Folding machine and method for manufacturing panty products

Abstract

The pant folding machine is configured to fold an intermediate pant product having first and second surfaces and formed by first and second continuous webs of waistband material and a core. The machine includes a frame, an entrance roller configured to receive the intermediate pant product in an unfolded state, a folding device, and an exit roller configured to receive the intermediate pant product in a folded state. The folding device includes a centerboard and first and second sideboards. The boards are positioned so that the centerboard engages the first surface of the intermediate pant product and the first and second sideboards each engage the second surface of the intermediate pant product. As the intermediate pant product is drawn along the boards, the intermediate pant product is folded by the boards to transition from an unfolded state to a folded state.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 420,000, filed October 27, 2022.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to systems, machines, and methods for forming or manufacturing disposable underwear or diapers, particularly pant-type products. [Background technology]

[0003] Generally, disposable undergarments, such as pant diapers (generally "pant products"), are composed of two nonwoven layers with embedded elastic material that form front and back waistbands, and an absorbent core that is inserted over or within the waistband for placement adjacent to the user's body. Such pant products are generally manufactured on an assembly or processing line of stations that perform various functions. For example, the core may be laminated and sectioned, and the waistband may be formed from a continuous web of material onto which the core is disposed. Subsequent processing steps may include forming cuffs, bonding to create seams, cutting the continuous web of material into individual products, and / or packaging. Manufacturers of pant products attempt to maintain or improve the speed and efficiency of various aspects of their systems and processes, as well as to provide improved product features. [Brief explanation of the drawings]

[0004] [Figure 1] 1 is a schematic diagram of a system for manufacturing pant products including a folding machine, according to an exemplary embodiment.

[0005] [Figure 2A] 2 is a representative plan view of an intermediate pant product that may be processed by the system for manufacturing pant products of FIG. 1 according to an exemplary embodiment.

[0006] [Figure 2B] 2 is a representative isometric view of an unfolded, finished pant product that may be produced by the system for manufacturing pant products of FIG. 1, according to an exemplary embodiment.

[0007] [Figure 3] 2 is a first isometric view of a folding machine of the system for manufacturing pant products of FIG. 1 according to an exemplary embodiment.

[0008] [Figure 4] 4 is a further isometric view of the folding machine of FIG. 3 in accordance with an exemplary embodiment.

[0009] [Figure 5] FIG. 4 is a side view of the folding machine of FIG. 3 according to an exemplary embodiment.

[0010] [Figure 6] 4 is an isolated side view of a folding board that can be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0011] [Figure 7] 4 is a first isolated isometric view of a roller and folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0012] [Figure 8] 4 is a further isolated isometric view of a roller and folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0013] [Figure 9] 4 is an isolated isometric view of a folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0014] [Figure 10] 4 is a representative cross-sectional view of an intermediate pant product passing through a folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0015] [Figure 11] 4 is a simplified diagram of an intermediate pant product showing schematic fold lines produced by a folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0016] [Figure 12] 4 is a simplified diagram of a folded intermediate pant product produced by a folding device that may be incorporated into the folding machine of FIG. 3 according to an exemplary embodiment.

[0017] [Figure 13] 2 is a representative isometric view of an unfolded, finished pant product that may be produced by the system for manufacturing pant products of FIG. 1 according to another exemplary embodiment.

[0018] [Figure 14] FIG. 10 is a first isolated isometric view of a roller and folding device that may be incorporated into a folding machine according to a further exemplary embodiment.

[0019] [Figure 15] 15 is a further isolated isometric view of the roller and folding device of FIG. 14 according to a further exemplary embodiment.

[0020] [Figure 16] 16 is an isolated isometric view of the folding device of FIGS. 14 and 15 according to a further exemplary embodiment. FIG.

[0021] [Figure 17] 17 is a representative cross-sectional view of an intermediate pant product passing through the folding apparatus of FIG. 16 according to a further exemplary embodiment.

[0022] [Figure 18] 17 is a simplified diagram of an intermediate pant product showing schematic fold lines produced by the folding apparatus of FIG. 16 according to a further exemplary embodiment.

[0023] [Figure 19]17 is a simplified diagram of a folded intermediate pant product produced by the folding apparatus of FIG. 16 according to a further exemplary embodiment.

[0024] [Figure 20] 2 is a side view of a folding board and band arrangement that may be incorporated into the folding machine of FIG. 1 according to a further exemplary embodiment.

[0025] Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION OF THE INVENTION

[0026] The following describes one or more exemplary embodiments of the disclosed folding machine and method for producing disposable panty products, as briefly described above and illustrated in the accompanying figures of the drawings. Various modifications to the exemplary embodiments may be contemplated by those skilled in the art.

[0027] In the embodiments discussed herein, directional or orientation terms (e.g., top, bottom, front, anterior, side, superior, inferior, distal, posterior, medial, and lateral) may be used to describe the structure and configuration of various elements, but these terms should be considered relative to one another in particular instances and should not be considered absolute limitations. Furthermore, the following discussion may refer to a material- or product-based coordinate system with respect to the primary direction of movement of the continuous web, e.g., a longitudinal orientation is parallel to the direction of movement at each location, a transverse orientation is "side-to-side" and perpendicular to the longitudinal orientation in the plane of the product, and a transverse orientation is perpendicular to the longitudinal and transverse orientations. In other cases, the following discussion may refer to absolute coordinate systems relative to specific machine orientations (e.g., x, y, and z).

[0028] As introduced above, disposable undergarments such as pant diapers (generally "pant products") are composed of two nonwoven layers with embedded elastic material that form front and back waistbands, and an absorbent core that is inserted over or attached to the waistband for placement adjacent to the user's body. Such pant products are generally manufactured on an assembly or processing line of stations that perform various functions. For example, the core may be laminated and sectioned, and the waistband may be formed from a continuous web of material onto which the core is disposed. Subsequent processing steps may include forming cuffs, bonding to create seams, cutting the continuous web of material into individual products, packaging, and / or other steps, particularly folding, as discussed in more detail below.

[0029] In some of the previous examples, the pant product was folded once at a lateral center (e.g., along a longitudinal centerline) while still on a continuous web to create an asymmetric intermediate pant product in which the core was approximately on one lateral side of the resulting longitudinal centerline and the two waistbands were approximately on the other lateral side prior to joining and separating the side seams. This configuration not only results in a relatively "wide" intermediate pant product, but can also result in a center of mass (and / or generally poorly distributed mass) that is not aligned with the trailing or folded longitudinal centerline, which can cause problems during such folding. Furthermore, the asymmetry of this web with a single fold can create problems in handling the continuous web, especially considering the desire to produce a large number of pant products in a short period of time. Such problems with asymmetric webs may require slower speeds and / or additional control mechanisms, such as control belts, to hold the core-bearing portion in place as the asymmetric web accelerates and decelerates through downstream processes.

[0030] Exemplary embodiments described herein relate to a folding machine and method in which an intermediate pant product core is tucked between the waistbands of a continuous web of material before forming seams and separating the pant products into individual products. In effect, the folding machine may use a set of three boards, in which a centerboard forms a fold generally along the longitudinal centerline of the core (and the overall unfolded intermediate pant product) on a first side or surface of the intermediate pant product, and a pair of sideboards on each side of the centerboard engage the other side of the intermediate pant product to form side folds. This configuration results in a "W" or "M"-shaped tri-fold with the core tucked between the waistbands, thereby providing a transversely symmetrically folded intermediate pant product. The resulting more evenly distributed mass provides a more stable intermediate pant product for further processing, including reducing or eliminating the need for control mechanisms (e.g., control belts), and / or simplifying downstream processing, including subsequent cutting and conveying steps. For example, the tri-fold configuration may reduce or eliminate the need for further folding of the individual pant products. Generally, the exemplary embodiments discussed herein may provide a more robust, stable, and faster production capability. Additionally, in some configurations, the folding machine may enable and / or facilitate the placement of seams on the inner surface of the pant product, thereby providing an improved customer experience.

[0031] It should be noted that the present folding techniques, machines, systems, apparatus, and methods are described herein with respect to products such as brief or pant-style diapers or underwear for babies, toddlers, children, or adults, although such examples may be applied to a wide variety of processes in which a continuous web of product is folded prior to further processing steps such as bonding and cutting.

[0032] Referring now to Figure 1, Figure 1 is a schematic diagram of a system or arrangement 100 for manufacturing or forming pant products having several stations, sections, machines, and / or units 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122, 124. At the outset, it should be noted that the system 100 of Figure 1 is merely exemplary, and the embodiments discussed below, particularly as they relate to folding, may be applicable to other or modified systems, machines, and / or processes. Generally, in accordance with the discussion below, the system 100 and associated sections 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122, 124 may include any suitable equipment for forming pant products, including material sources, processing equipment, belts, cutting devices, drums, conveyors, guides, manipulators, etc. For example, one or more controllers may be provided to facilitate operation and / or automation of the manufacturing, assembly, processing, folding, and / or packaging processes. Prior to a more detailed description of the folder 118, an example of the overall configuration of the system 100 is discussed below. In some cases, details regarding certain aspects of the overall configuration may be omitted for the sake of brevity or clarity.

[0033] Sections 102, 104, and 106 represent core (or insert) forming and processing units that function to create two-layer or "dual" primary structures with one or more additional layers or features, such as a topsheet (e.g., for skin contact), an acquisition layer (e.g., to facilitate wicking), a backsheet, a weight-loss structure, and / or an embossed pattern. In other examples, the core may have only a single layer, in which case sections 102 or 104 may be omitted, or may have three or more primary layers. Generally, the cores may be formed from one or more absorbent materials, such as pulp, paper, polymer, or tissue material. Additionally, section 108 functions as a bonding station to form cuffs attached to each core via ultrasonic or adhesive bonding means, and may optionally further function to transport the cores as a continuous stream that is later separated into individual pieces for assembly.

[0034] Sections 110, 112, and 114 represent joining or processing units where the front and back waistbands are joined to the core. In particular, the waistbands may be formed and / or otherwise provided by sections 112 and 114 in preparation for assembly with the core. Generally, the two waistbands (e.g., corresponding to the front and back waistbands of the finished product) may be formed from any suitable type of material, such as a nonwoven material that can be ultrasonically or adhesively bonded to accommodate strands, bands, or films / sheets of elastic material, thereby resulting in, in this example, two continuous webs of waistband material. Alternatively, the waistband material may be manufactured in an offline process and provided to the machine as a preformed single-layer or multi-layer elastic composite material. Furthermore, in some examples, the front and back waistbands may initially be formed from the same web of material and then cut to form the separate waistbands. Regardless, the continuous webs of front and back waistband material are transferred to downstream stations. In one example, section 110 may be considered to be one or more machines that function to separate, rotate, and re-pitch individual cores and facilitate attachment of the cores, for example with adhesive, to form a stream of intermediate pant products.

[0035] Further processing of the intermediate pant product occurs in sections 116, 118, and 120. Notably, section 116, which may be omitted in some embodiments, represents a cutting unit where a portion of the waistband is cut to create the curved leg openings. Section 118 represents a folding machine (generally, folding machine 118) where a continuous stream of intermediate pant products is folded in three places on an assembly or array of folding boards, as discussed in more detail below. Section 120 represents one or more bonding units where the folded intermediate pant product is ultrasonically bonded to form side seams. In alternative embodiments, the side seams may be formed in a single bonding unit, or additional bonding units may be provided. In still other embodiments, the side seams may be formed with an adhesive.

[0036] Section 122 represents a cutting or knife unit where the continuous web of intermediate pant products is separated into individual pieces approximately in the center of the side seams. Finally, in this example, section 124 represents a transfer unit where the individual pieces of intermediate pant products are picked up and rotated for packaging, and may further represent a packaging folding unit where the individual intermediate pant products are folded for packaging.

[0037] Thus, pant manufacturing system 100 operates to form a finished pant product from successive (and / or discrete) layers of various materials. By way of example, FIG. 2A shows a web, such as an intermediate pant product 140, folded by machine 118, discussed below, and FIG. 2B shows a finished, unfolded product 146. Generally, and as introduced above, each pant product is formed from a first waistband 150, a second waistband 160, and a core 170, which also collectively define a first (or inner) surface (or face) 142 and a second (or outer) surface (or face) 144. Typically, inner surface 142 is oriented toward a user when the finished product 146 is worn, and outer surface 144 is oriented away from a user when the finished product 146 is worn.

[0038] 2A , the intermediate pant product 140 is formed from one or more continuous webs of layers forming the waistbands (or waistband material) 150, 160 along the longitudinal dimension with the individual cores 170 extending generally laterally between the pair of waistbands (or waistband material) 150, 160, such that, for example, a first end 172 of each core 170 overlaps and / or is secured to a first waistband 150, a second end 174 of each core 170 overlaps and / or is secured to a second waistband 160, and a central portion 176 of each core 170 extends therebetween. As shown, each of the first and / or second waistbands 150, 160 can be considered to have a top edge 152, 162 extending along a distal end of the continuous web (and forming the top edge of the finished product 146) and leg contours 154, 164 adjacent the core 170 (and forming the leg holes of the finished product 146). As described in more detail below, the intermediate pant product 140 can be provided to a folding machine 118 (FIG. 1) to form a more symmetrical tri-fold configuration in which the waistbands 150, 160 are folded over one another and the core 170 is tucked between the waistbands 150, 160. The waistbands 150, 160 are then joined to form side seams 148 and separated at cut lines 149, as examples of additional processing steps, to ultimately form a finished pant product, such as pant product 146 of FIG. 2B. Additional illustrations and discussion of the folding of the intermediate pant product 140 are provided below.

[0039] The diagrams of Figures 3-8 show various aspects of the folding machine 118, which operates to apply three folds to the intermediate pant product 140, resulting in an "M" or "W" shape, as will be discussed in more detail below.

[0040] In the illustrated example, Figures 3 and 4 may be considered to be side isometric views of a folding machine (or apparatus or unit) 118 that receives a continuous stream of waistbands and cores from section 120 (e.g., similar to intermediate pant product 140), and Figure 5 is a side view of folding machine 118 oriented along the direction of travel of the incoming intermediate pant products. Generally, folding machine 118 may be considered to include a frame or base 180 that supports first and second rollers 190, 200, and a folding apparatus 210. In this example, the incoming intermediate pant products 140 are unfolded and "face-up," oriented so that the inner surface 142 engages the first roller 190 and the outer surface 144 is oriented toward the ground, and the outgoing intermediate pant products 140 are folded along three fold lines so that the outer surfaces 144 face outward in each lateral direction. As will be explained in more detail below, the orientation and configuration of the intermediate pant products 140 entering and exiting the folding machine 118 can be modified as needed or desired to yield a desired intermediate or finished product.

[0041] In one example, the frame 180 may form a first attachment structure 182 and a second attachment structure 184. In this example, the first attachment structure 182 is perpendicular to the second attachment structure 184 and parallel to the longitudinal direction of the incoming (or unfolded) intermediate pant product 140, and the second attachment structure 184 is oriented generally parallel to the longitudinal direction of the outgoing (or folded) intermediate pant product 140.

[0042] The first roller 190 may be considered an entrance roller and is supported on and extends from the first mounting structure 182 via a first roller support 192 to receive the incoming intermediate pant products 140 in an unfolded state and guide them to the folding device 210. A first roller guide 194 may also be supported on the first mounting structure 182 to facilitate guiding the intermediate pant products 140 to the folding device 210. The second roller 200 may be considered an exit roller and is supported on and extends from the second mounting structure 184 via a second roller support 202 to receive the intermediate pant products 140 in a folded state from the folding device 210 and guide the outgoing intermediate pant products 140 to the next or downstream section (e.g., section 124).

[0043] In some examples, one or more of the rollers 190, 200 may be powered to rotate to facilitate or drive the movement of the intermediate pant product 140, while in other examples, the rollers 190, 200 may not be powered (e.g., a "flywheel") so as to be driven by the movement of the intermediate pant product 140. In still other examples, the rollers 190, 200 may be fixed to rotate and simply provide a smooth surface to guide the intermediate pant product 140 into a desired position and / or orientation.

[0044] The folding apparatus 210 may be formed by three folding boards 212, 214, 216 mounted to the first mounting structure 182 via supports 218, 220. As best shown in the side view of FIG. 5 , in which the machine direction (MD) 217 ​​is shown, the entrance rollers 190 are positioned perpendicular to the exit rollers 200, thereby redirecting the incoming intermediate pant products 140 both vertically and orthogonally horizontally to result in a position for the outgoing intermediate pant products 140. However, other arrangements and / or configurations may be provided, particularly depending on the circumstances of the preceding and succeeding stations (e.g., stations 120 and 124, respectively, in FIG. 1 ). For example, in a further configuration, the intermediate pant products 140 may enter and exit the folding apparatus 210 and / or the folder 118 along a relatively common straight line (e.g., rather than rotated in an orthogonal direction). In this example, the boards 212, 214, 216 are fixed, although additional mechanisms may be provided to facilitate folding and transportation, as discussed in more detail below.

[0045] For clarity, an exemplary folding board (e.g., board 212) is shown in Figure 6 separated from folder 118. Centerboard 212 shown in Figure 6 also represents boards 214, 216. In one example, boards 212, 214, 216 are the same shape and size, but with different orientations. In other examples, boards 212, 214, 216 may be different from one another.

[0046] As shown, the board 212 is relatively flat and relatively thin, having opposed planar surfaces so as to define a board-engaging edge 230 and an opposite distal edge 236. The board-engaging edge 230 can be considered to include a guide edge portion (or nose) 232 and a fold edge portion 234, one slightly angled relative to the other. When installed in the machine 118, the board 212 is oriented so that the board-engaging edge 230 is oriented along a generally longitudinal direction. Generally, and as discussed in more detail below, the guide edge portion 232 can receive the intermediate pant product 140 and transition the intermediate pant product 140 into the fold edge portion 234 such that adjacent portions of material are pressed onto and around the edge portion 234 to form respective folds. The other boards 214, 216 operate in a similar manner, and as discussed in more detail below, the boards 212, 214, 216 operate collectively to form three folds.

[0047] 7 and 8 provide additional perspectives of the rollers 190, 200 and the boards 212, 214, 216. As shown, the boards 212, 214, 216 are positioned such that the centerboard 212 is disposed between the sideboards 214, 216. Furthermore, in the illustrated orientation of the incoming intermediate panty product 140, the individual boards 212, 214, 216 are positioned and aligned such that the folded edge of the centerboard 212 engages the outer surface 144 of the intermediate panty product 140 and the folded edges of the sideboards 214, 216 engage the inner surface 142 of the intermediate panty product 140. The sideboards 214, 216 are positioned to converge toward the centerboard 212 along the direction of product travel, e.g., more widely spaced at the front or upstream end and more closely spaced at the rear or downstream end. The converging spacing functions to complete the fold of the intermediate panty product 140 along the boards 212, 214, 216.

[0048] A more detailed description of the folding process of the folding apparatus 210 is provided by the diagrams of Figures 9-12. In particular, Figure 9 is an isolated view of the three boards 212, 214, 216 of the folding apparatus 210. Additionally, Figure 10 is a cross-sectional view in a lateral cross-section of the folding apparatus 210 and the intermediate pant product 140 as the product 140 is being folded by the boards 212, 214, 216. See also Figure 11, which is a simplified schematic illustration of the intermediate pant product 140. In particular, Figure 11 shows the inner surface 142 of the intermediate pant product 140, including the first and second waistbands 150, 160 and the core 170. The views of Figures 10 and 11 further include dashed lines 212a, 214a, 216a which generally represent the positions of the boards 212, 214, 216 as they engage the intermediate panty product 140 to form the folds.

[0049] As described above, the boards 212, 214, 216 can have similar shapes. However, in this example, the center board 212 is positioned with its engaging edge facing generally in a first direction (e.g., generally upward), and the side boards 214, 216 are positioned with their respective engaging edges facing generally in a second direction (e.g., generally downward). This arrangement allows the intermediate pant product 140 to pass between the center board 212 and the side boards 214, 216 and engage their engaging edges, allowing for three longitudinal folds.

[0050] In some examples, the center board 212 is positioned slightly forward of the side boards 214, 216 relative to the machine direction (MD) 217 ​​so as to initially engage the intermediate pant product before the side boards 214, 216, while in other examples, the boards 212, 214, 216 may have forward ends that are aligned with an upstream longitudinal position. In either case, the boards 212, 214, 216 are positioned so that at least a portion of the folding occurs simultaneously for all three boards 212, 214, 216, e.g., along at least a common portion of the entire longitudinal path.

[0051] As best shown by reference to Figures 10 and 11, the centerboard 212 engages the outer surface 144 of the intermediate pant article 140 at approximately a line 212a in the lateral center of the core 170 to form a center fold, and the sideboards 214, 216 engage the inner surface 142 of the intermediate pant article 140 at lines 214a, 216a approximately where the core 170 overlaps the respective waistbands 150, 160 to form first and second side folds.

[0052] Thus, the placement of the boards 212, 214, 216 causes the core 170 to be at least partially "tucked" between the inner (user-contacting) surfaces of the waistband materials 150, 160, thereby creating an "M-shaped" (or "W-shaped" depending on how you look at it) cross section, as best shown in Figure 10. In some instances, the entire mass of the core 170 may be located between the waistbands 150, 160, although the exact location of the side folds may vary based on the size and design of the product.

[0053] With further reference to FIG. 12 , a simplified schematic side view of the resulting folded intermediate pant product 140 is shown, for example, as it is transferred to and around the second roller 200. As shown, the folded intermediate pant product 140 is configured such that the outer surfaces of the waistbands 150, 160 face outward in a transverse orientation, with the core 170 at least partially tucked therebetween. The view of FIG. 12 also shows a schematic dashed-line representation 148 of the seam (subsequently formed by ultrasonic or adhesive bonding) and cut 149 (also subsequently formed) that results in an individual finished pant product 146 ( FIG. 2B ). Because the seam 148 is formed with the outer surface 144 of the intermediate pant product 140 facing outward, the fin portion 147 of the side seam 148 is positioned on the outside of the finished product 146, as shown in FIG. 2B . The folded, joined, and separated pant product 140 can be refolded, for example, along a transverse line, in a manner suitable for packaging. Generally, the folded intermediate pant product 140 may undergo any further processing before becoming a finished product that is packaged and distributed. For example, in some configurations, the folded intermediate pant product 140 may be partially unfolded to smooth out the tucks in the core 170. However, in other examples, the folded intermediate pant product 140 may be maintained in a "W-shaped" or "M-shaped" configuration, which may provide a more symmetrical distribution of mass for easier downstream handling and a more robust continuous web of core and waistband material, thereby enabling faster production speeds and efficiency. The folding device 210 may have various configurations to provide a tri-fold configuration for the resulting folded intermediate pant product 140. As a further example, with reference to FIGS. 13-19 , an alternative folding device 310 may be used to produce the folded intermediate pant product 240, thereby providing a finished, unfolded pant product 246.

[0054] Initially, the finished, unfolded product 246 is shown in the isometric view of Figure 13. Generally, and as introduced above, each pant product is formed from a first waistband 250, a second waistband 260, and a core 270, which also collectively define a first (or inner) surface (or face) 242 and a second (or outer) surface (or face) 244. Typically, the inner surface 242 is oriented toward a user when the finished product 246 is worn, and the outer surface 244 is oriented away from the user when the finished product 246 is worn. The waistbands 250, 260 are joined at a seam 248, which in this example is formed so that the inner (user-contacting) surface 242 of the intermediate pant product 240 faces outward, and the fin portion 247 of the side seam 248 is positioned on the inner (user-facing surface) of the finished product 246.

[0055] 14-15 provide an isometric view of an alternative folding device 310 positioned relative to rollers 290, 300 for folding a corresponding intermediate pant product 310. FIG. 16 is an isometric view of the alternative folding device 310 separated from rollers 290, 300, intermediate pant product 249, and other portions of a larger folding machine. Unless otherwise noted, a folding machine incorporating intermediate pant product 240 and folding device 310 of FIGS. 14-16 may be the same as (or different from) folding machine 118 described above.

[0056] As described above, the folding device 310 may include a centerboard 312 and sideboards 314, 316, which may have similar shapes. However, compared to the example discussed above, the sideboards 314, 316 in this example are arranged with their engaging edges facing generally in a first direction (e.g., generally upward), and the centerboard 312 is arranged with its engaging edges facing generally in a second direction (e.g., generally downward). This arrangement allows the intermediate pant product 240 to pass between the centerboard 312 and the sideboards 314, 316 and engage with their engaging edges, enabling three longitudinal folds.

[0057] In this example, as described above, the side boards 314, 316 are positioned slightly forward (upstream) of the side boards 314, 316 in the machine direction 217 so as to initially engage the intermediate pant product before the center board 312, but in other examples, the boards 312, 314, 316 may have forward ends that are aligned with an upstream longitudinal position.

[0058] In this arrangement, as better shown in the cross-sectional view of Figure 17, in which the intermediate pant product 240 is being folded by the folding apparatus 310, and the simplified schematic diagram of Figure 18, in which the engagement lines 312a, 314a, 316a of the corresponding boards 312, 314, 316 are shown, the center board 312 engages the inner surface 242 of the intermediate pant product 240 approximately at a line 312a in the lateral center of the core 270 to form a center fold. The side boards 314, 316 engage the outer surface 244 of the intermediate pant product 240 approximately at lines 314a, 316a at locations where the core 270 overlaps the respective waistbands 250, 260 to form first and second side folds.

[0059] As noted above, this causes the core 270 to be at least partially "tucked" between the waistband materials 250, 260, thereby creating a "W-shaped" (or "M-shaped" depending on how you look at it) cross section, as best shown in Figure 17. However, in this example, the folded intermediate pant product 240 has an inner surface 242 that faces laterally outward. In some examples, the entire mass of the core 270 may be located between the waistbands 250, 260, although the exact location of the side folds may vary based on product specifications.

[0060] With further reference to FIG. 19 , a simplified schematic side view of the resulting folded intermediate pant product 240 is shown, for example, as it is transferred to and around the second roller 200. As shown, the folded intermediate pant product 240 is configured such that the inner surfaces of the waistbands 250, 260 face outward in a transverse orientation, with the core 270 tucked therebetween. In some embodiments, a portion of the user-facing surface of the core 270 also faces outward in a transverse orientation, as shown in FIG. 19 . Those skilled in the art will recognize that the length of the outward-facing portion of the core 270 will vary based on product size and design. The view of FIG. 19 also shows schematic dashed-line representations 248 of the seams (subsequently formed by ultrasonic bonding) and cuts 249 (also subsequently formed) that result in individual folded products. The folded, bonded, and separated products 240 can be refolded, for example, along transverse lines, in a manner suitable for packaging. The seam 248 is formed so that the inner (user-contacting) surface 242 of the intermediate pant product 240 faces outward, so that the fin portion 247 of the side seam 248 is positioned on the inner (user-facing surface) of the finished product 246, as shown in FIG. 13.

[0061] Generally, the intermediate pant product 240 may undergo any further processing before becoming a finished product that is packaged and distributed. For example, in some configurations, the folded intermediate pant product 240 may be partially unfolded and / or refolded so that the outer surface 244 faces outward in the cross direction. In other words, the folded intermediate pant product 240 may be refolded from an "inside-out" orientation, which is more typical for such finished products, to a "right-side out" orientation. However, in other examples, the folded intermediate pant product 240 may be maintained in an "inside-out" orientation, which may, for example, facilitate donning or application of the final product by a user.

[0062] In any event, during further processing of the folded intermediate pant product 240, the seam 248 is generally formed on the product's inner surface 242, as bonding of the folded intermediate pant product 240 occurs to the inner surface 242, which in this example faces transversely outward. The resulting interior seam 248 in the finished pant product may provide a more desirable garment-like consumer product.

[0063] Further modifications and / or alternative configurations of the folding machine 118 may be provided. For example, bands or strips may be provided that cooperate with the board to facilitate smooth passage of the intermediate product along the board during folding. One example is provided by the diagram of FIG. 20, which is a sample folding board 320 (e.g., corresponding to boards 212, 214, 216, 312, 314, 316) that may be incorporated into the folding machine 118 discussed above. As shown, a rotating band 322 may be provided to move along the periphery of the mating edge of the board 320 in the direction of material travel corresponding to the machine direction (MD) 324. Such a band 322 may be driven by a motor attached to a frame (e.g., frame 180 in FIG. 1). The rotating band 322 may be applied to any one or more of the center or side boards to facilitate smooth transport of the material. In particular, the rotating band 322 may reduce friction between the center board and core of the intermediate product, thereby reducing or eliminating the possibility of the board tearing the core.

[0064] Accordingly, the exemplary embodiments discussed herein provide folding machines, systems, and methods that may provide process and packaging benefits. In particular, the folded intermediate pant product resulting from the folding device board may provide a more symmetrical distribution of mass for easier downstream handling and a more robust continuous web of core and waistband material, thereby enabling faster production speeds and efficiency. In some cases, by providing three folds of the intermediate pant product nearly simultaneously with the cooperating board, the overall footprint of the folding machine may be reduced. Furthermore, the examples described herein may facilitate or enable the formation of a finished pant product with interior side seams, thereby providing a more desirable consumer product.

[0065] Also provided are the following examples, which are numbered for ease of reference.

[0066] 1. A pant folding machine configured to fold an intermediate pant product having a first surface and a second surface, the intermediate pant product being formed by a continuous web of a first waistband material, a continuous web of a second waistband material, and a plurality of cores, each core extending between the first and second continuous webs of waistband material, the machine comprising: a frame; an entrance roller mounted on the frame and configured to receive the intermediate pant product in an unfolded state; and a folding device disposed downstream of the entrance roller and mounted on the frame and configured to receive the intermediate pant product from the entrance roller in an unfolded state, the folding device including a centerboard and a first side of the centerboard; a folding device comprising a first sideboard and a second sideboard on a second side of the centerboard, the centerboard, first sideboard, and second sideboard being arranged so that the centerboard engages with a first surface of an intermediate pant product and each of the first and second sideboards engages with a second surface of the intermediate pant product, and as the intermediate pant product is pulled along the centerboard and the first and second sideboards, the intermediate pant product is folded by each of the centerboard and the first and second sideboards to transition the intermediate pant product from an unfolded state to a folded state; and an exit roller mounted on the frame and configured to receive the intermediate pant product in a folded state from the folding device.

[0067] 2. The pant folding machine of example 1, wherein the entrance rollers and folding device are positioned so that the centerboard engages the intermediate pant product core.

[0068] 3. The pant folding machine of example 2, wherein the entrance rollers and folding device are positioned so that the centerboard engages the intermediate pant product core at approximately the lateral center.

[0069] 4. A pants folding machine as described in Example 3, wherein the inlet rollers and folding device are positioned so that the first sideboard engages the intermediate pants product adjacent to a first individual interface between the core and the first waistband material, and the second sideboard engages the intermediate pants product adjacent to a second individual interface between the core and the second waistband material.

[0070] 5. The pants folding machine of example 1, wherein the folding device is configured to fold the intermediate pants product into an M-shape or a W-shape.

[0071] 6. The pant folding machine of example 1, wherein the folding device is configured such that the intermediate pant product core is tucked in between the first waistband material and the second waistband material.

[0072] 7. The pants folding machine of example 1, wherein the entrance rollers are positioned perpendicular to the exit rollers.

[0073] 8. The pants folding machine of example 1, wherein the inlet rollers and folding device are positioned such that the centerboard engages a first surface as the outer surface of the intermediate pants product and the sideboard engages a second surface as the inner surface of the intermediate pants product.

[0074] 9. The pants folding machine of example 1, wherein the inlet rollers and folding device are positioned so that the centerboard engages the first surface as the inner surface of the intermediate pants product and the sideboard engages the second surface as the outer surface of the intermediate pants product.

[0075] 10. The pants folding machine of example 1, wherein the center board, the first side board, and the second side board are positioned to respectively engage intermediate pants products along a common longitudinal path.

[0076] 11. The pants folding machine of Example 1, wherein the centerboard, the first sideboard, and the second sideboard each have a first end oriented proximate to the entrance roller and a second end oriented proximate to the exit roller, the first ends of the centerboard, the first sideboard, and the second sideboard have a first lateral spacing, and the second ends of the centerboard, the first sideboard, and the second sideboard have a second lateral spacing, and the first lateral spacing is greater than the second lateral spacing.

[0077] 12. The pant folding machine of example 1, wherein the centerboard has relatively flat sides that face to define an edge that engages the intermediate pant product.

[0078] 13. The pants folding machine of example 1, wherein the center board, the first side board, and the second side board have generally the same shape.

[0079] 14. The pants folding machine of example 1, wherein the center board, the first side board, and the second side board are fixed.

[0080] 15. The pants folding machine of example 1, further comprising a conveying band extending along at least a peripheral portion of the centerboard, the conveying band configured to be driven in the direction of movement of the intermediate pants product.

[0081] 16. A method for folding an intermediate pant product defining a first surface and a second surface, and having a first waistband, a second waistband, and a core, the method comprising: receiving the intermediate pant product in an unfolded state; orienting the intermediate pant product along a folding device having a centerboard, a first sideboard on a first side of the centerboard, and a second sideboard on a second side of the centerboard, so that the centerboard engages the first surface of the intermediate pant product to form a center fold and so that each of the first and second sideboards engages the second surface of the intermediate pant product to form first and second side folds, respectively; and orienting the intermediate pant product away from the folding device in a folded state.

[0082] 17. A method of forming a diaper-type pant product, the method comprising: forming and providing a continuous web of a first waistband material; forming and providing a continuous web of a second waistband material; positioning a series of cores at least partially on the continuous web of the first waistband material and at least partially on the continuous web of the second waistband material to form an intermediate pant product having a first side and a second side; folding the intermediate pant product with at least two folding boards to result in a folded intermediate pant product; joining the continuous web of the first waistband material and the continuous web of the second waistband material of the folded intermediate pant product to create a series of side seams; and cutting the joined continuous webs adjacent the side seams to form a series of individual pant products.

[0083] 18. The method of Example 17, wherein the folding step includes creating a center fold in the core on a first surface of the intermediate pant product with a center board of at least two folding boards, creating a first side fold with a first side board of the at least two folding boards adjacent to an interface between the core and the continuous web of first waistband material on a second surface of the intermediate pant product, and creating a second side fold with a second side board of the at least two folding boards adjacent to an interface between the core and the continuous web of second waistband material on the second surface of the intermediate pant product.

[0084] 19. The method of example 18, wherein the first surface of the intermediate pant product is the outer surface and the second surface of the intermediate pant product is the inner surface, such that the joining and cutting steps operate to form individual pant products having side seams as outer side seams.

[0085] 20. The method of example 18, wherein the first surface of the intermediate pant product is an inner surface and the second surface of the intermediate pant product is an outer surface, such that the joining and cutting steps operate to form individual pant products having the side seams as interior side seams.

[0086] 21. A folded diaper-type pant product comprising: a first waistband; a second waistband joined to the first waistband at an interior seam; and a core extending between and at least partially overlapping the first and second waistbands, the core having a first fold line in its laterally central portion such that the core is tucked between the first and second waistbands to further form a first side fold line adjacent the interface of the core and the first waistband and a second side fold line adjacent the interface of the core and the second waistband.

[0087] The detailed description herein describes exemplary embodiments and is not intended to be limited to the combination(s) expressly disclosed. Thus, unless otherwise specified, features disclosed herein can be combined together to form additional combinations not otherwise shown for brevity. Thus, reference to a feature or aspect is intended to describe an example feature or aspect and does not imply that all embodiments thereof must have the described feature or aspect. Furthermore, it should be noted that the description illustrates several features. While certain features are combined to illustrate potential system designs, those features may also be used in other combinations not expressly disclosed. Thus, illustrated combinations are not intended to be limiting unless otherwise specified.

[0088] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that, as used herein, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0089] As used herein, unless otherwise limited or modified, a list having elements separated by conjunctive language (e.g., "and") and also preceded by the phrase "one or more of" or "at least one of" denotes a configuration or arrangement that potentially includes the 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" indicates the possibility of A only, B only, C only, 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).

[0090] The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments explicitly referenced herein were chosen and described to best explain the principles of the present disclosure and their practical applications, and to enable those skilled in the art to understand the disclosure and to recognize many alternatives, modifications, and variations of the described examples. Accordingly, various embodiments and implementations other than those explicitly described are within the scope of the following claims.

Claims

1. 1. A pant folding machine configured to fold an intermediate pant product having a first surface and a second surface, the intermediate pant product being formed by a continuous web of a first waistband material, a continuous web of a second waistband material, and a plurality of cores, each core extending between the first and second continuous webs of waistband material; The frame and an entrance roller mounted on the frame and configured to receive the intermediate pant product in an unfolded state; a folding device disposed downstream of the entrance rollers, mounted on the frame, and configured to receive the intermediate pant product from the entrance rollers in an unfolded state, the folding device comprising: a centerboard, a first sideboard on a first side of the centerboard, and a second sideboard on a second side of the centerboard, the centerboard, the first sideboard, and the second sideboard being arranged such that the centerboard engages a first surface of the intermediate pant product and each of the first and second sideboards engages a second surface of the intermediate pant product, and as the intermediate pant product is pulled along the centerboard and the first and second sideboards, the intermediate pant product is folded by the centerboard and each of the first and second sideboards to transition the intermediate pant product from the unfolded state to the folded state; an exit roller mounted on the frame and configured to receive the intermediate pant product in a folded state from the folding device; A pants folding machine comprising:

2. The pant folding machine of claim 1 , wherein the inlet rollers and the folding device are positioned such that the centerboard engages the core of the intermediate pant product.

3. 3. The pant folding machine of claim 2, wherein the inlet rollers and the folding device are positioned so that the centerboard engages the core of the intermediate pant product at approximately the lateral center.

4. 4. The pant folding machine of claim 3, wherein the inlet rollers and the folding device are positioned so that the first sideboard engages the intermediate pant product adjacent a first discrete interface between the core and the first waistband material, and the second sideboard engages the intermediate pant product adjacent a second discrete interface between the core and the second waistband material.

5. The pant folding machine of claim 1 , wherein the folding device is configured to fold the intermediate pant product into an M-shape or a W-shape.

6. The pant folder of claim 1 , wherein the folding device is configured such that the core of the intermediate pant product is tucked in between the first waistband material and the second waistband material.

7. The pant folding machine of claim 1 , wherein the entrance rollers are positioned perpendicular to the exit rollers.

8. 2. The pant folding machine of claim 1, wherein the inlet rollers and the folding device are positioned such that the centerboard engages the first surface as an outer surface of the intermediate pant product and the sideboard engages the second surface as an inner surface of the intermediate pant product.

9. 2. The pant folding machine of claim 1, wherein the inlet rollers and the folding device are positioned such that the centerboard engages the first surface as an inner surface of the intermediate pant product and the sideboard engages the second surface as an outer surface of the intermediate pant product.

10. 2. The pant folding machine of claim 1, wherein the centerboard, the first sideboard, and the second sideboard are positioned to respectively engage the intermediate pant products along a common longitudinal path.

11. 2. The pants folding machine of claim 1, wherein the center board, the first side board, and the second side board each have a first end oriented proximate to the entrance rollers and a second end oriented proximate to the exit rollers, the first ends of the center board, the first side board, and the second side board have a first lateral spacing, and the second ends of the center board, the first side board, and the second side board have a second lateral spacing, and the first lateral spacing is greater than the second lateral spacing.

12. 2. The pant folder of claim 1, wherein the centerboard has relatively flat sides facing to define edges that engage the intermediate pant product.

13. The pants folding machine of claim 1 , wherein the center board, the first side board, and the second side board have generally the same shape.

14. The pants folding machine of claim 1 , wherein the center board, the first side board, and the second side board are fixed.

15. The pant folding machine of claim 1 , further comprising a transport band extending along at least a periphery portion of the centerboard, the transport band being configured to be driven in a direction of movement of the intermediate pant product.

16. 1. A method of folding an intermediate pant product defining a first side and a second side, the intermediate pant product having a first waistband, a second waistband, and a core, the method comprising: receiving the intermediate pant product in an unfolded state; orienting the intermediate pant product along a folding device having a centerboard, a first sideboard on a first side of the centerboard, and a second sideboard on a second side of the centerboard, such that the centerboard engages the first surface of the intermediate pant product to form a center fold, and each of the first and second sideboards engages the second surface of the intermediate pant product to form first and second side folds, respectively; directing the intermediate pant product in the folded state away from the folding device; A method comprising:

17. 1. A method of forming a diaper-type pant product, comprising: forming and providing a continuous web of a first waistband material; forming and providing a continuous web of a second waistband material; positioning a series of cores at least partially on the continuous web of first waistband material and at least partially on the continuous web of second waistband material to form an intermediate pant product having a first surface and a second surface; folding the intermediate panty product on at least two folding boards to result in a folded intermediate panty product; joining the continuous web of first waistband material and the continuous web of second waistband material of the folded intermediate pant product to create a series of side seams; severing the joined continuous web adjacent to the side seams to form a series of individual pant products; A method comprising:

18. 18. The method of claim 17, wherein the folding step includes creating a center fold in the core on the first side of the intermediate pant product with a center board of at least two folding boards; creating a first side fold with a first side board of at least two folding boards adjacent to an interface between the core and the continuous web of first waistband material on the second side of the intermediate pant product; and creating a second side fold with a second side board of at least two folding boards adjacent to an interface between the core and the continuous web of second waistband material on the second side of the intermediate pant product.

19. 19. The method of claim 18, wherein the first surface of the intermediate pant product is an outer surface and the second surface of the intermediate pant product is an inner surface, such that the joining and severing steps operate to form the individual pant products having the side seams as exterior side seams.

20. 19. The method of claim 18, wherein the first surface of the intermediate pant product is an inner surface and the second surface of the intermediate pant product is an outer surface, such that the joining and severing steps operate to form the individual pant products having the side seams as interior side seams.

21. a first waistband; a second waistband joined to the first waistband at an interior seam; a core extending between the first waistband and the second waistband and at least partially overlapping the first waistband and the second waistband, the core having a first fold at a laterally central portion such that the core is tucked between the first waistband and the second waistband to further form a first side fold adjacent an interface between the core and the first waistband and a second side fold adjacent an interface between the core and the second waistband; A folded diaper-type pants product comprising:

Images