Patent Document

RELATED APPLICATIONS 
     The present application is a continuation application of and claims priority to co-pending U.S. patent application Ser. No. 11/240,262, filed Sep. 30, 2005, which is a continuation-in-part application of U.S. patent application Ser. No. 09/548,231, filed Apr. 12, 2000, now abandoned, which is a continuation of prior U.S. patent application Ser. No. 08/937,225, filed Sep. 11, 1997, now U.S. Pat. No. 6,049,916, which is a divisional of prior U.S. patent application Ser. No. 08/382,108 filed on Jan. 31, 1995, now U.S. Pat. No. 5,745,922, each of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Undergarments are made typically of cotton and/or synthetic materials. The cotton and synthetic panties typically do not offer barrier protection. Often the synthetic undergarments have a cotton lined crotch to absorb vaginal discharges or perspiration. The absorbent/barrier properties of regular undergarments are minimal such that any vaginal discharge and/or heavy perspiration may strike through onto outer clothing; i.e., liquid penetrates from the interior to the exterior of the panty. 
     Panty liners and feminine care sanitary napkins or pads used with regular undergarments have polyethylene backings that provide some barrier properties inhibiting liquid strike through. However, if the vaginal discharge extends to the sides or the ends of the pads, the discharge can leak or seep around an edge of the pad and onto the undergarment. Such leakage can stain the undergarment. Depending upon the amount of leakage, liquid may strike through or go around the undergarment and stain outer clothing and/or bedding. Women with heavy liquid flows may often use one or more maxi pads, double pads and/or tampons alone, or in combination, and change these pads and tampons frequently to prevent embarrassing, messy leakage around the edges of the pads and/or staining of outer clothing. In some cases, during their heaviest flow days, some women will restrict their activities and stay home. 
     Many women experience some leakage of menses from their pads to their undergarments. This varies from being limited to a small number of pads leaking onto only the undergarment during light flow to more prevalent leakage onto the wearer&#39;s outer clothing on pads worn during heavy flow. Normally this leakage occurs at the side of the pad, although end leakage is also a problem. Placement of maxi pads and overnight pads in the crotch of regular undergarments shows that, at best, the pads lay on the leg elastic and, at worst, overhang the leg elastics. This causes side leakage onto the undergarment and possibly onto outer clothing. Typical leakage from the pads is caused by poor fit of the pad to the body, improper positioning of the pad by the user and lack of absorbency. Leakage from the undergarment onto the outer clothing is typically due to incompatibility between the pad width and the panty crotch width and/or lack of barrier properties in the panty material around the edge portion of the pad. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention broadly includes a three dimensional, disposable, discrete panty, subassemblies of the panty, and apparatus and methods for making the panty. 
     In one aspect of the invention, a method for attaching elastic to a crotch area of an undergarment includes the steps of cutting an elastic thread into a plurality of elastic sections; providing a secondary absorbent for receipt of at least one of the elastic sections, the secondary absorbent defining an inner side and an opposing outer side; attaching the elastic sections to the inner side of the secondary absorbent as the elastic sections and the secondary absorbent move in a machine direction; maneuvering the secondary absorbent with the elastic sections attached thereto to a non-machine direction; and attaching the secondary absorbent to a garment web moving in the machine direction, the elastic sections of the inner side disposed against an inner crotch portion of the garment web, the opposing outer side visible in the crotch portion. In this aspect, each elastic section is from about one inch to about three inches in length. Also in this aspect, the elastic sections are attached to the inner side of the secondary absorbent by an adhesive. 
     According to a further aspect of the invention, a disposable garment assembly includes a disposable garment defining a length and a width and including an outer cover having a front body portion and a back body portion, the front body portion and the back body portion being connected by a crotch portion, the outer cover, when laid out flat, having a length and a width, the front body portion and the back body portion being connected together to form a waist opening, a first leg opening and a second leg opening, the first and second leg openings having respective first and second front and back leg edge portions and corresponding first and second side leg edge portions connecting the front and back leg edge portions, the outer cover comprising a first layer, and a second layer having a front portion and a back portion, the second layer front portion disposed adjacent the front body portion of the outer cover, the second layer back portion disposed adjacent the back body portion of the outer cover; a first absorbent defining a length and a width, each respectively less than the length and the width of the disposable garment, the first absorbent further including a liquid impermeable outer sheet and a liquid permeable inner sheet, the liquid impermeable outer sheet having a front portion and a back portion, and a center portion therebetween, each of the liquid impermeable outer sheet front and back portions of the first absorbent disposed adjacent one of the respective second layer front and back body portions of the outer cover, the first absorbent having a first absorbent capacity; a second absorbent including a first side and a second side and having a second absorbent capacity, the second absorbent attached in the crotch portion and covering the width of the first absorbent, the second absorbent underlying the first absorbent on the liquid impermeable outer sheet of the first absorbent, the first side of the second absorbent disposed facing the liquid impermeable outer sheet, the first absorbent capacity of the first absorbent being greater than the second absorbent capacity of the second absorbent; and a plurality of crotch elastics extendably affixed between the outer cover and the second side of the second absorbent proximate the crotch portion, the second absorbent affixed to the outer cover. 
     In this aspect of the invention, the second absorbent capacity of the second absorbent is about one-half the absorbent capacity of the first absorbent. For instance, the second absorbent capacity of the second absorbent can be about 3 grams to about 6 grams, more particularly, about 4 grams to about 6 grams. Also in this aspect of the invention, the second absorbent is a stain shield. 
     In a further aspect of the invention, a disposable garment has a length and a width, and includes an outer cover having front and back body portions connected by a crotch portion, the outer cover, when laid out flat, having a length between first and second ends and a width between first and second sides, the front and back body portions being connected together to form a waist opening and first and second leg opening. The outer cover in this aspect includes a first layer; a second layer having front and back body portions overlying respective front and back body portions of the outer cover; and a stain shield incorporated into the disposable garment, the stain shield having a length and a width and a garment facing side, the garment facing side having a front portion, a back portion and a center portion therebetween, the garment facing side of the center portion having a plurality of extensible crotch elastic pieces attached thereto proximate the crotch portion, the extensible crotch elastic pieces being disposed between the garment facing side and the outer cover of the crotch portion, the stain shield affixed to the outer cover, each of the garment facing side front and back portions of the stain shield disposed adjacent one of the respective second layer front and back portions, at least a portion of the stain shield having an overall total absorbent capacity of about 3 grams to about 6 grams. Also in this aspect, at least a portion of the absorbent has an overall total absorbent capacity of about 4 grams to about 6 grams. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the invention and the drawings, in which: 
         FIG. 1  is a plan view of a garment subassembly according to an aspect of the invention; 
         FIG. 2  is a plan view of the garment subassembly of  FIG. 1 , including a secondary absorbent in the crotch; 
         FIG. 3  is a cross section of the garment subassembly taken along line  3 - 3  of  FIG. 2 ; 
         FIG. 4  is a cross section of the garment subassembly taken along line  4 - 4  of  FIG. 2 ; 
         FIG. 5  is a perspective view of a disposable panty according to another aspect of the invention; 
         FIGS. 6 and 7  are enlarged cut-away views of a fragment of the subassembly of  FIG. 1 , particularly showing cross-crotch elastics in detail; 
         FIG. 8  is a side elevation view of an equipment layout for fabricating and processing subassemblies according to another aspect of the invention; 
         FIGS. 9 and 10  are pictorial views of a nip area of the elevation shown in  FIG. 8 ; 
         FIG. 11  is a plan view showing transverse positioning of front and back leg elastics along an advancing web as an outer cover layer and a body side layer are being joined according to an aspect of the invention; 
         FIG. 12  is a plan view as in  FIG. 10 , showing an alternate pattern for elastic threads; and 
         FIG. 13  is a perspective view showing steps in a method for cutting a plurality of elastics and attaching the elastics to a secondary absorbent according to another aspect of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description is made in the context of an article including a disposable panty, and corresponding panty subassemblies, for holding a sanitary pad in place as a primary absorbent during use of the panty. It is readily apparent, however, that the present invention can be employed with other disposable sanitary articles, such as feminine tampons, incontinent garments and the like. 
     The panty subassembly  10  of  FIG. 1  illustrates an embodiment of a two-layer panty subassembly prior to incorporation of the secondary absorbent. The panty subassembly of  FIG. 2  illustrates the finished panty including all elements, but before the final steps of assembling the composite to form the panty structure.  FIG. 5  shows the finally-assembled disposable panty structure. 
     Referring to  FIGS. 1-3 , the panty subassembly  10  has an outer cover layer  12  generally defining the overall length “L 1 ” and width “W 1 ” of the subassembly, and a body side layer  14  secured to the outer cover layer. The panty subassembly  10  generally includes a front body portion  16  terminating at a front waist portion  18  as a first edge of the subassembly, a back body portion  20  terminating at a back waist portion  22  as a second edge of the subassembly, and a crotch portion  24 . 
     The body side layer  14  includes a front layer element  19  generally overlying and secured to the outer cover layer  12  on the front body portion  16 , and a back layer element  21  generally overlying and secured to the outer cover layer  12  on the back body portion  20 . A space  23  separates the front layer element  19  from the back layer element  21 . 
     Referring to  FIGS. 2 and 5 , for assembling the subassembly of  FIG. 2  to form a panty  25  as in  FIG. 5 , a first side edge  26  of front body portion  16  is assembled with a first side edge  28  of the back body portion  20  to form a first side seal  30 . Similarly, a second side edge  32  of the front body portion  16  is assembled with a second side edge  34  of the back body portion  20  to form a second side seal  36 . The waist portions  18 ,  22  when assembled form a waist opening  38  for putting on and taking off the panty  25 . The waist opening  38  is surrounded at least in part by a waist elastic  40 . The waist elastic  40  is stretched and attached to the waist portions  18 ,  22  in the stretched state. The waist elastic  40  is released after attachment to produce waist folds or pleats  42  to allow expansion of the waist opening  38  so that the panty  25  can fit various sizes of people. Because users of this invention generally prefer a brief style panty, the front waist portion  18  preferably comes as high as the navel and is level around the wearer&#39;s waist. Having the panty at this height provides a snug fit. Alternative panty styles include bikini (e.g. regular leg cut or french leg cut) and hipster (e.g. regular leg cut or french leg cut). 
     Referring to  FIGS. 1 and 5 , the front body portion  16 , the back body portion  20 , and the crotch portion  24 , in combination, form left and right leg openings  44  and  46 , respectively, which are generally circular or oval in shape in the finally assembled panty  25 . The leg openings  44  and  46  are formed by cutting away portions of the outer cover layer  12 , and corresponding portions if any of body side layer  14 . Each leg opening  44 ,  46  is surrounded at least in part by a back leg elastic  48 , a front leg elastic  50 , and a crotch elastic  51  between the back leg elastic and the front leg elastic. Each of the respective elastics  48 ,  50 ,  51  is adjacent the respective one of the edges  52  of the corresponding leg openings. The front and back leg elastics  48 ,  50  are secured between the outer cover layer  12  and the body side layer  14  by adhesive  55 . The crotch elastics  51  are secured between outer cover layer  12  and a crotch elastic support sheet  53 , also by adhesive  55 . The elastics  48 ,  50 ,  51  are in the stretched state when secured to the outer cover layer  12 . Accordingly, when the elastics, the outer cover layer, the body side layer, and the support sheet  53 , are released after the elastics are secured to the outer cover layer, the elastics produce leg folds or pleats  54  at the edges of the leg openings  44 ,  46  to allow expansion of the leg openings  44 ,  46  to fit various sizes of legs. 
     The front body portion  16  may be divided into a front upper portion  56  and a front lower portion  58 . Similarly, the back body portion  20  may be divided into a back upper portion  60  and a back lower portion  62 . The upper portions  56  and  60  are preferably designed to include body elastics  64  which readily stretch to allow the wearer to put on the panty  25  and then readily contract to resume the normal release state of the body elastics. This ensures a close or snug fit to different body sizes and forms. A number of body elastics  64  are positioned on both the front and the back portions  56 ,  60 , respectively, at positions between the waist opening  38  and the leg openings  44 ,  46 , so that the panty  25  has a good fit, particularly around the body. 
     The lower body portions  58 ,  62  generally do not require the spaced elastics as in the upper body portions  56 ,  60 , although the elastic threads may be used. 
     The width of the crotch portion  24  between the left and right crotch elastics  51  should be wide enough to accommodate laying the primary absorbent  66  between the edges  52  without having the primary absorbent  66  obstruct the crotch elastics  51 . This allows the crotch elastics  51  to contract and draw up the sides of the crotch about the primary absorbent, to thus accommodate the thickness of the primary absorbent  66 , and to give surface area within the crotch portion  24  of the panty, adjacent edges  52 , to contain leakage from the primary absorbent  66 . 
     The width of the crotch portion  24  between the elastics  51  should not be so wide as to seem bulky or uncomfortable. A suitable width is at least about 2.75 inches (70 mm) between the crotch elastics. Width of crotch portion  24  is advantageous from about 3 inches (76 mm) to about 3.5 inches (89 mm). Preferably, the width is about 3 inches (76 mm). 
     Preferably, the crotch elastics  51  are from about 0.375 inch (10 mm) to about 0.625 inch (16 mm) wide. More preferably, the width is about 0.5 inch (13 mm). Preferably, ruffle material on the edge of the leg openings  44 ,  46  outside the leg and crotch elastics  48 ,  50 ,  51  is less than about 0.25 (6 mm). More preferably, the ruffle material is less than about 0.125 inch (3 mm). It is most desirable to eliminate any ruffle material from the edges of the leg openings  44 ,  46 . 
     The overall width of the crotch portion  24  includes the width between the left and right crotch elastics  51 , the width of the crotch elastics, and any ruffle material outside the crotch elastics to the edges  52  of the leg openings. Preferably, the overall width of the crotch portion  24  should be at least about 4 inches (102 mm). 
       FIG. 2  shows the panty subassembly  10  of  FIG. 1  with a secondary absorbent  68  secured in the crotch portion  24 , over the outer cover layer  12  and parts of the front and back layer elements  19 ,  21  of the body side layer  14 . The width of the secondary absorbent  68  is sized in relation to the width of the crotch portion  24 . Preferably, the width of the secondary absorbent  68  is at least the width of the crotch portion  24  between the crotch elastics  51 . More preferably, the width of the secondary absorbent is equivalent to the overall width of the crotch portion  24 . 
     The secondary absorbent  68  should have sufficient capacity to absorb any flow or seepage of body fluid around or through the primary absorbent  66 . The secondary absorbent  68  should preferably have a capacity and thickness substantially less than that of the primary absorbent  66 , thus providing a nonbulky and flexible fit. The secondary absorbent  68  should have a total capacity of about one-half the capacity of the primary absorbent  66 . Preferably, the secondary absorbent  68  should have a total capacity of at least about 3 grams and not more than 6 grams. More preferably, the total capacity of the secondary absorbent  68  should be from about 4 grams to about 6 grams. However, the basis weight of, or the type of, the secondary absorbent  68  should be selected to provide resistance to flexibility of less than around 400 grams, as measured by INDA Standard Test method IST 90.3-92 Standard Test Method for Handle-O-Meter Stiffness of Nonwoven Fabrics. 
     The secondary absorbent has a low stiffness. The low stiffness allows the absorbent and its barrier to remain attached to the conformable outer cover layer  12  and the body side layer  14  which conform to a wide range of body sizes and shapes. Preferably, the secondary absorbent has a stiffness of less than 400 grams along any axis tested, more preferably less than 300 grams along any axis and less than 100 grams along the axis parallel to the waist opening. The secondary absorbent alone will have a stiffness of less than 250 grams and preferably less than 100 grams along any axis and more preferably less than 75 grams along the axis parallel to the waist opening. 
     The overall length of the secondary absorbent  68  should be adequate to extend beyond the ends of the primary absorbent  66 , in order to be properly positioned to receive liquid which flows or seeps around the edges of the primary absorbent  66 . This overall length is typically at least about 15 inches (382 mm) thus extending beyond the crotch portion  24  along the longitudinal centerline A-A of the subassembly  10 . The length should be in the range of about 15 inches (382 mm) to about 19 inches (484 mm). Preferably, the length of the secondary absorbent  68  is about 17 inches (433 mm). 
     The width of the secondary absorbent  68  beyond the crotch portion  24  should be at least as wide as the width of the crotch portion  24 . The width of the secondary absorbent  68  may be narrowed beyond the crotch portion  24  but may thus compromise the containment of liquid flowing or seeping from the primary absorbent. More preferably, the width outside the crotch portion is wider than in the crotch portion, and is from about 5 inches (127 mm) to about 12 inches (306 mm), alternatively from about 5.5 inches (140 mm) to about 7.5 inches (191 mm). Preferably, the width is about 6.5 inches (165 mm). 
     Referring to  FIGS. 2 ,  3 , and  4 , the waist elastics  40 , the body elastics  64 , and the leg elastics  48 ,  50 ,  51  are generally covered by the front and back layer elements  19 ,  21  of the body side layer  14 . 
     Both outer cover layer  12  and body side layer  14  are compliant and soft feeling to the wearer. The following description of materials from which the outer cover layer  12  can be made applies equally to the material of the body side layer  14 . 
     The outer cover layer  12  may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness. Outer cover layer  12  may be made from a wide range of materials, such as natural fibers (e.g. wood or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers) or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. The outer cover layer  12  may be woven, nonwoven such as spunbonded, carded, or the like. A suitable outer cover layer  12  is carded, and thermally bonded by means well known to those skilled in the fabric art. Alternatively, the outer cover layer  12  is derived from a spunbonded web. In preferred embodiments, the outer cover layer is spunbonded polypropylene nonwoven with a wireweave bond pattern having a grab tensile of 19 pounds as measured by ASTM D1682 and Do, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM Do and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method To. Such spunbonded material is available from Kimberly-Clark Corporation, Roswell, Ga. The outer cover layer  12  has a weight of from about 0.3 ounce per square yard (osy) to about 2.0 osy, preferably about 0.7 osy. 
     The position and shape of the leg openings  44 ,  46  are important to avoid tightness in the crotch and groin area of the wearer, to obtain adequate buttocks coverage, and to prevent the panty  25  from tilting forward, e.g. tilting such that the front waist edge dips lower in relationship to the back waist edge.  FIGS. 1 and 2  illustrate the most preferred design for leg fit and buttocks coverage. The shape of the curve across the top of the leg is important. If the curve is too deep, the panty  25  will shift downward and backward resulting in a short front waist, increased back length and bagginess in the seat of the panty. This would cause the panty  25  to appear tilted when worn as evidenced by an unevenness around the waist of the wearer. 
     Thus, the majority of the front leg edge portion  70  of the front portion of each leg opening  44 ,  46  is defined by a straight section  72  having a length “L 2 ” at least about 70% of the length “L 3 ” of the entire front leg edge portion  70 . The straight section  72  should form an angle with the centerline A-A of between about 75 degrees and about 100 degrees, and most preferably about 90 degrees. 
     With the panty subassembly  10  laid out flat as in  FIG. 1 , the majority of the back leg edge portion  74  of the back portion of each leg is defined by a straight section  76  having a length “L 4 ” at least about 70% of the length “L 5 ” of the entire back leg edge portion  74 . The straight section  76  forms an acute angle with the longitudinal centerline A-A of the subassembly  10 . More preferably, the straight section  76  of the back leg edge portion  74  forms an acute angle α with the centerline A-A of the panty  25  of between about 50 degrees and 65 degrees and most preferably about 60 degrees. 
     The majority of the edge  78  of the crotch portion of each leg opening  44 ,  46  is defined by a straight section  80  having a length “L 6 .” Preferably, the straight sections  80  are straight for at least about 70% of the entire lengths “L 7 ” of the respective edges  78 . 
     Each back leg edge portion  74  includes an arcuate section “A 1 ” extending from one end  81  of the respective straight section  76  to a second end  82  connecting the respective back leg edge portion. 
     Each front leg edge portion  70  includes an arcuate section “A 2 ” extending from one end  84  of the respective straight section  72  to a second end  86  connecting the respective front leg edge portion  70  to the front end of edge  78  of the respective crotch portion. 
     The shape of the arcuate section “A 2 ” at the inner groin area is important. If the arc is too shallow, tightness may be experienced at the inner groin area. 
     The preferred narrow crotch width reduces coverage of the buttocks. To compensate for such reduction, the arcuate section “A 1 ” is preferably adjusted toward back waist portion  22 , such that the end  82  of the arcuate section “A 1 ” should be positioned slightly forward of centerline B-B as shown in  FIGS. 1 and 2 . 
     The waist, leg, and body elastics  40 ,  48 ,  50 ,  64  respectively are attached to the panty subassembly  10 , generally between the outer cover layer  12  and the body side layer  14 , using apparatus and processes described hereinafter. 
     Materials suitable for elastics include a wide variety including but not limited to elastic strands, yarn rubber, flat rubber (e.g. as bands), elastic tape, film-type rubber, polyurethane, and, tape-like elastomer, or foam polyurethane or formed elastic scrim. Each elastic may be unitary, multipart, or composite in construction. 
     Waist elastic  40  is typically about 0.5 inch (13 mm) wide. The elastic may comprise threads, ribbons, a film, or composite. The threads or ribbons may be multiple and may be applied as a composite. Preferably, the waist elastic is threads, more preferably four threads are used as the elastic and the threads are spaced about 0.17 inch (4.3 mm) apart. The threads may be made of any suitable elastomeric material. One suitable material is spandex such as Lycra® threads available from Dupont located in Wilmington, Del. Suitable waist elastics include threads having a total decitex (g/1000 m) of about 3760 for 0.5 inch (13 mm) wide elastic. Adhesive  55  is used to bond the elastic between the outer cover layer  12  and the body side layer  14 . A suitable adhesive includes, for example Findley H2096 hot melt adhesive, available from Findley Adhesives, Milwaukee, Wis. 
     The leg elastics  48 ,  50 , and crotch elastic  51 , including multiple threads in each, are typically about 0.5 inch (13 mm) wide. The elastic may comprise threads, ribbons, a film or composite. The threads, ribbons, etc., may be multiple and may be applied as a composite. The front leg elastics and the crotch elastics may be threads, preferably numbering three threads which are spaced about 0.17 inch (4.3 mm) apart. Back leg elastics numbering up to six threads may have a width of about 0.75 inch (19 mm) and a spacing of about 0.15 inch (3.8 mm) apart. The threads may be made of any suitable elastomeric material. One suitable material is spandex such as Lycra® threads available from Dupont, Wilmington, Del. Suitable leg elastics include threads having a total decitex (g/1000 m) of about 3760 for a 0.5 inch (13 mm) wide elastic. Adhesive  55  is used to bond the several elastics  48 ,  50 , and  51  to the outer cover layer  12 , the body side layer  14 , and the support sheet  53 . 
     To provide a snug leg fit and to draw up the sides of the crotch portion  24  to a cradle to receive the primary absorbent, the leg elastics  48 ,  50 , and the crotch elastics  51 , are elongated when applied to the layers  12  and  14  respectively. Preferably, the leg elastics  48 ,  50  are applied in multiple segments, with the amount of elongation of each segment while being incorporated into the subassembly  10  being determined according to the position to be occupied by the respective segment. In the case of only front and back leg elastics, the front leg elastics are elongated less than the back elastics. In the case of front elastics, back elastics, and crotch elastics, the front and crotch elastics are elongated less than the back elastics. Preferably, the front and crotch elastics are elongated to about 150% and the back elastics along the leg openings are elongated to about 250% The differing tensions allow easier attachment of the primary absorbent pad  66 , less tightness in the groin area, and less bunching of the crotch portion  24  caused by high leg elastic retraction. The back leg elastic is under higher elongation to help keep the seat of the panty from creeping up with movement during use. 
     Referring now to  FIGS. 1 ,  6 , and  7 , the suggested six (back) and three (front) threads of elastic on the respective back and front leg elastics  48  and  50  are each represented as single threads  112  of elastic. The following description of the characteristics and use of the single threads applies to the usual multiple threads suggested above. 
     The composite of the elastics extending about each of the leg openings  44  and  46  comprises a portion of the back leg elastics  48 , a portion of the front leg elastics  50 , and one of the left and right crotch elastics  51 . Referring specifically to  FIGS. 1 ,  6 , and  7 , the back leg elastic  48  extends, as a first section  48 A, from a first locus  92  at or propinquant the edge  28  of the subassembly, width-wise across the subassembly at a substantially consistent acute angle .alpha. with the centerline A-A that takes it toward a first edge of the subassembly at front waist portion  18 , and generally following the back leg edge portion  74  of the leg opening  46  along the straight section  76 A and onto the first arcuate section “A 1 ” toward the crotch portion  24 , generally terminating in the first arcuate section “A 1 ,” at or near the crotch portion  24 . Back leg elastic  48  extends, as a second section  48 B, from the first arcuate section “A 1 ” across the crotch portion to the second arcuate section “A 1 .” From the second arcuate section “A 1 ,” the back leg elastic  48  extends, as a third section  48 C, at an acute angle .alpha. with the centerline A-A away from the front waist portion  18 , and generally following the back leg edge portion  74  of the leg opening  44  along the straight section  76 B to a second locus  94  at or propinquant edge  34 . In the flat configuration shown for the subassembly in  FIGS. 1 ,  6 , and  7 , sections  48 A and  48 C are elongated 250%, while section  48 B is relaxed, and under no substantial elongation. Preferably, section  48 B includes a modest amount of slack in the elastic. 
     The front leg elastic  50  extends, as a first section  50 A, from a third locus  96  at or propinquant the side edge  26  of the subassembly width-wise across the subassembly and generally following the front leg edge portion  70  along its longitudinal straight section  72 A, and onto the first arcuate section “A 2 ” toward the crotch portion  24 , generally terminating in the first arcuate section “A 2 ,” at or near the crotch portion  24 . Front leg elastic  50  extends, as a second section  50 B, from the first arcuate section “A 2 ” across the crotch portion to the second arcuate section “A 2 .” From the second arcuate section “A 2 ,” the front leg elastic  50  extends, as a third section  50 C, width-wise across the subassembly and generally following the front leg edge portion  70  along its longitudinal straight section  72 B to a fourth locus  98  at or propinquant side edge  32 . In the flat configuration shown for the subassembly in  FIGS. 1 ,  6 , and  7 , sections  50 A and  50 C are elongated 150%, while section  50 B is relaxed, and under no substantial elongation. Preferably, section  50 B includes a modest amount of slack in the elastic. 
     Thus, in the embodiment seen in  FIGS. 1 ,  2 ,  6 , and  11 , the front and rear leg elastics extend across the width W 1  of the subassembly  10  as one or more continuous threads. 
     The crotch elastics  51  extend generally between the back and front leg elastics  48  and  50 , with respective ends of the crotch elastics generally being disposed at or near the arcuate sections “A 1 ” and “A 2 .” Accordingly, the elastic properties extant about each leg opening result from the combined contributions of the respective back leg section (e.g.  48 A), the respective front leg section (e.g.  50 A), and the respective crotch elastic  51 . 
     The reason for providing leg elastics in multiple sections is at least two-fold. First, using multiple sections of elastics facilitates placing of the elastics on the outer cover layer  12  while maintaining advantageous production speeds. As suggested in  FIGS. 1 ,  8 , and  9 , the subassembly of e.g.  FIG. 1  is made as a sequence of such subassemblies in a continuous web  100 , with the width “W 1 ” of the subassembly disposed in the “with machine” direction of the processing apparatus. In such arrangement, the front and back waist elastics  40 , the front and back body elastics  64 , and the front and back leg elastics  48 ,  50  can all be assembled into the subassembly by appropriate continuous feeding of respective continuous threads of elastics into the processing apparatus in the “with machine” direction while the web  100  continuously advances in the “with machine” direction at a constant speed. 
     Given the orientation of the crotch elastics at essentially 90 degrees to the direction of advance of the web  100 , placing the crotch elastics as a portion of a continuous element of either the front or back leg elastics would suggest either (1) momentarily and regularly stopping the advance of the web  100  while the crotch elastic is fed into place, or (2) severely slowing the web  100  and severely driving an elastics guide, in a direction transverse to the web in order to apply the crotch elastic while the web was thus slowed. In either scenario, severe stresses would be placed on the respective drive apparatus, as well as on the web. The invention contemplates, rather, that the crotch elastics are placed in the subassembly  10  as a separate operation placing separate elastics segments, where the crotch elastics segments are first elongated and oriented transverse to the web  100 , and are then placed on the web as the web passes the appropriate operating station (not shown) subsequent to placing the leg, body and waist elastics in the subassembly, though the sequence of placing the elastics is not critical. 
     Referring now to  FIGS. 8 and 9 , a first continuous web, which ultimately becomes cover layer  12 , is pressed against the assembly roll  102  by turning roll  104 . A second continuous web, which ultimately becomes body side layer  14 , passes under adhesive applicator  106  and over turning rolls  108  and  110 , and is pressed against the assembly roll  102  by turning roll  110 . Elastic threads  112  are fed from a continuous supply  114  of elastic thread through feed nip  116 , through thread guides  118  and sets of guide fingers  120 A and  120 B, and between cover layer  12  and body side layer  14  at the nip formed by assembly roll  102  and turning roll  110 . 
     Referring especially to  FIGS. 10 and 11 , thread guides  118  and corresponding sets of guide fingers  120 A and  120 B are elements of lateral guides  122 A and  122 B respectively. Each of the lateral guides  122 A and  122 B is mounted on a transverse slide bar  124  for sliding transverse to the with machine direction of travel of the webs. Each lateral guide  122  is connected to a transverse drive mechanism  126  including linkage arms  128  and  130 , vertical drive shaft  132 , and a cam follower. The cam followers follow the corresponding cams inside the respective cam housings. The cams are linked to the machine drive shaft  140  by drive belt  142 . Thus, the cams, and correspondingly the thread guides and the sets of guide fingers, move transversely with respect to the with machine direction of the webs as the drive shaft turns. The end result is that rotation of the processing line drive shaft  140  effects transverse motion of the thread guides and the sets of guide fingers, as indicated by the arrows in  FIG. 10 , in cooperation with the design of the cams and cam followers. 
     Referring to  FIG. 8 , the guide fingers  120  are positioned close to the nip  144  so that they closely control the transverse positions of the elastics with respect to the webs  12  and  14  as the webs  12  and  14  enter the nip  144  and correspondingly trap the elastics between them, fixing the position of the elastics between them by means of adhesive  55 . Accordingly, the guide fingers  120  are preferably physically positioned, and provide guidance to the threads of elastic, within one inch of the nip  144 . To the extent the fingers can be placed closer to the nip  144 , they provide more positive guidance to the elastic. By careful design of the guide fingers  120 , and by careful control of the positioning of the guide fingers  120  with respect to nip  144 , the guide fingers  120  can be advantageously positioned within 0.5 inch of the line of contact defined at the nip between roll  102  and  108 . 
     The limitation on how close the guide fingers  120  can be placed to the nip is controlled by the ability to design fingers which can affirmatively guide the threads of elastic while avoiding having the fingers themselves drawn into the nip. The criticality of urging the fingers as ultimately close as possible to the nip can be attenuated by directing the threads  112  onto the adhesive-coated layer  14  ahead of nip  144 , preferably instantaneously ahead of the nip  144 , as suggested by the depiction in  FIG. 8 . By directing the threads of elastic onto layer  14  ahead of the nip, the open distance spanned by the threads between the fingers  120  and the adhesive-coated layer  14  is minimized, being held to less than 0.5 inch, for example 0.25-0.375 inch (6 mm to 10 mm). 
     The transverse movement of the lateral guides  122 , and thus fingers  120 , as the webs advance along the processing line, creates transverse positioning of the elastics threads  112  with respect to the with machine direction of the advancing webs  12  and  14 .  FIG. 11  shows the pattern of transverse movement of the sets of guide fingers  120 A and  120 B relative to the movement of the web in the with machine direction, along the processing line. In  FIG. 11 , the sets of fingers  120 A and  120 B are depicted at several locations along the front and back edges of the leg openings  44 ,  46 , to indicate that it is the positioning of the sets of fingers  120 A and  120 B, and the dynamic changing of that positioning by the drive mechanism  126 , that determines the instantaneous transverse location of the elastics in the web at any point and time while the elastics are being placed in the web at nip  144  as shown in  FIGS. 8-11 . Comparing  FIGS. 1 ,  10 , and  11 , it is seen that the set of fingers  120 A generally places the threads of the back leg elastics generally parallel to each other in the web, while the set of fingers  120 B generally places the threads of the front leg elastics generally parallel to each other in the web, both along their respective portions of the designed paths defining the front leg edge portion  70  and back leg edge portion  74  of the leg openings  44  and  46 . The threads of elastic deviate slightly from their parallel relationships with each other as the elastic threads traverse paths that deviate from the with machine direction, the distance between the threads  90  being generally constant as they emerge from the fingers  120 . Such deviations from the parallel, resulting from the cross machine traverse of the elastics, are included herein within the phrase “generally parallel” as respects the relationships of the threads of elastic to each other. 
     It will be understood that  FIG. 11  represents only one panty in the continuous sequence of panty subassemblies  10  contained in the web  100  passing through nip  144 . It will also be understood that the web passing through the nip  144  is further acted upon at cutter  146  to cut away material from the web  100  in creating the leg openings  44  and  46 . 
     In general, then, webs  12  and  14  are provided as substantially endless rolls from unwind stands (not shown). Web  14  is typically provided as front and back layer elements  19  and  21 . Space  23  separates the elements  19  and  21 , and generally corresponds with the crotch portion and the portion of the web  12  which is cut out to form leg openings  44  and  46 . Adhesive  55  is applied to the front and back elements  19  and  21  of web  14  by adhesive applicator  106 . Webs  12  and  14  are joined adhesively, with elastic threads being interposed between webs  12  and  14  at nip  144 , and with space  23  interposed between the front and back elements  19 ,  21  of the body side layer  14 . The transverse positions of the elastics change according to a pre-set path of transverse movements, driven by the drive shaft  140  which drives and times the several operations along the processing line. The threads of elastic  112 , as placed by the guide fingers  120 , traverse respective paths that ultimately follow the front and back edges of the leg openings  44  and  46 , as defined at cutter  146 , in registration with the advance of the web, and accordingly, with the advance of the series of panty subassemblies  10  being defined in the web at nip  144  and cutter  146 . The portions of the threads of elastic located along the front and back edges of the leg openings are stretched. The portions traversing the crotch portion are relaxed. The crotch portions of the elastic are separately placed in the subassembly  10  at a later processing station, preferably downstream from the cutter  146 . 
     A second embodiment of the subassembly is illustrated in  FIG. 12 . In the second embodiment, the front edge  148  of back layer element  21  is disposed rearwardly of that same edge  148  as depicted in the embodiment of  FIG. 10 , while the guide fingers  120 A traverse the same path as in  FIG. 10 . Accordingly, as the threads of elastic  112  extend across the crotch portion  24 , the threads  112  are guided forwardly of edge  148 , into space  23 , and are thus not held between the layers  12  and  14 , and thus are not controlled by the adhesive on layer  14 . Rather, the tension is maintained on the threads of elastic  112  across the crotch portion  24 , such that the threads retract along the edge  148  of the layer element  21  in a configuration that loosely resembles a rope under tension. The rope is subsequently cut such that the cut portions of the threads retract to positions generally defined by the intersection of the edge  148  of the back layer element  21  and the path of the threads adhesively held between layer  12  and the back layer element  21 . Thus, the threads  112  generally include loose intermediate ends  150  after being cut, as shown in  FIG. 7 . 
     Body elastics  64  and waist elastics  40  can be incorporated at nip  144  in the conventional manner of providing stationary feeds and guides at the nip. 
     In another embodiment of the invention shown in  FIG. 13 , a section of web processing equipment  297  is shown including a drive side DS and an operator side OS. As generally shown, a plurality of elastic threads  212  are attached to a stain shield or secondary absorbent web  267 , and the secondary absorbent  267  and attached elastic threads  212  are cut to create a plurality of stain shields  268  having respective elastic pieces or sections  251 A attached thereto. The elasticized stain shields  268  are maneuvered as shown and attached to a garment web  201  to form a garment blank subassembly. This garment blank subassembly is similar in many ways to the embodiments described above; therefore, only certain features of this embodiment are described below for the sake of brevity and reference is made to the foregoing descriptions for like or similar components of the garment blank subassembly to enable this aspect of the invention. 
     With more particular reference to  FIG. 13 , the processing equipment  297  supplies the plurality of elastic threads  212  from an elastic thread roll  214  generally in a machine direction MD. The elastic threads  212  are routed by a series of guide rollers G in a known manner and are attached in a stretched condition in a non-machine direction (NMD) in this example to the secondary absorbent web  267  using an adhesive  255 A. As shown, the adhesive  255 A is applied intermittently to the elastic threads  212  by a plurality of applicators  206 A to form a plurality of adhesive gaps  213  along the elastic threads  212 . The cutter  246  cuts the secondary absorbent web  267  into the stain shields  268  at each adhesive gap  213 . As further shown, the stain shield  268  the resultant sections  251 A are attached to a first or inner side  268 B, which opposes a second or outer side  268 A discussed further below. 
     The exemplary cutter  246  shown in  FIG. 13  is a roller cutter having a plurality of blades  246 A,B attached thereto for cutting the elastic sections  251 A at the adhesive gaps  213  as discussed above. The cutter  246  is controlled by a controller  299  disposed on the operator side OS of the processing equipment  297  in this example. Those skilled in the art will instantly recognize that the controller  299  can be a computer or a programmable logic controller, which can be programmed to cut the elastic threads  212  at the adhesive gaps  213  based on a passage of time or a sensed length of passing elastic threads  212  to create the sections  251 A. As shown, each end of each section  251 A, which formed the gaps  213  in the elastic threads  212  before the elastic threads  212  were cut, retract after being cut to create a retraction area  268 C on the outer side  268 B. In this example, the sections  251 A are from about one (1) inch to about three (3) inches in length. 
     As further shown in  FIG. 13 , a second adhesive applicator  206 B applies a second amount of adhesive  255 B to the outer sides  268 B of the stain shields  268 . As shown, a plurality of applicator assembly segments  297 A-D subsequently maneuver or rotate the adhesive coated stain shields  268  transverse to the machine direction MD. As further shown, the applicator assembly segments  297 A-D affix the adhesive coated outer sides  268 B and the underlying elastic sections  251 A to the garment web  201  with the inner sides  268 A facing upward or outward from within a crotch area or portion  224 . As shown, the inner sides  268 A are located between a plurality of garment elastics  251 B. In this manner, the individual elastic sections  251 A are rapidly manipulated, positioned and attached to the crotch area  224  without having to maneuver the entire garment web  201  and/or cut the elastic threads  212  and apply the elastic sections  251 A to the crotch portions  224  through acute angles at high machine speeds. 
     Wherever herein this teaching refers to “multiple” elements, e.g. multiple threads of elastic or multiple paths of traverse, any two or more such elements are included. 
     Having thus described the invention in full detail, it will be readily apparent that various changes and modifications may be made without departing from the spirit of the invention. All such changes and modifications are contemplated as being within the scope of the present invention, as defined by the following claims.

Technology Category: y