MXPA01000285A - A process for making a shaped product with no material waste - Google Patents

Abstract

A distinctive technique for creating a shaped article (90, 100) includes a pivoting of a first portion (56) of a cooperating web layer (26) substantially about a first joining region (40) to lie laterally adjacent to a first portion (52) of a primary web layer (24). The cooperating web layer (26) has been positioned in a superposed facing relation with the primary web layer (24) with the primary web layer having a first and second, lateral side edge regions (32, 34), and the cooperating web layer having third and fourth, lateral side edge regions (36, 38). The first side edge region (32) of the primary web layer (24) has been synchronized to the third side edge region (36) of the cooperating web layer (26) along the first joining region (40), and the second side edge region (34) of the primary web layer (24) has been synchronized to the fourth side edge region (38) of the cooperating web layer (26) along a second joining region (42) to provide a synchronized laminated web (44). The laminated web has been separated along a serpentine division line (46) to provide a first composite web (48) and at least a second composite (50). The first composite web (48) has the first portion (52) of the primary web layer (24) combined with the first portion (56) of the cooperating web layer (26), and the second composite web (50) has a second portion (54) of the primary web layer (24) combined with a second portion (58) of the cooperating web layer (26).

Description

A PROCESS TO MAKE A PRODUCT FORMED WITHOUT ANY WASTE MATERIAL Field of the invention The present invention relates to a method and an apparatus for making a formed article. More particularly, the invention relates to a method and apparatus for making an article formed more efficiently while reducing the amount of waste material.

BACKGROUND OF THE INVENTION Conventional articles, such as fabrics and associated products, have been prepared by forming the fabric and then cutting selected portions to form the desired shapes and contours on opposite, lateral sides of the fabric. Other techniques have included cutting a leaf into two elongated tissues so that one edge of each tile is straight and the other edge has alternating concave and convex parts. The fabrics have been fixed to each other or to a lower sheet impervious to water so that the parts of the straight edge thereof are facing each other and the alternating concave and convex parts face outwards. xa? ** ** * '"*' * yy- .r? $ *. '*' \ * shaped item having side contours with a repeat pattern of multiple segments in which the pattern includes two or more different pattern segments. As a result of this, conventional techniques have not been sufficiently capable of efficiently producing the individual shaped articles which are not symmetrical along their lengthwise directions.

BRIEF DESCRIPTION OF THE INVENTION The present invention provides a distinctive process for creating a shaped article, such as the fabric formed representatively shown. Stated generally, the technique of the invention includes a pivoting of a first portion of a layer of tissue cooperating substantially around a first attachment region lying laterally adjacent a first portion of a primary tissue layer. The cooperating tether layer has been placed in an overlying relationship with the primary fabric layer with the primary fabric layer having a first and a second side edge regions, and the cooperating fabric layer having a third layer. and a fourth regions of lateral side edges. The first lateral edge region of the primary tissue layer has been synchronized with the third lateral edge region of the cooperating tissue layer along the first attachment region, and the second lateral edge region of the tissue layer. primary has been synchronized with the fourth side edge region of the cooperating tissue layer along a second joining region to provide a synchronized laminated fabric. The laminated fabric has been separated along a serpentine division line to provide a first composite fabric and at least one second composite fabric. The first composite fabric has the first part of the first fabric layer combined with the first part of the cooperating fabric layer, and the second composite fabric has a second part of the primary fabric layer 10 combined with a second part of the fabric. layer of cooperative tissue.

In a distinctive aspect of the apparatus of the invention, an apparatus for creating a shaped article can to include a positioning mechanism for placing a cooperating layer in a superposed front face with a primary tissue layer. The primary tissue layer has a first and a second lateral side edge region, and the cooperative tissue layer has a third and a fourth regions of lateral side edges. A coordinating mechanism synchronizes the first edge region of the primary tissue layer with the third edge region of the cooperating tissue layer along a first joining region, and synchronizes the second edge region of the primary tissue layer with the fourth edge region of the cooperating tissue layer along the length of a second joining region to form a laminated fabric synchronized A splitter mechanism separates the laminated fabric along a serpentine dividing line to provide a first composite fabric and at least one second composite fabric. The first composite fabric has a first part of the primary fabric layer combined with a first part of the cooperative tissue layer, and the second composite fabric has a second part of the primary fabric layer combined with a second part of the primary layer. cooperative tissue. A relocation mechanism pivots the first part of the cooperating tissue layer substantially around the first attachment region to rest laterally on one side of the first portion of the primary tissue layer.

A further aspect of the technique of the invention may include a pivoting of the second part of the co-operating layer substantially co-operatively around the second attachment region to rest laterally on one side of the second part of the primary tissue layer. .

In its various aspects and configurations, the present invention can produce a desired shaped and contoured article at high speeds and can produce the shaped article with a side contour having a periodically repeated pattern in which each individual repeated pattern section or cycle has for at least two different pattern segments. The present invention can produce Advantageously individual shaped articles which are not substantially symmetrical along their longitudinal directions, and long. Therefore, the present invention can generate the individual shaped articles having 5 longitudinally opposite end sections that are dissimilar and distinctly different, while also reducing the amount of waste material. In particular aspects, the techniques of the invention can produce the desired shaped articles while substantially generating zero waste of the tissues of selected components.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention may be more fully understood and additional advantages may be apparent by reference to the following detailed description and the accompanying drawings in which: Figure 1 representatively shows a "schematic view 20 of the process and apparatus of the invention; Figure 2 shows a representative isometric view of the method and apparatus of the invention in the region where the synchronized laminated fabric is formed cor clamping connection, and where a cutter generates the line of «A-« a si, Aa * xi, £ MBHK? E &rTJlß < & . -. "». . .- '' ". r -. «^ f * - * -'.- __g- * gj. gfeggf ^ desired serpentine division to form a pair of composite tissues; Figure 3 representatively shows a pivoting and an unfolding of the individual composite tissues of Figure 2 to form their corresponding contoured tissues; Figure 3A representatively shows a side cross-sectional view of the tissue taken along the line 3A-3A of Figure 3; Figure 4 representatively shows a connector member which is interposed between a lateral edge region of the primary tissue layer and a lateral edge region of the cooperating tissue layer along its corresponding joining region to synchronize the region from the edge of the primary tissue layer to the edge region of the cooperating tissue layer with an indirect fastening; Figure 4A representatively shows a cross-sectional view of the joining region of the resultant contoured tiaj after a portion of the cooperative weave layer has been pivoted about the joining region of Figure 4 to place the connecting member between 'the fastened parts of the layers of cooperative and primary tissue; Figure 5 representatively shows an expanded view of another system of the connecting members which are interposed between a lateral edge region of the primary tissue layer and a region of the lateral edge of the cooperative tissue layer 5 along its corresponding region of region for synchronizing the edge region of the primary tissue layer with the edge region of the cooperating tissue layer with an indirect fastener; Figure 5A representatively shows a side cross-sectional view of the union region of the resulting contoured tissue after a portion of the layer of cooperating tissue has been pivoted about the joint region of Figure 5 to place the limbs. connectors between the clamped portions of the layers of cooperative and primary tissue; Figure 6 representatively shows a siete of connector members which are bent in a form of C which is concave in the outer direction laterally, and which are located in each of the designated joint regions; Figure 6A representatively shows a unitary connector member which extends across the width | ^ fi ^ .. W t **. .. **** ",. *. ^ Longitudinally with pattern segments which are substantially non-symmetrical along their lengths in the machine direction, longitudinal; Figure 9 representatively shows the operation of a relocating mechanism which provides the desired pivoting around the designated joint regions, and the operation of a selecting mechanism which divides the contoured tissue into a plurality of shaped articles; Fig. 10 representatively shows an isometric view of a configuration which synchronizes the layers of cooperative and primary tissue without an indirect direct bonding of the primary tissue layer to the cooperative tissue layer, and which employs a cutter to generate the desired serpentine division line; Figure 11 representatively shows a pivoting and unfolding of the individual composite tissues of Figure 10 to form their corresponding contoured tissues; Figure HA representatively shows a cross-sectional view taken along line 1A-HA of Figure 11; - * • # * & $ £. -gfiÉÉaigfc sitf:,. * - ^ -. and ... - ^ ^ ^ ^ ^ ^ ^ ^ ^ fafej, Figure 12 shows representatively a schematic view of contoured tissues in which the associated parts of the layers of cooperative and primary tissue are spaced and separated by a selected distance at length of the lateral transverse direction; Fig. 13 representatively shows a configuration of the invention which assembles a complementary tissue layer between a part of the cooperating tissue layer and a part of the primary tissue layer to provide a composite contoured tissue; Figure 13A representatively shows a cross-sectional view of the contoured tissue taken along line 13A-13A of Figure 13; Figure 14 shows an isometric view representative of a configuration of the invention in which the synchronized laminated fabric is formed of a tubular member, and The cutter generates the desired serpentine dividing line to form a pair of substantially composite seamless fabrics; Figure 14A representatively shows a cross-sectional and side view of the tubular member; 25 Fig. 14B representatively shows a cross-sectional and side view taken along line 14B-14B of Fig. 14; Y Figure 15 representatively shows a pivoting of the tops of the composite fabrics of Figure 14 around the edge regions bent to laterally rest on one side of the bottoms of the composite tissues to form the contoured tissues, and 10 division of the contoured tissues along their transverse directions to form the individual shaped articles.

DETAILED DESCRIPTION OF THE INVENTION With reference to FIGS. 1, 2 and 3, a distinctive technique 20 for making a desired shaped article, such as the contoured fabric shown representatively 90, includes a pivoting of a first portion 56 of a fabric layer. cooperator 26 substantially around a first joining region 40 for laterally resting on one side of a first portion 52 of a primary tissue layer 24. The layer of cooperating tissue 26 has been placed in a front and superimposed relationship with the outer layer. primary tissue 24 with said primary tissue layer 24 having a first and a second, lateral side edge regions 32 and 34, and the layer of cooperative tissue 26 having a third and a fourth lateral side edge regions 36 and 38. The first side edge region 32 of the primary fabric layer 24 has been synchronized with the third side edge region 36 of the cooperative fabric layer 26 as along the first junction region 40, and the second lateral edge region 34 of the primary tissue layer 24 has been synchronized with the fourth lateral edge region 38 of the cooperative tissue layer 26 along a second region. 42 to provide a synchronized laminated fabric 44. The fabric laminate 44 has been separated along a serpentine dividing line 46 to provide a first composite weave 48 and at least a second composite weave 50. The first composite weave 48 has the first part 52 of the primary weave layer 24 combined with the first part 56 of the layer of cooperating tissue 26, and the second composite fabric 50 has a second portion 54 of the primary tissue layer 24 combined with a second portion 58 of the cooperative tissue layer 26.

In another aspect of the invention, a pivoting of? a second part 58 of the layer of cooperating tissue 26 around the second joining region 42 can be configured to provide a second contoured tissue 92. In still other aspects, the technique of the invention can further include a sectioning of the first contoured tissue in a plurality of 25 individual formed articles 100. In a more particular aspect, the technique can divide the first contoured tissue 90 into a plurality of shaped articles, individual 100 cilia are longitudinally non-symmetrical.

A distinctive apparatus for creating the desired formed article 5 may include a positioning mechanism, such as that provided by the master rolls 78, which place a layer of cooperative tissue 26 in a front relation and superposed with a primary tissue layer 24. The primary tissue layer 24 has the first and second edge regions of side sides 32 and 34, and the cooperating fabric layer 26 has a third and a fourth lateral side edge regions 36 and 38. A coordinating mechanism 80, such as that provided by the direct coupling joints shown representatively at the point 98, synchronizes the first shore region 32 ce la primary tissue layer 24 with the third edge region 36 of the layer of cooperating tissue 26 along a first joining region 40, and synchronizes the second edge region 34 of the first fabric layer 24 with the fourth region of edge 38 of the layer of cooperative tissue 26 along a second region of joint 42 to thereby form a synchronized laminated fabric 44. A splitting mechanism, such as that provided by a cutter 82, separates the laminated fabric 44 along a serpentine dividing line 46 to provide a first composite fabric 48 and at least one second composite fabric 50. The The first composite fabric 48 has a first portion 52 of the primary tissue layer 24 combined with a first portion 56 of the , • - • *. - > -, »• * §Ífi || ^ g ^ • * * ¿& i% ^^ ^ layer of cooperative tissue 26, and the second composite fabric 50 has a second part of the primary tissue layer 24 combined with a second portion 58 of the cooperating teat layer 26. A relocation mechanism, such as that provided by a bending device 84 , pivots the first portion 56 of the cooperating tissue layer 26 substantially around the first attachment region 40 to lie laterally on one side of the first portion 52 of the primary tissue layer 24 to form a first contoured tissue 90. Therefore, the first contoured tissue may be operatively supplied by a side-by-side, generally adjacent combination, which moves simultaneously, and cooperates with the first portion 56 of the layer of cooperating tissue of the first layer portion 52 of primary tissue.

Another aspect of the invention may include a second relocation mechanism which provides a pivoting of the second portion 58 of the cooperating tissue layer 26 substantially around the second attachment region 42 to lie laterally on one side of the second portion 54 of the primary tissue layer 24 to form a second contoured tissue 92. Therefore, the second contoured tissue can be provided operatively by a side-by-side, generally adjacent, combination that moves simultaneously, and cooperating with the second part 58 of the co-operating layer and the second part 54 of the primary woven layer.

In additional aspects, the invention may include a disconnector mechanism 83 which divides the first and / or second contoured tissues into a plurality of individual, formed articles 100. In a more particular aspect, the technique may divide the designated contoured tissues 90. and / or 92 in a plurality of individual, formed articles 100 which are not longitudinally symmetrical.

It should be noted that in parts of the present description it can be particularly mentioned the manner in which the various aspects of the invention may be related. to the first composite fabric 48. However, it should be readily appreciated that the same discussion and description is also attempted to apply to the manner in which the various aspects of the invention can be related to the second composite fabric 50 in an appropriate corresponding context.

In addition, the method and apparatus of the invention can be configured to produce the individual shaped articles 100 which are substantially symmetrical along their longitudinal extensions with medial, longitudinally opposite portions of each article formed being substantially images identical to each other. Desirably, the technique of the invention can be configured to produce the articles individual 100's which are not substantially symmetrical along their longitudinal extensions.

It should be noted that the present disclosure can mention the manner in which various aspects of the invention can be employed to construct a particular shaped article. It should be appreciated that the present invention can be employed to construct a particular component or subset of a more complex article. So, the contoured fabrics 90 and 92 or the formed article, individually 100 can further be assembled to or otherwise be combined with other components, as desired. Additionally, it should be appreciated that either or both layers of primary tissue 24 and the layer of cooperative tissue 26 may be a composite fabric, which is constituted of a predetermined plurality of sublayers or sub-components, as desired.

With reference to figure 1, an appropriate conveyor mechanism, such as that provided by the system illustrated of the transport rollers 64, is constructed and arranged to move and direct a continuous primary fabric layer 24 along a designated machine direction 28. The primary fabric layer is supplied at a predetermined speed from a supply appropriate it the primary tissue layer, such as that provided by the illustrated supply roll 62 or other accumulation of bulking storage of the material. For the purposes of the present invention, machine operation 28 is the direction along which a particular component or material is longitudinally transported along and through a particular local position of the apparatus and method of operation. the invention. In the configuration shown, for example, the primary tissue layer 24 can be supplied and transported throughout the apparatus and the process towards the location of an operative fastening device, such as the system shown representatively of the applicators. of adhesives 94.

A conventional tissue guide mechanism can be used to control the placement of the tea layer: primary 24 along a transverse direction 30 of the process. For purposes of the present invention, the transverse direction 30 lies generally within the plane of the material that is being transported through the process and is aligned perpendicular to the machine direction 28. Therefore, in In the view of the arrangement representatively shown in Figure L, the transverse direction 30 extends perpendicularly to the plane of the drawing sheet.

The primary tissue layer 24 can be composed of various materials, such as polymer films, non-woven fabrics, foam layers, fabrics fibrous placed by air, carded and bound tissues, tissues joined through air, and the like, as well as the combination thereof. The primary fabric layer may be composed of synthetic materials, natural materials, or combinations thereof. In the configuration shown representatively, the primary tissue layer 24 is composed of a non-woven fabric. For example, the first fabric may be a non-woven fabric or other yarn-linked fabric which includes synthetic polymer fibers, such as fibers composed of polyethylene, polyester, polypropylene, or combinations thereof. In other configurations, the primary tissue layer may be composed of a binder which includes the cellulosic fibers.

An appropriate transport mechanism, such as that provided by the illustrated system of the transport rollers 68, is configured to supply and move]: a layer of continuous cooperating fabric 26 substantially along the designated machine direction 28. The layer of tissue Cooperator is supplied at a predetermined speed from an appropriate supply of the cooperating fabric layer, such as is provided by the illustrated supply roll 66 or other bulking storage accumulation of the material. A conventional tissue guide mechanism can be employed to control the placement of the primary tissue layer 24 along a transverse direction 30 of the process.

The cooperative tissue layer 26 may also be composed of various types of materials, such as; polymer films, non-woven fabrics, foam layers, fibrous fabrics placed by air, carded and bonded fabrics, fabrics bonded through air, and the like, as well as the combination of the same. In particular aspects of the invention, the process and apparatus can be constructed to provide the cooperating tissue layer and / or primary in a configuration which is substantially impermeable to liquid. In another aspect, the process and apparatus may be arranged to provide the cooperative and / or primary beam layer in a configuration which is permeable to air and has the ability to breathe. A positioning mechanism, as provided by the system shown by the steering rollers 78, operatively locates and transfers the cooperating tissue layer, in motion 26 in a face-to-face relationship. , and superimposed with the primary tissue layer, which moves 24. At the process and apparatus site where the cooperating tissue layer 26 and the primary tissue layer 24 are operatively brought together for further processing, each one of the layers of primary tissue and tissue are substantially continuously directed along the designated machine direction 28 of the process and the apparatus.

For the purposes of the present invention, a named component region is operatively synchronized with another, the second component region, when the selected 5-component regions are configured. and arranged to move at substantially the same speed and in substantially the same direction. The regions of selected components may or may not be in physical contact with each other during the synchronized condition. Also, the regions of 10 selected components may or may not be fixed with each other during the synchronized condition.

In a particular aspect, the synchronization of the first edge region 32 of the primary tissue layer 24 to the The third edge region 36 of the cooperative tissue layer 26 may include an operative fastening to the first edge region 32 to the third edge region 36 along the first region 40, as representatively shown in Figure 2. Additionally, the synchronization of the second region 0 of the edge 34 of the primary tissue layer 24 with the fourth edge region 38 of the cooperative tissue layer 26 can include an operative fastening of the second edge region 34 to the fourth region. from edge 38 along the second junction region 42. In the configurations shown 5 representatively, for example, the first junction region 40 and the second junction region 42 may each extend. ~ 'z -. Ar '' x • "ZzSz -:. * 'And ~' - 'X- - *" jéíf f substantially longitudinally along the machine direction 28 of the process and the apparatus. The fastening operation can provide a substantially direct fastener 98, or an indirect fastener.

With reference to Figure 2, the synchronization of the first edge region 32 of the primary tissue layer to the third edge region 36 of the tissue layer cooperating with the direct coupling 98 may include a first, substantially permanent fixation to the first edge region to the third edge region along the first joint region 40. Alternatively, synchronization of the first edge region 32 of the primary tissue layer with the third edge region 36 of the tissue layer Cooperator may include a temporary fastening of the first edge region to the third edge region along the first joint region 40.

Similarly, the synchronization of the second edge region 34 of the primary tissue layer to the edge region 38 of the tissue layer cooperating with the direct attachment 98 may include a second, substantially permanent fixation of the second region of edge to the fourth region of the bank along the second junction region 42. Alternatively, the synchronization of the second edge region 34 of the primary tissue layer with the fourth edge region 38 of the cooperating tissue layer can including a temporary fastening of the second edge region to the fourth edge region along the second joint region 42.

The arrangement and configuration of the direct clamping mechanism can be substantially continuous, or it can; be intermittent with a regular or irregular pattern, as required. Additionally, the clamping mechanism can be of any operational type, such as adhesive joints, thermal joints, sonic joints, welds, pins, staples, sewing, knitting and the like, as well as the combinations of them. In the illustrated arrangement, for example, the clamping mechanism includes the adhesive bonds 80 formed through the operation of the adhesive applicators shown 94.

Various types of conventional techniques for depositing or applying, or for forming the synchronized laminate fabric 44 can be employed. For example, techniques for air deposition such as spraying, melt blowing, swirling or the like can be used, as well as the combinations thereof. Alternativame > Therefore, various contact techniques, such as slot adhesive, pearl coating, or photogravure coating on the substrates can be used.

With reference to Figures 4 to 5A, the synchronization of the first edge region 32 of the primary tissue layer to the third edge region 36 of the layer of tissue cooperating with an indirect coupling can, for example, include at least a connector member, provided separately 96 which is interposed between the first side edge region 32 of the primary tissue layer and the third side edge region 36 of the cooperating woven layer along the first attachment region 40. Similarly, another connector member, provided separately 96 can be interposed between the second side edge region 34 of the primary tissue layer and the fourth side edge region 38 of the cooperating tissue layer along the second joining region 42. Each of the connector members extends substantially longitudinally in the machine direction 28 along their corresponding joint region 40 or 42, and may be of equal or unequal size along their transverse directions 30. Members connectors may extend longitudinally in a substantially continuous or discontinuous configuration, as desired, to provide the synchronized laminated fabric 44. In the arrangement of Figure 4, for example, the connector member 96 may be bent into a C-shape which is convex in the laterally exterior direction.

The examples of the configurations of the connector member 96 are shown representatively in FIGS. 6 through 6C. More particularly, Figure 6 representatively shows a pair of connector members 96 which are bent into a C shape which is concave in the laterally outer direction, and are located in each of the joining regions 40 and 42. Additionally, the C-shaped connector member is attached to the lateral surfaces inward of the corresponding portions of the primary tissue layer and the cooperating tissue layer. Figure 6A representatively shows a unitary connector member, of: a piece which extends across the width of the transverse direction of the synchronized fabric 44 and is located in both of the joining regions 40 and 42. Figure 6B representatively shows a pair of connector members provided separately, one of which is located in each joint region. Each connector member is in the form of a sheet layer arranged substantially parallel to the primary and cooperating tissue layers 24 and 26. Figure 6C representatively shows another pair of connector members 96 which are bent into a C shape and They are convex in the laterally outer direction. Each bent connector member is attached to the lateral surfaces outwardly of the primary and cooperating tissue layers 24 and 26 in their corresponding attachment regions 40 and 42.

Referring again to Figures 1, 2 and 3, a selected splitting mechanism 82 can separate the laminated fabric 44 along a serpentine dividing line 46 which extends longitudinally in the machine direction 28 along the length of an intermediate section located 60 of the laminated fabric 44, and undulates laterally side by side with a pattern that repeats periodically and cyclically. The repeating pattern provides a first pattern segment 86, and a second pattern segment, directionally opposite and transverse 88, the which undulates back and forth substantially in a regular pattern that repeats cyclically. The dividing mechanism can be provided by the cutter 82 illustrated. Suitable cutting mechanisms may include die cutters, water cutters, laser cutters or others power beam cutters, and the like, as well as combinations thereof. The serpentine division line can be continuously curvilinear, or it can be composed of an interconnected series of individual straight line parts, or individual arched line parts, as well as the combinations thereof.

Where the technique of the invention is configured to provide individual shaped articles 100, the synchronized tissue 44 can define a plurality Interconnected of the sections of article 101 along the mechanical direction 28, as shown representatively in the ^ .jy ^^^^^ ^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^ FIGURES 7 and 8. More particularly, FIGURE 7 representatively shows a configuration in which the individual shaped articles 100 are intended to have a longitudinal symmetry (with substantially married-shaped piles that combine at the longitudinal ends, and opposite of the article). In an arrangement of Figure 7, the repeating pattern of the serpentine dividing line 46 can provide a first pattern segment 86, and a second longitudinally adjacent pattern segment 88. The second pattern segment 88 longitudinally identical in relation to the pattern segment. first pattern segment 86. Therefore, when observing the individual length dimensions of the two pattern segments along the same machine direction, the second pattern segment 88 is observed as being substantially identical to the first segment. of pattern 86, but it is observed that it is "flipped" in the longitudinal direction, in a manner which provides the arrangement of a substantially identical configuration in the longitudinal direction, as compared to the first pattern segment.

With reference to Figure 8, another aspect of the invention can be configured to provide the article formed with a desired non-symmetry along the machine and longitudinal direction. To provide longitudinal asymmetry, the splitting mechanism can be configured to separate the laminated fabric 44 along a dividing line serpentine, variegated, distinctive 46. The variegated division line, of multiple section 46 extends longitudinally in the machine direction 28 along the indicated midsection 60 of the laminated fabric 44, and undulates laterally on the 5 side with a pattern that repeats itself periodically and cyclically. The repeating pattern provides a first pattern segment 86, and a second pattern segment, longitudinally adjacent 88. The second pattern segment is distinct from the first pattern segment, and is not longitudinally symmetrical with the first pattern segment.

The first pattern segment 86 of the selected variegated poltron has a first return and return return configuration which traverses through a first angle 87, and the second pattern segment 88 of the selected variegated pattern has a second backward and backward Ccimbio configuration which traverses through a second angle 89. The second angle of return change differs from the first return angle, and it can be relatively greater or less than the first angle of the return change. As a result, the variegated dividing line 46 can advantageously provide for the production of individually formed articles having a pair of longitudinally opposed end portions which differ from one another.

With reference to Figures 1 and 9, the various configurations of the invention can include an appropriate relocation mechanism 84 which can operatively pivot either or both of the first and second parts 56 and 58 of the cooperating tissue layer. 26 around the first and second junction regions 40 and 42, respectively. Equivalently, the relocation mechanism can pivot either one or both of the first and second parts 52 and E > 4 of the primary tissue layer 24 around the first and second joining regions 40 and 42, respectively. The relocation mechanism 84 can, for example, be provided by means of a folding board, a splitting board, an air jet system which blows by opening the first and second parts, a vacuum system and opens the first parts. and second, or similar, as well as combinations thereof.

In a particular aspect of the invention, the pivoting of the first portion 56 of the layer of cooperating tissue 26 around the first attachment region 40 to lie laterally on one side of the first portion 52 of the primary tissue layer 24 is configured to provide the first contoured fabric 90 with bilateral symmetry in the transverse direction 30. Similarly, the pivoting of the second part 58 of the layer of cooperative tissue 26 around the second attachment region 42 for lateral rest adjacent to the second portion 54 of the primary tissue layer 24 can be configured to provide the second contoured tissue 92 with bilateral symmetry.

Additionally, the pivoting of the first part 56 of the layer of cooperating tissue 26 about the first joint region 40 can be configured to provide the first contoured fabric 90 with a predetermined longitudinal variation along the machine direction 28. Similarly, the pivoting of the second part 58 of the layer of cooperating tissue 26 around the second joining region 42 can be configured to provide the second contoured tissue 92 with the predetermined longitudinal variation desired. Desirably, the longitudinal variation in the longitudinal direction may directly correspond to at least two different patterned segments 86 and 88 provided in the repeating pattern of the variegated serpentine division line, previously described [46].

The process and apparatus of the invention can provide a synchronization of the primary and cooperative tissue layers 24 and 24 without indirect or direct attachment of the primary tissue layer to the cooperating tissue layer, as illustrated in the figure. 10. Therefore, the coordinating mechanism 80 operatively maintains the primary tissue layer and the cooperating tissue layer along the joining regions 40 and 42 in a manner in which they simultaneously maintain the simultaneous movement desired. ? -in substantially the same speeds and direction. Suitable coordinating mechanisms can, for example, include pairs of pressure point rollers, movable clamps, air jets, pneumatic pressure devices, vacuum suction devices, devices that produce electrostatic attraction, devices that produce magnetic attraction and the like, as well as combinations thereof. The example of the arrangement in figure 10 shows an isometric view representative of a configuration of the invention in which the synchronized laminated fabric is formed without a coupling joint, and a rotary die cutter provides the splitter mechanism 82 which generates the desired serpentine dividing line 46 to form another pair of composite fabrics 48 and 50. Figure 11 representatively shows the pivoting and unfolding of the individual composite tissues, resulting from Figure 10 to form their corresponding contoured tissues 90 and 92.

The technique of the invention can further provide a lateral space of the first part 56 of the layer of cooperative tissue 26 away from the first portion 52 of the primary tissue layer 24 by a discrete space distance 22 along the direction Transverse 30, as it moves representatively in FIGS. 10 to HA. Similarly, the invention can provide a lateral spacing of the The second part 58 of the cooperative tissue layer 26 away from the second portion 54 of the primary tissue layer 24 by a discrete spaced distance 22 along its corresponding transverse direction 30.

As illustrated in FIG. 12, the lateral spacing distance 22 may be introduced after the relocation mechanism 84 has pivoted the first portion 56 of the layer of cooperating tissue 26 around the first region 40 of the primary tissue layer. 24, or after the relocating mechanism has pivoted the second part 58 of the layer of cooperating tissue 26 around the first joined region 42 of the primary tissue layer 24, such as the case. The sectioning mechanism 83 may or may not be employed at this stage to divide the contoured tissues 90 and 92 into the individual shaped articles.

In a further aspect of the invention, a selected contouring pattern can further be processed prior to any sectioning operation in the transverse direction. As representatively shown in Figures 13 and 13A, for example, the contoured fabric 90 can be supplied to an assembly mechanism, such as the mechanism provided by a roller assembly system 74. In the roller assembly, a first layer Complementary provided separately 70 can be placed in one place -..., - .. «a ^. -A ¿£ .. intermediate interposed between the first part 56 of the cooperative tissue layer and the first portion 52 of the primary layer. The first complementary fabric layer 70 has a pair of laterally opposite side edge regions 102 and 104 5 which extend longitudinally along the designated machine direction 28. The first part 56 of the layer of cooperating fabric 26 can or not being clamped or otherwise attached to one side of the edge region 102 of the complementary tissue layer 70, and the first portion 52 of the primary tissue layer 24 may or may not be attached or otherwise attached to another side of the edge region 104 of the first complementary tissue layer to provide a first, contoured composite fabric 90.

Similarly, the second part 58 of the cooperating tissue layer 26 may be laterally spaced away from the second portion 54 of the primary tissue layer 24 by its associated spaced distance 22 along the transverse direction 30, and another layer complementary provided separately can be placed at an intermediate location between the second part 58 of the layer of cooperating tissue and the second part 54 of the primary tissue layer .. The second part 58 of the layer of cooperative tissue 26 may or may not be fastened to its corresponding region from edge to side of the second layer of complementary tissue 72, and the second part 54 of the primary tissue layer 24 may or may not be fastened to its corresponding side edge region of the second layer of complementary tissue to provide a second, contoured compound 92.

As illustrated in FIGS. 3, 12 and 13, each contoured woven article 90 and / or 92 may have a plurality of convex, alternating outer regions 110 and concave outer regions 112. Additionally, in the various configurations of the invention, each tissue item contoured 90 and / or 92 may be divided with the selected disconnecting mecha- nism 83 along its transverse direction 30 to provide a plurality of individual shaped articles 100. Desirably, the convoluted fabric is directionally divided transversely into a plurality of said regions. convex outlets 110 to provide the plurality of the individual shaped articles. In other desired aspects, each of the individual formed articles 100 may be longitudinally non-symmetrical along its longitudinal, machine direction 28 (eg, Figures 12 and 13).

The disconnecting mechanism 83 may be provided with the illustrated rotary cutters. The appropriate cutter mechanisms can also include the 5 matrix cutters, the water cutters, the cutters ^ ¡^^^^^^^^^^^ ^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^ t lasers or other beam energy cutters, and the like, as well as combinations thereof.

With reference to Figures 14 through 14B, the designated primary tissue layer and the designated cooperative tissue layer can be simultaneously provided by a tubular member 114 composed of a selected material. The tubular member may be operatively flattened to provide the synchronized laminated fabric 44. The flattened honeycomb has a pair of side-opposite, folded, side-by-side regions 116 and 118 which correspond to the first and second joined regions previously described: of the laminated fabric 44. In the desired arrangements, the folded edges are substantially seamless. The flattened member can be separated along the serpentine dividing line 46 of the invention to provide the first composite fabric 48 and the second composite fabric 50. The first composite fabric has a first upper part of the tubular member 114 combined with a first lower part of the tubular member. Similarly, the second composite fabric has a second upper part of the tubular member 114 combined with a second lower part of the tubular member.

With reference to Figure 15, the first part of the composite fabric 48 can be pivoted substantially around the first bent edge region 116 to ^ _ ^ _ _ _. ^. ^^ «^^^^^^^^^^^^^ - ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ Similarly, the second, upper part of the second composite fabric 50 can be pivoted substantially around the second folded edge region 118 to rest laterally on one side of said second lower part of the second composite fabric to form the second composite fabric 92. , the contoured fabrics can be divided along their transverse directions to provide the individual shaped articles having the previously described shapes.

The aspect of the invention which employs the tubular member 114 can provide the contoured tissues 90 and 92 in a configuration which does not have a seam extended longitudinally along the middle portions of the contoured tissues. Similarly, the incorporation of the tubular member can provide the individually wrapped articles 100 with a configuration which does not have a seam extending longitudinally along the middle portions of the individual shaped articles.

Having described the invention in quite complete detail, it will be readily apparent that various changes and modifications can be made without departing from the spirit of the invention. All those changes and modifications are contemplated as being within the scope of the invention as defined by the appended claims.

Claims (20)

R E I V I N D I C A C I O N S

1. A process for creating a shaped article, comprising a pivoting of a first part of a layer of 5 cooperating tissue essentially around a first attachment region to lie laterally on one side of a first p > art of a layer of primary tissue; where said layer of cooperative tissue has been placed in an overlying relationship with said primary tissue layer, said primary tissue layer having the first and second lateral edge side regions, and said layer of cooperating tissue having the edge regions. side third and fourth side; Said first edge region of the primary tissue layer has been synchronized with said third edge region of said layer of cooperative tissue along the first joint region, and said second edge region with the primary tissue layer. it has been synchronized with said fourth edge region of said layer of cooperating tissue along a second joining region to provide a synchronized laminated fabric; Y 25 said laminated fabric has been separated along a serpentine dividing line to provide a p composite fabric and at least one second composite fabric, said first composite fabric has said first part of the primary fabric layer combined with said first part of the cooperative tissue layer, and said second composite fabric has a second part of the primary tissue layer combined with a second part of the cooperative tissue layer.

2. The process, as claimed in clause 1, further characterized in that it comprises a pivoting of the second part of the layer of cooperating tissue around said second joining region to lie laterally on one side of the second part of the layer of fabric. primary tissue.

3. The process, as claimed in clause 1, characterized in that said laminated fabric has been separated along a serpentine dividing line which has been extended longitudinally along a designated middle section of the laminated fabric and has been laterally wavy 'with a periodically repeating pattern, and wherein said repetitive paitron has included at least two different pattern segments.

4. The process, as claimed in clause 1, characterized in that said pivoting of the first part of the cooperating tissue layer around the first joining region to lie laterally on one side of the first »- * & - *« iaa »Bfcto- & & amp; -.? -w- &'; ^ Mm ^? y. * yrty ... ^. g1 *., ^ part of the primary-tissue layer is configured to provide a first contoured tissue with bilateral symmetry.

5. The process, as claimed in clause 1, characterized in that said pivoting of said first part of the layer of tissue cooperating around said first joining region to lie laterally on one side of the first part of the primary tissue layer. is configured to provide a first contoured tissue which has a predetermined longitudinal variation.

6. The process, as claimed in clause 1, characterized in that said pivoting of said first part of the cooperating tissue layer around said first attachment region to lie laterally on one side of said first portion of the primary tissue layer is configured to provide a first contoured tissue having a plurality of outer regions alternating, convex and concave, and where said process further comprises a sectioning in the transverse direction of said first contoured fabric in a plurality of convex outer regions to provide a plurality of individual shaped articles. - ". £ '* ^ ... .. r é.? * - &? R ~ * ^; x- ^. -" rx-' '

7. The process, as claimed in clause 6, characterized in that said sectioning of said first contouring into a plurality of individual articles provides individual shaped articles which are longitudinally non-symmetrical.

8. The process, as claimed in clause 1, characterized in that said first edge region of the primary tissue layer has been synchronized to said third edge region of said layer of cooperative tissue by a first fastening of said first region of edge to said third edge region along said first joint region, and said second edge region of the primary tag layer has been synchronized with said fourth edge region of said layer of cooperative tissue by a second fastener of said edge. second shore region to said fourth shore region layer along said second junction region.

9. The process, as claimed in clause 1, characterized in that said first edge region of the primary tissue layer has been synchronized to said third edge region of said layer of cooperative tissue by a first direct attachment of said first region. from shore to said third shore region along said first region * of junction, and said second edge region of the primary tissue layer has been synchronized to said fourth edge region of said layer of cooperative tissue by a second direct attachment of said second edge region to said fourth edge region 5 to along said second junction region.

10. The process, as claimed in clause 1, characterized in that said first edge region of the primary tissue layer has been synchronized with said 10 third edge region of said cooperating tissue layer by first indirectly holding said first edge region to said third edge region along said first joint region, and said second edge region of the primary tissue layer. has been synchronized with this fourth 15 edge region of said layer of cooperating tissue by a second indirect fastening of said second edge region to said fourth edge region along said second joint region.

11. The process, as claimed in clause 10, characterized in that said first indirect clamping assembly of said first edge region of the primary tissue layer provides said third edge region of said layer of cooperative tissue. has included an assembly of so At least one connector member provided separately between said first shore region and said third shore region at length of said first junction region; and said providing the second indirect clamping assembly of said second edge region of the primary tissue layer to said fourth edge region of said layer of cooperative tissue has included an assembly of another connector member provided separately between said second edge region and said fourth shore region along said first junction region.

12. The process, as claimed in clause 1, characterized in that said first edge region of the primary tissue layer has been synchronized with said third edge region of said layer of cooperative tissue by means of a first essentially permanent clamping of said first edge region to said third edge region along said first joint region, and said second edge region of the primary tissue layer has been synchronized with said fourth edge region of said layer of cooperative tissue by a second essentially permanent fixation of said second edge region to said fourth edge region layer along said second joint region.

13. The process, as claimed in clause 1, characterized in that said first edge region of the primary tissue layer has been synchronized to said third edge region of said layer of cooperative tissue by a first temporary fastening of said first region. from shore to said third shore region along said first junction region, and said second edge region of the primary woven layer has been synchronized to said fourth shore region of said layer of cooperative tissue by a second temporary clamping of said second edge region to said fourth edge referential layer along said second joint region.

14. The process, as claimed in clause 1, characterized in that it also comprises: laterally spacing said first part of the cooperating tissue layer out of said first part.e of the primary tissue layer by a distance in the discrete transverse direction; Y a placement of a complementary first layer at a location interposed between said first part of the cooperating tissue layer and said first part of the primary tissue layer, said first complementary tissue layer having a pair of side-by-side regions laterally opposite.

15. The process, as claimed in clause 14, characterized in that it also comprises: "., * < * &< Sk & amp; at i¡dy &xii subject said first part of the layer of cooperating tissue to a region" of the side edge of said first layer of complementary tissue; Y fastening said first part of the primary tissue layer to another lateral edge region of said first complementary tissue layer.

16. The process, as claimed in clause 14, further characterized because it comprises: a lateral spacing of said second part.e of the cooperating tissue layer out of said second portion of the primary tissue layer by a distance in the discrete transverse direction; Y a placement of a second complementary layer at a location interposed between said second portion of the cooperating tissue layer and said second portion of the primary tissue layer, said second complementary tissue layer having a pair of laterally opposite side edge regions.

17. The process, as claimed in clause 16, further characterized in that it comprises: fastening said second part of the layer of cooperating tissue to a side edge region of said second layer of complementary tissue; Y 5 fastening said second part of the primary tissue layer to another side edge region of said second layer of complementary tissue.

18. An apparatus for creating a shaped article, comprising: a positioning mechanism which places a layer of cooperating tissue in an overlying face relationship with a primary tissue layer, said primary tissue layer having the first and second side edge side regions, and said layer of cooperating tissue having lateral third and fourth side bank regions; a coordinating mechanism which synchronizes said first edge region of the primary tissue layer with said third edge region of said layer of cooperating tissue along said first joining region, and synchronizes said second edge region of the layer of primary tissue with said fourth edge region of said layer of cooperating tissue along a second joining region to form a laminated and synchronized fabric. A splitter mechanism which separates said laminated fabric along a serpentine dividing line to provide a first composite fabric and at least a second composite fabric, said first composite fabric having a first part of said primary fabric layer combined with a first part of said cooperating tissue layer, and said second composite fabric has a second portion of said primary tissue layer combined with a second portion of said cooperative tissue layer; Y A relocation mechanism which pivots said first part of the cooperating tissue layer essentially around said first joining region for steel. 15 laterally to one side of said first part of the primary tissue layer.

19. The apparatus, as claimed in clause 18, further characterized in that it comprises another relocation mechanism 20 which pivots said second part of the cooperating tissue layer essentially around the second attachment region to lie laterally on one side of said second p > art of the primary tissue layer.

20. The apparatus, as claimed in clause 18, characterized in that said divider mechanism separates said laminate weave out of said serpentine divider line in a configuration which extends longitudinally along a designated middle section of the laminated fabric and undulates laterally with a periodic repeating pattern, said repeat pattern having including at least two different pattern segments. SUMMARY A distinctive technique for creating a shaped article includes pivoting a first part of a layer of tissue cooperating essentially around a first joining region to lie laterally on one side of a first layer of a primary tissue layer. The cooperative weave layer has been placed in an overlapped relation with the primary fabric layer with the primary weave layer having the first and second side edge side regions and the cooperating weave layer having the side edge regions. lateral third and fourth. The first side edge region of the primary tissue layer has been synchronized to the third side edge region of said layer of cooperating tissue along the first attachment region, and the second side edge region of the tissue layer. The primary region has been synchronized to the fourth side edge region of the cooperating te'j layer along a second joining region to provide a synchronized laminated fabric. The laminated fabric has been separated along a serpentine dividing line to provide a first composite fabric and at least one second composite. The first composite fabric has the first part of the primary tissue layer combined with the first part of the cooperative tissue layer, and the second composite fabric has a second part of the primary tissue layer combined with a second part of the primary tissue layer. co-operating fabric layer. -z¡r ¡ss Jf. "