Disposable Pant Waistband Bonding via Segmented Seaming

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Solution Overview

Problem

Conventional methods for manufacturing disposable pant-like garments with waistbands face challenges in creating underwear-like aesthetics and secure fits at commercial manufacturing speeds, as the seaming mechanism must penetrate multiple layers of material, leading to difficulties in bonding both waistband and non-waistband regions without damaging the material, especially at higher production speeds.

Innovation Solution

A method involving a garment web with waist edge openings and leg openings, where elastic waistbands are positioned and attached to create waistband side seams separately from the main side seams, allowing for a more controlled bonding process that avoids damaging non-waistband regions and facilitates efficient manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single seaming mechanism is used to create the entire side seam including both waistband and non-waistband regions, then manufacturing process simplicity is maintained, but the seaming mechanism must be aggressive enough to penetrate twelve layers of material which damages the non-waistband regions

Engineering Contradiction:

Improveseaming process simplicityVSAvoidmaterial damage in non-waistband regions

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The side seam construction is segmented into two separate operations: first, the non-waistband region is seamed by bonding the front and back panels together; second, the waistband is separately attached to the already-seamed panels. This segmentation allows each seaming operation to be optimized for its specific region, avoiding the need for an aggressive single-pass seaming mechanism that would damage the non-waistband materials.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the seaming mechanism penetrates twelve layers of material in the waistband region, then adequate bonding of the waistband is achieved, but the non-waistband regions become damaged, perforated, or burned

Engineering Contradiction:

Improvewaistband bonding effectivenessVSAvoiddamage to non-waistband materials

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The non-waistband panels are bonded together in advance before the waistband is attached. This preliminary bonding creates a stable base structure, allowing the subsequent waistband attachment to focus solely on bonding the waistband layers without needing to penetrate the non-waistband regions, thereby preventing damage to those materials.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a single aggressive seaming mechanism is used to ensure adequate penetration through waistband layers, then waistband bonding is sufficient, but manufacturing speed increases difficulty of avoiding damage

Engineering Contradiction:

Improvebonding strength in waistband regionVSAvoidmanufacturing speed capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By segmenting the seaming process into two separate operations (panel bonding followed by waistband attachment), each operation can use a seaming mechanism optimized for its specific task and speed requirements, rather than requiring a single overly aggressive mechanism that limits manufacturing speed due to the risk of damage.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the production of disposable garments with secure fits and underwear-like aesthetics while reducing the complexity and aggression of the seaming mechanism, ensuring effective bonding across all regions and maintaining material integrity, even at higher manufacturing speeds.

Implementation Method 1

joining the front panel to the back panel via a pair of side seams requires that the seaming mechanism (e.g., an ultrasonic, heat, and/or pressure bonder) penetrate six layers of material

Methodology Applied

Scientific EffectUltrasonic bonding: Ultrasonic Vibration

Implementation Method 2

joining the front panel to the back panel via a pair of side seams requires that the seaming mechanism (e.g., an ultrasonic, heat, and/or pressure bonder) penetrate six layers of material

Methodology Applied

Scientific EffectHeat bonding: Heating

Implementation Method 3

joining the front panel to the back panel via a pair of side seams requires that the seaming mechanism (e.g., an ultrasonic, heat, and/or pressure bonder) penetrate six layers of material

Methodology Applied

Scientific EffectPressure bonding: Compression

Data Source

PatentUS9474658B2Method of making disposable pants having underwear-like waistbands, and pant made thereby

Publication Date: 2016.10.25 KIMBERLY CLARK WORLDWIDE INC

AI summary

A method of manufacturing disposable absorbent garments and a garment made thereby. In particular embodiments, the method comprises removing notches or holes of a garment web or webs adjacent to front and back waist edges to define a series of spaced apart front and back waist edge openings. The method includes providing front and back elastic waistband webs, and positioning the respective waistband webs to overlay at least a portion of each opening, and bonding the waistband webs to each other. The garment includes first and second waist edge cutouts, wherein two side seams extend from the waist edge cutouts to respective leg openings. The garment further includes front and back elastic waistbands attached to each other at first and second waistband side seams.