Footwear products and system and method for its training

Description

1 / 15 PANTS PRODUCTS AND SYSTEM AND METHOD FOR THEIR FORMATION CROSS-REFERENCE ON RELATED REQUEST

[0001] Not applicable. DISSEMINATION AREA

[0002] This disclosure relates generally to a disposable pants product with elastic threads anchored by means of adhesive-free welding at its side seams and a system and method for forming or manufacturing it. Fundamentals of Disclosure

[0003] Typically, disposable underwear, such as pull-up diapers (“pants products” in general), are made of two layers of weft fabric with embedded elastic threads that form a front and back waistband and an absorbent core that is inserted over or inside the waistbands to be positioned close to the user's body. Such pants products are usually manufactured on a multi-station processing line that performs various functions. For example, the cores may be layered and sectioned, the waistbands may be formed from continuous wefts of material over which the cores are positioned, the waistbands are joined to create side seams, and the continuous weft of material is cut into individual products.

[0004] Elastic yarns are positioned in waistbands and can be fixed to them with adhesive or anchoring bonds formed by mechanical means (e.g., thermal, pressure, or ultrasonic). During the typical manufacturing process of an elastic waistband, the elastic yarns are positioned in a tensioned state between a first weft layer and a second weft layer. The first and second weft layers are normally layers of nonwoven materials or warps. The elastic yarns are positioned in groups forming the waistband elastic. Several anchoring means for fixing the elastic yarns within the waistband and leg cuff regions are known. In some embodiments, anchoring bonds are formed when bonds are formed in the weft layers on opposite sides of the elastic yarns, and when the tensioned elastic yarns are relaxed, Petition 870260035218, dated 04 / 15 / 2026, page 5 / 7 1 / 15 PANTS PRODUCTS AND SYSTEM AND METHOD FOR THEIR FORMATION CROSS-REFERENCE ON RELATED REQUEST

[0001] Not applicable. DISSEMINATION AREA

[0002] This disclosure relates generally to a disposable pants product with elastic threads anchored by means of adhesive-free welding at its side seams and a system and method for forming or manufacturing it. Fundamentals of Disclosure

[0003] Typically, disposable underwear, such as pull-up diapers (“pants products” in general), are made of two layers of weft fabric with embedded elastic threads that form a front and back waistband and an absorbent core that is inserted over or inside the waistbands to be positioned close to the user's body. Such pants products are usually manufactured on a multi-station processing line that performs various functions. For example, the cores may be layered and sectioned, the waistbands may be formed from continuous wefts of material over which the cores are positioned, the waistbands are joined to create side seams, and the continuous weft of material is cut into individual products.

[0004] Elastic yarns are positioned in waistbands and can be fixed to them with adhesive or anchoring bonds formed by mechanical means (e.g., thermal, pressure, or ultrasonic). During the typical manufacturing process of an elastic waistband, the elastic yarns are positioned in a tensioned state between a first weft layer and a second weft layer. The first and second weft layers are normally layers of nonwoven materials or warps. The elastic yarns are positioned in groups forming the waistband elastic. Several anchoring means for fixing the elastic yarns within the waistband and leg cuff regions are known. In some embodiments, anchoring bonds are formed when bonds are formed in the weft layers on opposite sides of the elastic yarns, and when the tensioned elastic yarns are relaxed, Petition 870250084411, dated 09 / 19 / 2025, page 9 / 179 2 / 15 The bonds engage the relaxed elastic yarns by friction to “pinch” the elastic yarns together. In other embodiments, anchor bonds are formed when sections of the weft layers surrounding the elastic yarns are melted and encapsulate at least partially the elastic yarns. Anchor bonds can be formed as pairs of bonds positioned on opposite sides of a given elastic yarn or as a single bond spanning at least the width of the elastic yarn.

[0005] Anchoring links are visually present in the trouser product and it is desirable that these links be arranged in a visually pleasing manner. In the waistband area, since each elastic thread must be attached to the waistband weave layers in several places by the anchoring links, the manufacturer is limited in the designs that can be formed with the linking pattern. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a representative isometric view of a finished disposable pants product according to an exemplary embodiment.

[0007] FIG. 2 is a schematic representation of a system for manufacturing the trousers product of FIG. 1.

[0008] FIG. 3 is a simplified representation shown in a plan view of trouser products during the manufacturing steps.

[0009] FIG. 4 is a plan view of a representative trouser product.

[0010] FIGS. 4A, 4B, 4C and 4C' are cross-sectional views of parts of the trouser product modalities of FIG. 4, with the spacing between the weave layers exaggerated for clarity purposes.

[0011] FIG. 5 is a perspective view of an anvil used in the system according to a first embodiment.

[0012] FIGS. 6 to 10 are partial top plan views of anvil modalities.

[0013] Similar reference symbols in different drawings indicate similar elements. DETAILED DESCRIPTION Petition 870250084411, dated 09 / 19 / 2025, page 10 / 179 3 / 15

[0014] The following describes one or more exemplary embodiments of the disposable pants products disclosed and systems and methods for their manufacture, as shown in the attached figures of the drawings briefly described above. Various modifications to the exemplary embodiments may be contemplated by one skilled in the art.

[0015] In the modalities discussed here, representations of directions or orientations (e.g., up, down, front, front, side, top, bottom, back, inside, and outside) can be used to explain the structure and configurations of the various elements, but these representations should be considered relative to each other in the specific examples and should not be considered as absolute limitations. Furthermore, the discussion below may refer to a material- or product-based coordinate system with respect to continuous weaves in the primary direction of movement, for example, with a longitudinal orientation being parallel to the direction of movement at a respective location, a lateral orientation being “side-by-side,” perpendicular to the longitudinal orientation within the product plane, and a transverse orientation being perpendicular to both the longitudinal and lateral orientations.In other cases, the discussion below may refer to an absolute coordinate system relative to the specific orientation of the machine (e.g., x, y, z).

[0016] FIG. Figure 1 depicts a disposable pant product 10. Typically, the disposable pant product 10 is formed from a first waistband 12, a second waistband 14, and a core 16 which also collectively define a first face (or inner face, or first surface, or inner surface) 18 and a second face (or outer face, or second surface, or outer surface) 20. Typically, the inner face 18 is oriented towards the user when wearing the pant product 10 and the outer face 20 is oriented away from the user when wearing the pant product 10. The first and second waistbands 12, 14 have upper edges 22, 24 which define an opening at the waist and leg contours 26, 28 (which are shown only on one side of the pant product 10 in FIG. 1) which form the leg openings near the core 16. The first and second waistbands 12, 14 have Petition 870250084411, dated 09 / 19 / 2025, page 11 / 179 4 / 15 opposite side edges 30, 32 extending between the top edges 22, 24 and the leg contours 26, 28. The side edges 30 of the first and second waistbands 12, 14 are joined as described here to form a first side seam 34, and the side edges 32 are joined as described here to form a second side seam 36. A waistband area 38 above each of the leg contours 26, 28 is joined as described here.

[0017] The first and second waistbands 12, 14 may be formed from any suitable type of material, such as a woven or non-woven material. The core 16 may be formed from one or more absorbent materials, such as paper, polymer or woven materials, and may include additional layers, such as a top layer (e.g., for skin contact), an acquisition layer (e.g., to facilitate absorption), a bottom layer, a non-bulking structure and / or embossed pattern. In other examples, the core has only a single layer, or it may have more than two primary layers.

[0018] With reference to FIG. 2, a portion of an exemplary manufacturing line 100 is illustrated. As shown, a first layer of continuous weft 102, a plurality of continuous elastic yarns 104, and a second layer of continuous weft 106 are fed by a roller apparatus 108, which may include one or more rollers, to a linking apparatus 110. The elastic yarns 104 move under tension from a basket apparatus (not shown) or similar device. The elastic yarns 104 may have any suitable cross-sectional shape that facilitates the formation of an elastic composite structure with desired elasticity, visual aesthetics, and manufacturability. As non-limiting examples, the elastic yarns 104 may have a round, rectangular, square, or irregular cross-sectional shape, as may be the case when each elastic yarn 104 is a multifilament product.Elastic threads 104 may be composed of any suitable elastic material, including, for example, sheets, threads or ribbons of thermoplastic elastomers, natural or synthetic rubber, or elastic yarns, as non-limiting examples. Each elastic thread 104 may be supplied in the form of an individual elastomeric thread or be a manufactured multifilament product that includes many filaments. Petition 870250084411, dated 09 / 19 / 2025, page 12 / 179 5 / 15 individual elastomers joined together, as by a dry spinning manufacturing process, to form a single coalesced elastic yarn 104.

[0019] The roller apparatus 108 includes guide rollers that are employed to precisely position and (optionally) tension the elastic yarns 104 and the first and second weft layers 102, 106 as they move towards the binding apparatus 110. The roller apparatus 108 includes an upper roller 112, a lower roller 116 and a yarn guide roller 114 that guide a first assembly 118, which includes the first weft layer 102, the second weft layer 106 and the elastic yarns 104, into the binding apparatus 110. It is considered that the rollers 112, 114, 116 can be replaced by other known types of feeding apparatus and / or replaced by a single roller unit or other known type of feeding apparatus in an alternative embodiment.

[0020] After the second weft layer 106 is brought close to the first weft layer 102 and the elastic yarns 104, the first assembly 118 is joined by the joining apparatus 110. The joining apparatus 110 can be any known mechanical joining system, including, as non-limiting examples, a thermal welding system, a pressure welding system, a rotary ultrasonic welding system, or a blade ultrasonic welding system. In the illustrated embodiment, the joining apparatus 110 includes a rotary anvil 120 and a fixed-blade ultrasonic horn 122, also known as a sonotrode, which cooperate to join (i.e., fuse) the first weft layer 102 to the second weft layer 106. Alternative embodiments may include multiple fixed-blade horns or one or more rotary horns.

[0021] Although the first weft layer 102 and the second weft layer 106 are represented and described here as physically separate components, it is anticipated that alternative embodiments may utilize a unitary weft structure that is folded to capture the elastic yarns 104 between the upper and lower layers of the unitary weft structure. In such an embodiment, the portion of the unitary structure positioned below the elastic yarns 104 would be termed the first weft layer 102 and the portion of the unitary structure positioned above the elastic yarns 104 Petition 870250084411, dated 09 / 19 / 2025, page 13 / 179 6 / 15 would be termed second weft layer 106. For example, a folding device (not shown) may be included to fold a portion of the unitary weft structure over another portion of the unitary weft structure to overlap the elastic yarns 104. A product with a folded waistband may alternatively be formed with a folding device (not shown) that folds a portion of the waistband of one of the first weft layers 102 over and around the portion of the waistband of the second weft layer 106 to create a folded waistband as shown in FIG. 4C. FIG. 4C' depicts an alternative embodiment that does not include a folded waistband.

[0022] The pants product 10 may include a multi-piece chassis, wherein the front and / or back waistband includes two or more joined weft pieces. In such embodiments, additional weft layers (not shown) may be joined to the first and second weft layers 102, 106 at a location upstream of the binding apparatus 110 and subsequently fed together with the first and second weft layers 102, 106 into the binding apparatus 110, with the elastic yarns 104 positioned between the first and second weft layers 102, 106 and one or more additional weft layers.

[0023] The anvil 120 and the horn 122 are illustrated according to an embodiment of the disclosure. As shown, the anvil 120 includes an arrangement of discrete projections 124 extending outward from the anvil face 126. The projections 124 may have flat working surfaces, flat side surfaces, or some mixture of curved and straight working and side surfaces in alternative embodiments. The working surfaces of each projection 124 may have a smooth or substantially smooth surface contour or an arrangement of grooves. The working surface 128 of the horn 122 has a smooth or substantially smooth surface contour or an arrangement of grooves formed in the working surface 128. In either case, the working surface 128 cooperates with the projections 124 on the anvil face 126 to form discrete connections or welds 130.

[0024] These projections 124 are constructed to form links 130 that merge the first and second layers of weave 102, 106, as graphically represented. Petition 870250084411, dated 09 / 19 / 2025, page 14 / 179 7 / 15 in FIG. 4B. The projections 124 may include any number of projections 124 and may be arranged in any number of alternative configurations to obtain a desired pattern of waistband links 130 in the final pants product 10, which may be anchor links or lamination links. In one embodiment, anchor links are formed when the elastic yarns 104 are engaged by friction by adjacent links when the elastic yarns 104 are relaxed. In one embodiment, the anchoring links are formed when the projections 124 engage the weft layers 102, 106 on opposite sides of the elastic yarns 104, which causes the sections of the weft layers 102, 106 close to the elastic yarns 104 to melt and at least partially wrap around the elastic yarns 104 and / or engage the elastic yarns 104 by friction in a position relative to the weft layers 102, 106.Lamination bonds are formed when only the weft layers 102, 106 are joined and the elastic yarns 104 are not engaged by the bonds. In one embodiment, the projections 124 can be arranged so that the elastic yarns 104 are between a first row of projections 124 on one side of the elastic yarns 104 that form lamination bonds and a second row of projections 124 on the opposite side of the elastic yarns 104 that form lamination bonds so that the elastic yarns 104 are between the rows of projections 124. The projections 124 that form anchor bonds can be provided in addition to the projections 124 that form lamination bonds. In another embodiment, the projections 124 can be arranged so that each elastic yarn 104 passes between two adjacent projections 124 on the face 126 of the anvil 120 and the resulting bonds form anchor bonds or form lamination bonds.The respective working surfaces of the projections 124 can be configured to form connections of similar size and shape, or connections of different size and / or shape in alternative embodiments. As non-limiting examples, the respective support surfaces of the projections 124 can be circular, rectangular, crescent-shaped, or have irregular shapes that can be selected to form a desired overall pattern in the final trouser product 10. In one embodiment, the connecting device 110 can be replaced by one. Petition 870250084411, dated 09 / 19 / 2025, page 15 / 179 8 / 15 adhesive system (not shown) that applies an adhesive to the elastic yarns and / or to one or more weft layers 102, 106.

[0025] During the manufacturing process, the first and second weft layers 102, 106 are positioned between the face 126 of the anvil 120 and the working surface 128 of the horn 122. The elastic yarns 104 are positioned between the first and second weft layers 102, 106 in a tensioned state. The position of the horn 122 is controlled to maintain a clamping gap between the working surface 128 of the horn 122 and the support surfaces of the projections 124. The connecting apparatus 110 may include any known positioning means that exerts force on at least one of the horn 122 and the anvil 120 to maintain the desired clamping gap. The connecting apparatus 110 forms connections 130 within it (see FIG. 4) and forms a second assembly 132.

[0026] In one embodiment, the second assembly 132 moves downstream to a cutting device 134 which separates the second assembly 132 into the first waistband 12 and the second waistband 14, which lie side by side. Alternatively, the cutting device 134 is removed and the roller device 108 and the connecting device 110 form the first waistband 12, and a second roller device 108' and a second connecting device 110' form the second waistband 14, which are combined into a roller 136 so that the first and second waistbands 12, 14 lie side by side. This forms a third assembly 138.

[0027] Subsequently, the third set 138 passes through the known apparatus to form a fourth set 140. The apparatus includes, but is not limited to, an insert placement apparatus 142, which places an absorbent insert 144 in the first weft layers 102 that form the core 16, and a folding apparatus 146 which folds the absorbent insert 144 and overlaps the first and second waistbands 12, 14 so that the first weft layers 102 face each other (see FIG. 3.). An optional die-cutting apparatus (not shown) that forms leg contours may also be provided in the apparatus.

[0028] After that, the fourth set 140 passes through an ultrasonic side seam connecting device 148. The ultrasonic side seam connecting device Petition 870250084411, dated 09 / 19 / 2025, p. 16 / 179 9 / 15 148 includes a first anvil 150 and its ultrasonic horn 152, and optionally one or more additional anvils and corresponding ultrasonic horns. Each anvil 150 is supplied with one or more anvil inserts 158 having a predetermined profile. In embodiments that include multiple anvil / horn stations, the anvils 150 are spaced laterally in line and in the direction of the machine. The ultrasonic horn(s) 152 apply(s) vibration energy to the fourth assembly 140 simultaneously and in cooperation with a respective anvil 150 to form anchoring connections or welds 162, 164 on the respective side edge parts 166, 168 of the fourth assembly 140 which will subsequently form the side seams 34, 36 of an individual final trouser product 10 and thus form a fifth assembly 170.In one embodiment, the 130 links are also within the 166, 168 side edge portions, so that the 162, 164 anchor links are, in addition to the 130 links, within the 166, 168 side edge portions. In another embodiment, the 120 anvil does not form the 130 links in the areas that eventually form the 166, 168 side edge portions, so that only the 162, 164 anchor links are within the 166, 168 side edge portions. In one embodiment, the 130 links are more widely spaced from each other than the 162, 164 links. In other embodiments, the 130 links are less widely spaced than the 162, 164 links, or the spacing between the 130 links and the 162, 164 links is equidistant. In some embodiments, an optional adhesive system (not shown) may be positioned upstream of the ultrasonic side seam bonding apparatus 148 to apply adhesive to at least part of the side edge parts 166, 168.

[0029] The fifth set 170 then passes through a cutting device 172 that forms cutting lines 174 between the side edge parts 166, 168 to separate the fifth set 170 into individual trouser products 10. The cutting device 172 may be a cutting unit or knife that separates the continuous weft into discrete trouser products 10 at a location between the side edge parts 166, 168. Although the side edge parts 166, 168 are represented as two distinct bonding regions positioned on opposite sides of cutting lines 174 in FIG. 3, the side edge parts 166, 168 may be a continuous bonding region spanning a line of. Petition 870250084411, dated 09 / 19 / 2025, page 17 / 179 10 / 15 cut 174 respectively in embodiments where the projections 176 form a continuous pattern through the anvil insert 158, as described in more detail below and illustrated in FIGS. 5-7 and FIG. 10.

[0030] Thus, manufacturing line 100 operates to form final pants 10 products from the various continuous (and / or discrete) layers of materials.

[0031] The insert 158 ​​of each anvil 150 includes an arrangement of discrete projections 176 extending outward from the anvil face 178. The upper face of the projections 176 may have flat or substantially flat working surfaces 177, as shown in embodiments of FIGS. 5-9, or may include a plurality of grooves 188 extending downward into the body of the projection 176, as shown in FIG. 10. The working surface(s) 180 of the horn(s) 152 are flat or have a substantially smooth surface contour in a non-limiting embodiment. Alternatively, the work surface(s) 180 may include an arrangement of projections that interact with the projection pattern 176 on the anvils 150.

[0032] The projections 176 are constructed to form anchoring links 162 that fuse the first weft layer 102, the second weft layer 106 and the elastic threads 104 on each side edge part 166, 168, as shown in FIGS. 4A.Projections 176 may include any number of projections 176 arranged in any number of alternative configurations to achieve a desired pattern of side seam bindings on the final trouser product 10. Projections 176 may have a flat work surface, flat side surfaces, or some mixture of curved and straight work and side surfaces in alternative embodiments. Projections 176 form at least one pair of anchor bindings, and preferably at least three pairs of anchor bindings, along the length of each of the elastic yarns 104 in each side edge portion 166, 168. Binding each elastic yarn at least three times in each side edge portion 166, 168 provides additional structure to prevent the respective elastic yarn 104 from returning to the area (forming the waistband area 38) between the side edge portions 166, 168. Petition 870250084411, dated 09 / 19 / 2025, page 18 / 179 11 / 15

[0033] During the manufacturing process, the first waistband 12 and the second waistband 14 are positioned between the face 178 of each anvil 150 and the working surface 180 of the horn(s) 152. The elastic threads 104 are still in the tensioned state. The position of the horn(s) 152 is controlled to maintain a clamping clearance between the working surface 180 of the horn(s) 152 and the support surfaces of the projections 176. The side seam binding apparatus 148 may include any known positioning means that exerts a force on at least one of the horn(s) 152 and the anvil 150 to maintain the desired clamping clearance.

[0034] The respective work surfaces 177 of the projections 176 can be configured to form links of similar size and shape, or links of different size and / or shape in alternative embodiments. As non-limiting examples, the respective work surfaces 177 of the projections 176 can be circular, rectangular, crescent-shaped, or have shapes that can be selected to form a desired overall pattern in the final trouser product 10.

[0035] The anchoring links 162, 164 on the side edge parts 166, 168 are sized and positioned to ensure proper anchoring of each elastic yarn 104 and may be spaced closer together than the spacing of the links 130 formed in the area between the side edge parts 166, 168 (which forms the waistband area 38). Since the anchoring links 162, 164 on the side edge parts 166, 168 (which form the side seams 34, 36) fix the elastic yarns 104 to the first and second weft layers 102, 106, the links 130 in the area (which forms the waistband area 38) between the side edge parts 166, 168 may have any desired patterning. In this way, the manufacturer can choose between using anchor bonds and / or lamination bonds in the area between the side edge parts 166, 168 (which forms the waistband area 38) and, in this way, can create a variety of visually pleasing bonding patterns.

[0036] FIGS. 5-9 show modalities of the anchor projection patterns 176a, 176b, 176c, 176d provided in insert(s) 158 for anvil(s) 150. In FIGS. 5 and 6, the anchor projection 176a is a set of raised circles that are in offset rows and columns. In FIG. 7, the anchor projections Petition 870250084411, dated 09 / 19 / 2025, p. 19 / 179 12 / 15 176b are a set of elongated raised bars that are in staggered rows and columns, with the bars being angled relative to each other in adjacent rows. In FIG. 8, the projections 176c form columns of elongated slots 184 that are angled relative to a longitudinal direction through which the elastic wires 104 pass, so that each elastic wire 104 passes over three of the projections 176c. In FIG. 9, the projections 176d are continuous bars that extend along the length of the insert 158. When paired with a slotted horn, the anchoring projections 176a-176d of FIGS. 5-9 form bonds by melting sections of the weft layers 102, 106 close to the elastic yarns 104 and at least partially enveloping the elastic yarns 104 and / or locking the elastic yarns 104 in position relative to the weft layers 102, 106 by friction.

[0037] In the embodiments of FIGS. 5-9, the work surfaces 177 of projections 176a-176d are smooth or substantially smooth, meaning that they do not include any internal grooves or notches. These projections 176a-176d can be paired with a horn having a grooved working surface, so that the interaction between the horn and each projection 176a-176b forms a pattern of multiple anchoring links 162, 164, some of which form pairs located on opposite sides of a respective elastic thread 104, to anchor the thread 104 in position at the side seam 34, 36. Alternatively, the projections 176a-176d can be paired with a horn having a grooved working surface, so that the interaction between the smooth horn and each projection 176a-176b forms a single anchoring link 162, 164, which extends the length of one or more elastic threads 104 to anchor the thread 104 in position at the side seam 34, 36.

[0038] In the embodiment of FIG. 10, on the other hand, the working surfaces 177 of the projections 176e include grooves 188 that extend downwards in height from the projections 176e. This style of grooved projections can be paired with either a horn with a smooth working surface or a horn with a grooved working surface to form a pattern of anchoring links 162, 164, some of which form pairs located on opposite sides of a respective elastic thread 104, to anchor the thread 104 in position at the side seam. Petition 870250084411, dated 09 / 19 / 2025, page 20 / 179 13 / 15 34, 36. Projections 176e are shown in FIG. 11 arranged as a set of elongated raised bars that are angled with respect to the central longitudinal axis of insert 158.

[0039] In general, the embodiments may include projections with or without internal grooves. The projections may have the general form of shorter angled bars, similar to those in FIG. 7, arcs, curved or chevron-shaped bars that generally extend along the length of the insert, points, angled bars, horizontal bars, vertical bars, or any other circular, rectangular, crescent-shaped, or irregular shapes. The projection embodiments may be arranged in a pattern of at least one of points, vertical lines, horizontal lines, angled lines, and curved lines. The horn 152 interacts with the plurality of projections to form a plurality of discrete links corresponding to each point or line of the pattern.

[0040] The embodiments shown in FIGS. 8 and 9 include a section 186 that is devoid of the projections 176c. This provides an area where the side edge parts 166, 168 can be easily separated from each other by the cutting device 172. Such a central section 186 can be provided in the inserts 158 shown in FIGS. 5-7 and FIG. 10. With this central section 186, the connections 162, 164 do not lie along the outer edges of the resulting side seams 34, 36, which provides a smoother feel along their edges. In alternative embodiments, the projections 176c, 176d of FIGS. 8 and 9 can be reconfigured to encompass the central section 186, thus defining a continuous pattern of projections and a continuous pattern of connections 162, 164 that extend across the entire width of the side seams 34, 36. In the embodiments shown in FIGS. 5-10, the interaction between the horn(s) 152 and the anchoring projections 176a, 176b form links 162, 164 that perform the dual function of creating side seams 34, 36 that fuse the first and second waistbands 12, 14 and anchor the elastic threads 104 in place at the side seam 34, 36 when the trousers 10 are cut into discrete pieces and the elastic threads 104 are relaxed. Petition 870250084411, dated 09 / 19 / 2025, page 21 / 179 14 / 15

[0041] The description detailed here describes illustrative embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise indicated, the functionalities disclosed herein may be combined to form additional combinations not shown for the sake of brevity. Thus, references to a functionality or mode are intended to describe a functionality or mode of an example, not to imply that each embodiment thereof must have the functionality or mode described. Furthermore, it is important to emphasize that the description illustrates a range of functionalities. While certain functionalities have been combined to illustrate possible system designs, these functionalities may also be used in other combinations not expressly disclosed. Thus, the combinations depicted are not intended to be exhaustive, unless otherwise indicated.

[0042] The terminology used here is intended only to describe specific modalities and is not intended to be limiting in its disclosure. As used herein, the singular forms “a”, “an”, “the” and “the” should also include plural forms, unless the context clearly indicates otherwise. It should also be understood that the terms “comprises” and / or “comprising”, when used in this descriptive report, specify the presence of declared functionalities, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more functionalities, integers, steps, operations, elements, components and / or groups thereof.

[0043] As used herein, unless otherwise limited or modified, lists with elements separated by conjunctive terms (e.g., “and”) and which are also preceded by the phrase “one or more of” or “at least one of” indicate configurations or arrangements that potentially include individual elements of the list, or any combination thereof. For example, “at least one of A, B, and C” or “one or more of A, B, and C” indicate the possibilities of only A, only B, only C, or any combination of two or more of A, B, and C (e.g., A and B, B and C, A and C, or A, B, and C). Petition 870250084411, dated 09 / 19 / 2025, p. 22 / 179 15 / 15

[0044] The description of this disclosure is presented for illustrative and descriptive purposes only, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to persons skilled in the art, without departing from the scope and spirit of the disclosure. The embodiments explicitly referenced herein have been chosen and described to better explain the principles of the disclosure and its practical application, and to enable others skilled in the art to understand the disclosure and recognize many alternatives, modifications, and variations in the examples described. Consequently, numerous embodiments and implementations beyond those explicitly described are within the scope of the claims. Petition 870250084411, dated 09 / 19 / 2025, p. 23 / 179

Claims

1 / 6 CLAIMS 1. System for manufacturing a disposable pants product, characterized in that it comprises: a first apparatus configured to form first and second sets side by side, each set comprising a plurality of elastic yarns tensioned between the first and second weft layers, wherein the first apparatus joins the first and second weft layers of each of the first and second sets; an insert placement apparatus configured to place an absorbent insert in the first weft layer of each of the first and second sets; a folding apparatus configured to fold the absorbent insert and to overlap the first and second sets so that the first weft layers face each other and the opposite side edge parts of the first and second sets align with each other;and a second device configured to form a plurality of links connecting the aligned side edge parts to form side seams and to secure the elastic threads in the side seams.

2. System according to claim 1, characterized in that the second apparatus comprises: an anvil having a plurality of projections defining a lateral stitching pattern; and an ultrasonic horn having a working surface that interacts with the plurality of projections to form the plurality of connections; and wherein at least one of the working surface of the ultrasonic horn and the faces of the plurality of projections has grooves formed thereon.

3. System according to claim 1 or 2, characterized in that the second apparatus includes a first ultrasonic anvil and horn and a second ultrasonic anvil and horn that are spaced from the first ultrasonic anvil and horn. Petition 870250084411, dated 09 / 19 / 2025, page 24 / 179 2 / 6 4. A system, according to any of the preceding claims, characterized in that each elastic thread is attached at least once to each side edge.

5. A system, according to any of the preceding claims, characterized in that each elastic thread is linked at least three times on each side edge.

6. A system according to any of the preceding claims, characterized in that the first device forms connections that are more widely spaced from each other than the connections formed by the second device.

7. A system, according to any of the preceding claims, characterized in that the second apparatus includes an anvil and an ultrasonic horn; and wherein the anvil comprises at least one insert having a plurality of projections on it that form a plurality of discrete links.

8. A system, according to any of the preceding claims, characterized in that the first weft layer of each of the first and second sets is formed from a common continuous weft layer and the second weft layer of each of the first and second sets is formed from a common continuous weft layer, and further comprising a cutting apparatus for cutting the common continuous wefts in the first and second sets.

9. A system according to any of the preceding claims, characterized in that the first apparatus includes a first linking apparatus configured to form links to join the first and second weft layers of the first set and a second linking apparatus configured to form links to join the first and second weft layers of the second set.

10. System, according to any of the preceding claims, characterized in that the first apparatus comprises an anvil having a plurality of projections on it and an ultrasonic horn. Petition 870250084411, dated 19 / 09 / 2025, page 25 / 179 3 / 6 11. System, according to any one of claims 1-9, characterized in that the first apparatus comprises an adhesive applicator that joins the first and second layers of the mesh.

12. System, according to any of the preceding claims, characterized in that the first apparatus further joins the elastic threads to the first and second weft layers in each of the first and second sets.

13. Disposable pants product, characterized in that it comprises: a first waistband connected to a second waistband at the first and second seams and defining a waist opening at the upper edge thereof and a pair of leg openings, wherein the first waistband includes elastic threads between the first and second weft layers and a waistband binding pattern joining the first and second weft layers, and the second waistband includes elastic threads between the first and second weft layers and a waistband binding pattern joining the first and second weft layers of the second waistband, wherein the first side seam includes first aligned side edge parts of the first and second waistbands and a side seam binding pattern joining the first side edge parts and anchoring the elastic threads at the first side seam,The second side seam includes aligned second edge pieces from the first and second waistbands and a side seam binding pattern joining the second side edge pieces and anchoring the elastic threads to the second side seam; and an absorbent core positioned between the first weft layers of the first and second waistbands.

14. Disposable pants product, according to claim 13, characterized in that the waistband linking pattern further connects at least one of the elastic yarns of the first waistband to the first and second weft layers of the first waistband and at least one of the elastic yarns of the second waistband to the first and second weft layers of the second waistband.

15. Disposable pants product, according to claim 13 or 14, characterized in that the side seam connection pattern comprises at least one weld anchoring each elastic thread. Petition 870250084411, dated 09 / 19 / 2025, page 26 / 179 4 / 6 16. Disposable pants product, according to any of the preceding claims, characterized in that the side seam connection pattern comprises at least three welds anchoring respective ends of each elastic thread.

17. (Original) Disposable pants product, according to any of the preceding claims, characterized in that the links in the waistband link pattern are more spaced apart from each other than the links in the side seam link pattern.

18. Disposable pants product, according to any of the preceding claims, characterized in that the elastic threads are positioned between pairs of discrete links of the side seam link pattern that anchor the elastic threads in the first and second side edge parts.

19. Disposable pants product, according to any of the preceding claims, characterized in that the pattern of the side seam connections comprises a repetitive pattern of at least one of the following points, vertical lines, horizontal lines, angled lines and curved lines; and wherein each point or line comprises a plurality of connections.

20. Method for manufacturing a disposable pants product, characterized in that it comprises: forming a first assembly including first and second weft layers that are joined and having a plurality of elastic yarns under tension between them; forming a second assembly including first and second weft layers that are joined and having a plurality of elastic yarns under tension between them; placing an absorbent insert in the first weft layer of each of the first and second assemblies; folding the absorbent insert and overlapping the first and second assemblies so that the first weft layers face each other and the opposite side edge parts of the first and second assemblies align with each other; and connecting the aligned side edge parts to join the first assembly, the second assembly and the plurality of elastic yarns so that the plurality of elastic yarns Petition 870250084411, dated 09 / 19 / 2025, page.27 / 179 5 / 6 is anchored to the side seam areas of the disposable pants product by a plurality of discreet connections.

21. Method according to claim 21, characterized in that at least one of the plurality of elastic yarns is attached to the first and second weft layers in the forming steps.

22. A method according to claim 21 or 22, characterized in that it comprises forming a continuous assembly including a first layer of common continuous weft and a second layer of common continuous weft having a plurality of elastic yarns under tension between them; and cutting the continuous assembly to form the first assembly and the second assembly.

23. A method, according to any of the preceding claims, characterized in that it comprises mechanically, thermally, or ultrasonically joining the first set, the second set, and the plurality of elastic threads in the side seam regions.

24. A method, according to any of the preceding claims, characterized in that it comprises joining the first set, the second set, and a plurality of elastic threads in the side seam regions with a side seam connection pattern comprising a repetitive pattern of at least one of points, vertical lines, horizontal lines, angled lines, and curved lines; and wherein each point or line comprises a plurality of connections.

25. A method, according to any of the preceding claims, characterized in that it comprises joining the first and second weft layers of the first set and the first and second weft layers of the second set with a waistband binding pattern; and joining the aligned side edge parts with a side seam binding pattern; wherein the bindings in the waistband binding pattern are more spaced from each other than the bindings in the side seam binding pattern.

26. Method, according to any of the preceding claims, characterized in that it comprises joining the first and second layers of the first set's weave and the first and second layers of the second set's weave with adhesive.

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