich.
U.S.A., and Stockhausen GmbH & Co. KG, D-47805 Krefeld, Federal
Republic of Germany. Typically, a superabsorbent material is
capable of absorbing at least about 15 times its weight in water,
and desirably is capable of absorbing more than about 25 times its
weight in water.
[0074] In one embodiment, the absorbent structure 60 includes a
blend of wood pulp fluff and superabsorbent material. One preferred
type of pulp is identified with the trade designation CR1654,
available from U.S. Alliance, Childersburg, Ala. U.S.A., and is a
bleached, highly absorbent sulfate wood pulp containing primarily
soft wood fibers and about 16 percent hardwood fibers. As a general
rule, the superabsorbent material is present in the absorbent
structure 60 in an amount of from 0 to about 90 weight percent
based on total weight of the absorbent assembly. The absorbent
structure 60 suitably has a density within the range of about 0.10
to about 0.35 grams per cubic centimeter. The absorbent structure
60 may or may not be wrapped or encompassed by a suitable tissue
wrap that may help maintain the integrity and/or shape of the
absorbent assembly.
[0075] The absorbent structure 60 can also incorporate other
materials that are designed primarily to receive, temporarily
store, and/or transport liquid along the mutually facing surface
with absorbent structure 60, thereby maximizing the absorbent
capacity of the absorbent assembly. One suitable material is
referred to as a surge layer (not shown) and includes a material
having a basis weight of about 50 to about 120 grams per square
meter, and including a through-air-bonded-carded web of a
homogenous blend of 60 percent 3 denier type T-256 bicomponent
fiber including a polyester core/polyethylene sheath and 40 percent
6 denier type T-295 polyester fiber, both commercially available
from Kosa Corporation of Salisbury, N.C. U.S.A.
[0076] In particular embodiments, the absorbent structure 60 is
thin to provide a slim, comfortable, non-bulky pant 10. Any
suitable thin absorbent structure may be used, such as for example,
the thin absorbent described in WO 02/49565, published Jun. 27,
2002, by Sawyer et al., which is incorporated herein by
reference.
[0077] The absorbent structure 60 can include a pair of containment
flaps 62 (FIG. 3A) which are configured to provide a barrier to the
transverse flow of body exudates. A flap elastic member (not shown)
can be operatively joined with each containment flap 62 in any
suitable manner as is well known in the art. The elasticized
containment flaps 62 define an unattached edge which assumes an
upright, generally perpendicular configuration to form a seal
against the wearer's body. Suitable constructions and arrangements
for the containment flaps 62 are generally well known to those
skilled in the art and are described in U.S. Pat. No. 4,704,116
issued Nov. 3, 1987 to Enloe, which is incorporated herein by
reference.
[0078] In the alternative, a pant-like garment insert could be used
for the absorbent structure 60. For example, the pant-like garment
insert suitably includes a body side liner, an outer cover, and an
absorbent assembly between the body side liner and the outer cover,
and side panels. Examples of suitable pant-like garment inserts
include a training pant, such as HUGGIES.RTM. PULL-UPS.RTM.
Disposable Training Pants, or a disposable underpant, such as
GOODNIGHTS.RTM. Disposable Underpants, both manufactured by
Kimberly-Clark Corporation, Neenah, Wis., U.S.A. A training pant as
the pant-like garment insert for the absorbent structure 60 can
include front side panels 34 and back side panels 134 (FIGS. 2B and
3B). The manufacture of training pants having side panels can be
accomplished in the manner described in U.S. patent application
Ser. No. 09/855,484, filed 15 May 2001 (U.S. Publication US
2002/0000291, Jan. 3, 2002) by Joseph D. Coenen et al., which is
incorporated herein by reference.
[0079] As another alternative, a pad-type absorbent could be used
for the absorbent structure. The pad-type absorbent can be attached
in the crotch-region 26 of the pant 10. An example of a suitable
pad-type absorbent is a feminine care pad such as KOTEX.RTM.
Feminine Napkins, KOTEX.RTM. LIGHTDAYS.RTM. disposable panty
liners, or an incontinence absorbent pad such as POISE.RTM.
Feminine Guards and Pads or DEPEND.RTM. Guards for MEN, all
manufactured by Kimberly-Clark Corporation, Neenah, Wis.,
U.S.A.
[0080] For reference, arrows 48 and 49 depicting the orientation of
the longitudinal axis and the transverse axis, respectively, of the
garment shell 64 are illustrated in FIGS. 3A and 3C.
[0081] The garment shell 64 is desirably constructed of materials
which are comfortable against the skin and non-irritating. It is
contemplated that the garment shell 64 can be either disposable or
durable, in the embodiments without an absorbent structure, and
disposable in the embodiments with an absorbent structure. Both
nonwoven and woven materials are contemplated for the garment shell
64. For example, the garment shell 64 for pant 10 can be selected
from a wide variety of materials, including elastic, stretchable,
or nonstretchable materials. The garment shell 64 can be a single
layer of material or a multi-layered laminate structure. One
example of a suitable material is a spunbond polypropylene nonwoven
web. The garment shell 64 may also be made of those materials of
which the absorbent structure 60 is made. It is desired that the
garment shell 64 provides a relatively cloth-like texture to the
wearer.
[0082] The present invention also includes various methods for
making pants having side seams from a flat web, as shall now be
explained and illustrated. Referring to FIG. 4, a single flat web
100 is provided moving in the direction represented by arrow 102.
In the alternative, two webs that are joined at their edges to form
a double-width piece (not shown) can be used for the flat web 100.
The flat web 100 can be composed of any material previously
described for the garment shell 64.
[0083] The method of the present invention can be carried out using
machine direction assembly so that arrow 102 can correspond to the
longitudinal direction as shown by arrow 48 (FIG. 5) with the
products connected end to end or waist to waist, or the method of
the present invention can be carried out using cross-machine
direction assembly so that arrow 102 can correspond to the
transverse direction as shown by arrow 49 (FIG. 10) with the
products connected side-to-side.
[0084] In the machine direction process (FIGS. 5-9), portions of
the flat web 100 are removed to define leg openings 104 (FIG. 5) by
die cutting, or by any other suitable method known in the art. The
leg openings 104, as more fully described below, become the leg
openings 52 of the pant 10.
[0085] Strips 106 are applied to the selected areas located between
the leg openings 104. Strips 106 can include elastic or non-elastic
material. Examples of suitable non-elastic material include heat
contractible materials, such as heat shrinkable films, for example,
films formed of polyether block amides (PEBAX.RTM., available from
the Atofina Company of France) or the like. If the strips 106 are
elastic, the elastic can be formed of any suitable material
previously described for the waist elastic member 58. As an
alternative, strips 106 can include any of the previously described
delayed retraction materials.
[0086] Referring to FIG. 7, if the strips 106 are elastic, the
strips 106 can be applied to the flat web 100 using a looper drum
108. Looper drums like looper drum 108 are known and are described,
for example, in U.S. Pat. No. 5,171,388 issued Dec. 15, 1992 to
Hoffman et al., herein incorporated by reference. Drum 108 includes
surface grooves 110. Drum 108, as illustrated in FIG. 7, includes
four surface grooves 110, but any number of surface grooves 110 may
be included. The surface grooves 110 are spaced around the drum 108
So that each garment shell 64 eventually includes one strip 106.
The flat web 100 travels around the drum 108 in the direction of
arrow 102. The flat web 100 runs down into the surface grooves 110
by virtue of the fact that the drum 108 includes apertures across
its surface and is under vacuum. Adhesive (shown for purposes of
illustration as dots between strip 106 and the flat web 100 over
the surface groove 110) is applied to the strip 106. In the
alternative, the adhesive can be applied to the flat web 100 in the
selected areas between leg openings 104. Suitable adhesives, which
can be applied continuously or intermittently as beads, a spray,
parallel swirls, or the like, can be obtained from Findley
Adhesives, Inc., of Wauwatosa, Wis. U.S.A., or from National Starch
and Chemical Company, Bridgewater, N.J. U.S.A
[0087] The flat web 100 passes by the elastic application module
112 and the strip 106 of elastic is applied in a substantially
unstretched condition to the flat web 100 over the surface groove
110. The flat web 100 with the strip 106 of elastic continues
moving in the direction of arrow 102 out of surface groove 110 and
off the drum 108. The flat web 100 with strip 106 of elastic passes
through nip 114 to press and secure the strip 106 of elastic to the
flat web 100. The nip 114 is defined by rolls 116 turning in the
direction of arrows 118. In the alternative, any other suitable
method for pressing and securing the strip 106 of elastic to the
flat web 100 can be used. As the flat web 100 exits the nip 114,
the flat web 100 can be drawn at a slower rate by the downstream
process than the surface speed of rolls 116, allowing the strip 106
of elastic to contract and reduce the length of web 100.
[0088] FIG. 6 shows the flat web 100 after the contraction of the
strips 106. The contraction of the flat web 100 defines contracted
areas 120 in the selected areas between leg openings 104. The
contracted area 120, as described more fully below, becomes the
contracted crotch region 26 of the pant 10.
[0089] In the alternative, the strip 106 can be applied to the flat
web 100 by any other method known in the art such as, for example,
a corrugating drum such as that described in U.S. Pat. No.
4,397,704 issued Aug. 9, 1983 to Frick, an elastic application
system in which the material is gathered into folds running in the
cross-machine direction and a continuous elastic is applied in the
machine direction and severed at the location of the folds in the
base material such as described in U.S. Pat. No. 4,417,938 issued
Nov. 29, 1983 to Sigl, an intermittent adhesive application that
allows the elastic to snap back from non-adhesive zones, a high
efficiency interface roll such as that described in U.S. Pat. No.
6,022,443 issued Feb. 8, 2000 to Rajala et al., U.S. Pat. No.
5,556,504 issued Sep. 17, 1996 to Rajala et al., and U.S. Pat. No.
6,319,347 issued Nov. 20, 2001 to Rajala et al., all of which are
here incorporated by reference, or by any other any means known in
the art.
[0090] FIGS. 6 and 11 also show waist elastics 58 applied to the
flat web 100. The waist elastics 58 can be applied by any method
known in the art at any stage in the manufacturing of the pant
10.
[0091] In the alternative, the tension on the flat web 100 can be
reduced by cutting the flat web 100 into separate pieces
approximately midway between successive strips 106 to define a
garment shell 64 (FIG. 3C). It is also contemplated, however, that
the step of cutting the flat web 100 can be carried out after
contraction of the flat web 100.
[0092] Referring to FIG. 8, in the alternative, the strips 106,
whether elastic or nonelastic, can be applied to the selected areas
of the flat web 100 between the leg openings 104 by a cut and place
module as is commonly known in the art.
[0093] Next, the flat web 100 can be contracted elastically or
inelastically by any suitable means. For example, if the strip 106
is an elastic capable of delayed retraction, the flat web 100 can
be contracted by activating the strip 106 to restore the elasticity
by time, temperature, radiation or other appropriate energy. In the
alternative, if the strip 106 is a heat shrinkable material, the
flat web 100 can be contracted inelastically by activating the heat
shrinkable material by applying heat or other appropriate
energy.
[0094] In particular embodiments, the strips 106 are applied to the
flat web 100 after contraction or pregathering of the flat web 100.
In the machine direction, the flat web 100 can be pregathered by
corrugating in the selected areas between the leg openings 104 by
using a corrugating drum 150 (FIG. 9) in preparation for attachment
of strip 106. Corrugating drums like corrugating drum 150 are known
and are described, for example, in previously mentioned U.S. Pat.
No. 4,397,704 issued Aug. 9, 1983 to Frick. Alternatively, a drum
with discontinuous grooves that correlate with the location of
strips 106 can be used. The flat web 100 travels around the drum
150 in the direction of arrow 158. Pressing roll 154 has teeth 156.
The flat web 100 is pushed down into the grooves 152 by the teeth
156, thereby corrugating the flat web 100. Drum 150 and pressing
roller 154 move in the direction of arrows 158 and 160,
respectively.
[0095] Next, the strips 106 can be applied to the corrugated flat
web 100 by a conventional cut and place applicator. Strips 106 can
be attached to the web 100 using adhesive, thermal or ultrasonic
bonding, or other means known in the art. Use of a corrugating drum
or other device to pregather the flat web 100 permits the use of an
unstretched elastic or of a non-elastic, non-retractive material
such as a film or nonwoven material with properties similar to flat
web 100. Alternatively, the strip 106 may include any of the
previously described materials. The strips 106 maintain the
corrugation in the contracted area 120 (FIG. 6).
[0096] In the cross-machine direction process (FIGS. 10-12),
portions of the flat web 100 are removed to define leg openings 104
by die cutting, or by any other suitable method known in the art.
The leg openings 104, as more fully described below, become the leg
openings 52 of the pant 10.
[0097] As with the machine direction assembly process, strips 106
are applied to the selected areas located between the leg openings
104. In the cross-machine direction assembly process, strips are
applied on the flat web 100 in an orientation perpendicular to
arrow 102, as shown in FIG. 10.
[0098] The application of strip 106 of elastic material can be
accomplished by a variety of methods, such as by moving the distal
edges of the flat web 100 closer together and allowing the center
portion of the web to become looped using the same principles of
the previously described looper drum, but with the strip 106 being
applied in an orientation perpendicular to arrow 102, or by other
methods as are known in the art. As with the previously described
looper drum, the flat web 100 can be fully extended again after
application of the strip 106 in order to fully adhere the strip 106
to the web 100. In alternative embodiments, the strips 106 can be
applied to the flat web 100 by a process in which an elastic or
inelastic piece of material is cut, rotated and placed onto the
flat web 100, for example, as described in U.S. Pat. No. 5,716,478
issued Feb. 10, 1998 to Boothe et al., U.S. Pat. No. 5,759,340
issued Jun. 2, 1998 to Boothe et al. and U.S. Pat. No. 4,608,115
issued Aug. 26, 1986 to Schroth et al., all of which are herein
incorporated by reference, or by any other means known in the art.
Where the strip 106 is a heat contractible material or a material
capable of delayed retraction, the strip can be applied to web 100
as the web travels in the direction of arrow 102 (FIG. 10) in a
flat and unlooped state.
[0099] Next the flat web 100 can be contracted elastically or
inelastically by any of the previously described methods. FIG. 11
shows the flat web 100 after the contraction of the strips 100. The
contraction of the flat web 100 defines contracted area 120 in the
selected areas between the leg openings 104. The contracted area
120, as described more fully below, becomes the contracted crotch
region 26 of the pant 10.
[0100] In particular embodiments, the strips 106 are applied to the
flat web 100 after contraction or pregathering of the flat web 100.
In the cross-machine direction, the flat web 100 can be pregathered
by corrugating in the selected areas between the leg openings 104
by using intermeshing grooved rollers 170 and 172 (FIG. 12) in
preparation for attachment of strip 106. Intermeshing grooved
rollers like 170 and 172 are known in the art and are described,
for example, in U.S. Pat. No. 5,755,902 issued May 26, 1998 to
Reynolds, herein incorporated by reference. Roller 170 includes
grooves 174 only in the middle portion of the roll to correspond to
the desired location of the contracted area 120 on the flat web.
The flat web 100 travels through nip 176 formed by rolls 170 and
172 in the direction of arrow 102. Roller 172 has complementary
grooves (not shown) designed to intermesh with grooves 174 of
roller 170. The flat web 100 is pushed into the grooves 174 by the
complementary grooves on roll 172 to provide the corrugation in the
contracted area 120. Rolls 170 and 172 move in the direction of
arrows 178 and 180, respectively. The corrugations are held in
place by attaching strips 106 on top of the corrugations.
[0101] The strip 106 can be applied to the corrugated flat web 100
by a cut and place module as is commonly known in the art and can
be attached to the web using thermal, ultrasonic or adhesive
bonding, or any other means known in the art. The strip 106 may
include an inextensible material such as a film or nonwoven
material with properties similar to web 100, or may include any of
the previously described materials.
[0102] In either the machine direction process or the cross-machine
direction process, the flat web 100 can now be cut into individual
pieces, each of which will form a garment shell 64. The cutting can
be accomplished by, for example, pinch cutting, shear cutting or
any other means known in the art. As another alternative, the flat
web 100 can be provided as separate pre-cut pieces each of which
pre-cut separate pieces will eventually become a single garment
shell 64, so that this cutting step could be skipped and the
process could start with a pre-cut piece as the flat web 100. FIG.
3C shows the garment shell 64 prior to folding and formation of the
side seams 54. As shown and as previously mentioned with respect to
FIGS. 1, 2A, and 2B the garment shell 64 can include a front region
22, a back region 24, a contracted crotch region 26, an inner
surface 28, and an outer surface 30 (not shown), front waist edge
38, back waist edge 39, and waist elastic member 58. The garment
shell 64 can also include strip 106. It is also contemplated that
the garment shell 64 can be made upside-down, i.e., with the inner
surface 28 facing downwardly (not shown). The garment shell 64 can
then be folded and the side seams 54 formed by any conventional
method known in the art to form the pant 10 (without an absorbent
structure). It is contemplated that the step of contracting the
flat web 100 can occur either before or after the step of cutting
into individual garment shells 64, and also before or after the
formation of the side seams 54.
[0103] In either the machine direction process or the cross-machine
direction process, in alternative embodiments, the strip 106 need
not be a single strip of material. In particular embodiments,
elastic strands or ribbons as are known in the art can be used
instead of a single strip of material for strip 106. The elastic
strands or ribbons can be straight or curved. In addition, in the
embodiments in which the flat web is corrugated, it is contemplated
that instead of attaching a strip 106, the corrugation in the
contracted area 120 can be maintained by fusing or bonding the
corrugations together in the selected areas between the leg
openings 104. The corrugations can be bonded to themselves to hold
them in place by adhesive, thermal or pressure bonding, or by any
other means known in the art.
[0104] In the machine direction process, the strip 106 need not be
a separate piece of material applied to the flat web 100. Instead,
the flat web 100 may include an integral elastic zone aligned along
the machine direction center line, instead of strip 106, with the
elastic zone active in only the crotch region. Elastization of only
the crotch region of the pant may be achieved by, for example, an
elastic laminate structure in which the elastic is attached to the
laminate using an intermittent adhesive. Intermittent adhesive
application would allow the elastic to snap back from non-adhesive
zones, which would be uncontracted as a result; contracted,
adhesive-bearing zones can be located only in the crotch region of
the garment. As an alternative, the elastic nature of certain
regions may be inactivated by chopping or overbonding the elastic
or other methods known in the art, for example, as described in
U.S. Pat. No. 6,248,097 issued Jun. 19, 2001 to Beitz, herein
incorporated by reference.
[0105] Referring to FIGS. 2A, 2B, 3A and 3B in particular
embodiments, an absorbent structure 60 is included in the pant 10.
The absorbent structure 60 can be introduced into the pant 10 in
any suitable manner known in the art. In particular embodiments,
the absorbent structure 60 can be placed on top of the contracted
crotch region 26 on the inner surface 28 of the garment shell 64,
either prior to formation of side seams 54 or after side seams 54
are made. It is also contemplated, however, that the absorbent
structure 60 can be attached prior to contracting and/or cutting
the flat web 100. Where the absorbent structure 60 is added to the
pant 10 prior to formation of side seams 54, cut and place methods
such as are known in the art may be used. Alternatively, for a
closed pant (i.e., side seams already formed), the absorbent
structure 60 may be inserted into the pant such as by the method
described in the PCT Publication WO 02/52967 by Rabe, et al., or by
other means as may be known in the art. The absorbent structure 60
can be attached to the garment shell 64 at the front waist edge 38
and back waist edge 39, or at some point below the front waist edge
38 and back waist edge 39 on the front region 22 and back region
24. Additionally or alternatively, the absorbent structure 60 can
be attached in the contracted crotch region 26. The attachment can
be accomplished by ultrasonic or adhesive bonding, or any other
suitable method known in the art. As shown in FIGS. 2A and 2B,
attachment to the front and back regions 22 and 24 provides for a
loose fit in the contracted crotch region 26.
[0106] In particular embodiments, the absorbent structure 60 is
stretchable or elasticizable in order to provide the desired close
to the body fit for the absorbent structure 60 while the garment
shell 64 hangs loosely. Alternatively, a suspension system for the
absorbent structure may be required to provide a loose fit for the
garment shell 64, such as described in U.S. Pat. No. 6,168,585
issued Jan. 2, 2001 to Cesco-Cancian, herein incorporated by
reference.
[0107] The garment shell 64 with the absorbent structure 60 can
then be folded and the side seams 54 formed by any conventional
method known in the art to form the pant 10, as shown in FIGS. 2A
and 2B. After folding the garment shell 64 and forming the side
seams 54 (with or without an absorbent structure 60), if a
temporarily inhibited elastic or latent elastic is used as the
waist elastic 58, it may need to be activated to restore the
elasticity.
[0108] The various components of the pant can be connected together
by any means known to those skilled in the art such as, for
example, adhesive, thermal and/or ultrasonic bonds, pressure bonds
and also sewing and other methods used in durable garment
manufacturing. Desirably, most of the components are connected
using ultrasonic bonding for improved manufacturing efficiency and
reduced raw material costs. For example, in particular embodiments,
the side seams 54 are made using ultrasonic bonding. Certain
garment manufacturing equipment which is readily known and
understood in the art, including frames and mounting structures,
ultrasonic and adhesive bonding devices, transport conveyors,
transfer rolls, guide rolls, tension rolls, and the like, have not
been shown in the Figures.
[0109] It will be appreciated that details of the foregoing
embodiments, given for purposes of illustration, are not to be
construed as limiting the scope of this invention. Although only a
few exemplary embodiments of this invention have been described in
detail above, those skilled in the art will readily appreciate that
many modifications are possible in the exemplary embodiments
without materially departing from the novel teachings and
advantages of this invention. For example, features described in
relation to one embodiment may be incorporated into any other
embodiment of the invention. Accordingly, all such modifications
are intended to be included within the scope of this invention,
which is defined in the following claims and all equivalents
thereto. Further, it is recognized that many embodiments may be
conceived that do not achieve all of the advantages of some
embodiments, particularly of the preferred embodiments, yet the
absence of a particular advantage shall not be construed to
necessarily mean that such an embodiment is outside the scope of
the present invention.
* * * * *