WO2012053945A1

WO2012053945A1 - Method for applying elastic elements to a disposable article and disposable article produced according to the method

Info

Publication number: WO2012053945A1
Application number: PCT/SE2010/051122
Authority: WO
Inventors: Lucas BÄCK; Lennart Nilsson; Maria Dalin
Original assignee: SCA Hygiene Products AB
Current assignee: Essity Hygiene and Health AB
Priority date: 2010-10-18
Filing date: 2010-10-18
Publication date: 2012-04-26
Anticipated expiration: 2013-04-18

Abstract

A method for producing an elasticated chassis web for use as a continuous and coherent layer in a disposable pant garment, comprising the steps of attaching two continuous elongated leg elastic elements along curvilinear paths to a continuous base web as the base web is moved in a machine direction, (MD), and forming leg openings in the base web while in the same operation cutting out and completely removing pieces of the base web together with parts of the leg elastic elements extending across segments of the base web intended to form part of a crotch portion in the disposable pant garment. The invention also relates to a pant garment (100) having front and rear waist edges (175,176) and leg edges (127), a front body portion (107), a rear body portion (108) and a crotch portion (109) between the front and rear body portions (107, 108) and comprising a coherent chassis layer (101) extending continuously from the front waist edge (175) to the rear waist edge (176) and having elastic elements (110, 111) attached along the leg edges (127). The front body portion (107) and the rear body portion (108) are connected in the crotch portion (109) by a strip (126) of the chassis layer (101) having a smaller maximum width than a minimum width of the crotch portion (109).

Description

METHOD FOR APPLYING ELASTIC ELEMENTS TO A DISPOSABLE ARTICLE AND DISPOSABLE ARTICLE PRODUCED ACCORDING TO THE METHOD

TECHNICAL FIELD

The invention pertains to a method for producing an elasticated chassis web for use as a continuous and coherent supporting layer in a disposable garment and to a disposable garment comprising the chassis web.

BACKGROUND OF THE INVENTION

When designing disposable garments for wearing about the lower trunk such as disposable pants, disposable diapers and pant diapers it has become increasingly more important that the articles closely resemble regular underwear in appearance and comfort. For this reason it is necessary for the manufacturers to carefully tailor the articles to optimise fit and comfort. In order to fit snugly around the lower torso, the absorbent articles are provided with elastic elements arranged around contoured leg openings formed by making cut-outs in the garment material.

A major concern when producing disposable garments such as disposable pants, diapers, pant diapers, and the like, is to keep the manufacturing costs as low as possible while providing products with high functionality and an appealing finish. To keep costs at a minimum, high production speeds and little material waste are desirable features of the production method.

The problem of applying elastic elements intermittently and in a nonlinear configuration at the leg edges of an absorbent article has been addressed in US 7,326,31 1 B2 and in International Patent Application WO 98/25767 A1. The methods disclosed in US

7,326,31 1 B2 and WO 98/25767 A1 involve making an elastic laminate by attaching a continuous elastic element in a curved pattern on a supporting web and dividing the supporting web in two halves each carrying discrete portions of the elastic element. The two parts of the supporting web are then attached along the side edges of a production web with the elastic portions forming leg elastic in the finished product. Although allowing leg elastic to be incorporated in an absorbent article in a fairly simple manner, the methods in US 7,326,31 1 B2 and WO 98/25767 A1 both require additional material for carrying the elastic element to be introduced in the manufacturing process. As the supporting webs have no function in the finished product but are merely a means for handling the elastic elements in the process, the supporting webs add unwanted cost to the absorbent article and entail excess material consumption which is negative for environmental reasons. When making disposable absorbent articles, the manufacturers are highly concerned to keep the use of materials to a minimum in order to reduce the carbon footprint of the disposable absorbent article.

A common way of forming disposable garments such as pants, diapers and pant diapers is by a cross direction production method where the webs and components forming the garments are moved along a production path parallel with the cross direction of the garments. As the leg edges of a pant-type garment extend generally in the longitudinal direction of the garment transverse to the machine direction, cross-direction production commonly involves applying continuous pre-stretched leg elastic elements along two curvilinear paths extending in the machine direction to form a front half leg elastic and a rear half leg elastic. Continuous application of the elastic elements is preferred, as it allows for higher production speeds than methods involving application of discrete elastic pieces. However, one problem with continuous elastic application in cross direction production is that the leg elastic elements will also extend across the crotch portions of the finished disposable garments. The pre-stretched elastic elements in the crotch portions cause the crotch portion material to contract and deform, giving rise to unwanted corrugations that can act as channels in which liquid may flow out of the disposable garment. For this reason, it is normally preferred if the elasticity in this area can be removed or neutralised.

International Patent Application WO 01/72237 A2 discloses a cross direction type method for applying leg elastic along leg openings in pant type diapers. The method involves adhesively attaching elastic elements in a semicircular pattern along first and second parallel travelling webs having inner edges facing each other. The webs and the elastic elements are then covered by a covering web to form two parallel elastic laminates. The inner edges of the elastic laminates are trimmed off, at the same time removing parts of the elastic elements that would otherwise have extended across the crotch portions of the assembled pant diapers. The two parallel laminates having the leg elastic elements captured between the layers of the laminates are then again covered by a covering web to form a continuous elasticated chassis web that may be further processed into pant diapers by adding waist elastic, absorbent cores, cutting out leg openings, forming side joins, etc.

The method of removing elastic elements from the crotch portions of pant garments as disclosed in WO 01/72237 A2 suffers from the same major drawback as the methods disclosed in US 7,326,31 1 B2 and WO 98/25767 A1 in that additional material is needed for carrying and supporting the elastic elements in the process.

A further attempt at solving the problem with unwanted elastication in the crotch portion of a disposable pant garment is found in International Patent Application WO 96/23477. The method in WO 96/23477 involves causing the elastic elements to be present in the crotch portion of the produced garments "in a substantially relaxed state". This is accomplished by severing the elastic elements in the crotch portions, or by applying the stretched elastic in a non-bonded curve and allowing the elastic to relax and assume a non-curved shape.

One disadvantage with the method according to WO 96/23477 is that it may be difficult to synchronize the additional relaxation step to be performed at the correct positions along the production web. Furthermore, as the method requires a separate relaxation step it will complicate the production process with the risk of causing a reduction in speed and an increase in faulty products. A major disadvantage of the method WO 96/23477 is that the end product will still have elastic elements present in the crotch portion of the product. This is highly undesirable both for comfort reasons and for the reason that the elastic elements diminish the undergarment-likeness of the finished disposable pant garment.

One objective of the present invention is therefore to offer a simplified and more efficient manufacturing method for the production of disposable pant garments. A further object of the invention is to reduce waste of covering materials when producing disposable pant garments. A still further objective is to provide a low-cost yet highly functional, comfortable and aesthetically pleasing disposable pant garment. SUMMARY OF THE INVENTION

In accordance with the invention, there is provided an improved method for producing an elasticated chassis web for use as a continuous and coherent layer in a disposable garment. The method includes the steps of a) feeding a continuous base web along a production path in a machine direction, MD, the continuous base web having a cross machine direction, CD, transverse to the machine direction, MD, and parallel side edges in the machine direction and having leg edge segments and crotch segments extending in the cross machine direction, CD, and alternating in the machine direction, MD; b) stretching first and second continuous elastic elements; c) feeding said first and second continuous elastic elements in said machine direction, MD, along first and second regularly undulating wave-shaped curves, said curves having equal wave length, I, and having wave crests directed towards said side edges of said continuous base web and wave troughs directed away from said side edges of said continuous base web, said wave crests and wave troughs of said first wave-shaped curve being in register with said wave crests and wave troughs of said second wave-shaped curve with said elastic elements being at a maximum distance from each other within said leg edge portions of said continuous base web and with said elastic elements being at a minimum distance from each other within said crotch segments; d) attaching said first and second stretched elastic elements to said continuous base web along said first and second regularly undulating wave-shaped curves within said leg edge segments of said continuous base web, leaving said first and second elastic elements free from attachments to said continuous base web within said crotch segments along unattached elastic segments located between a first attachment site on a first side of each of said wave troughs of said first and second elastic elements and a second attachment site on a second side of each of said wave troughs of said first and second elastic elements as said continuous base web is fed in said machine direction, MD; e) cutting out identically shaped cut-out pieces from said continuous base web, wherein,

- said cut-out pieces are spaced apart in said crotch segments;

- a contour of each said cut-out piece is defined by a cutting line extending along each elastic element, between said elastic elements and forming a closed loop;

- each said cut-out piece has a leg opening part being located within a leg edge segment of said continuous base web and a leading end part and a trailing end part extending in said machine direction, MD, from said leg opening part in said leg edge segment into adjoining crotch segments on a leading and a trailing side of said leg edge segment;

- a pair of first attachment sites of said first and second elastic elements are located on said leading end part of said cut-out piece; f) forming cut-off crotch segments of said stretched and attached elastic elements by means of said cutting line severing each said first and second stretched elastic element once within said unattached segment of each said elastic element on a first side of said first attachment sites, causing said severed unattached segments to snap-back inside of said contour of said cut-out pieces, and severing each said elastic element once on a second side of said first attachment sites, such that said cut-off crotch elastic segments are attached to said cut-out pieces; and g) removing said cut-out pieces and said cut-off crotch elastic segments from said continuous base web.

The method of the invention involves cutting out and completely removing pieces of the crotch segments of the base web together with parts of the leg elastic elements that would otherwise have extended across the crotch segments. The small, cut-away portions of the elastic elements with the retracted non-attached ends are attached to the cut-out pieces at the first attachment sites in the first end parts of the cut-out pieces and will be removed from the web when removing the cut-out piece. In this way, the cut-away elastic pieces can be safely and easily disposed of in a controlled manner without leaving cut-off pieces of elastic that have to be removed by special suction means. If not properly taken care of and removed from the production web, loose pieces of elastic elements may cause problems in the process by getting caught in the production equipment or by being incorporated between layers in the produced product.

By means of the invention, unwanted crotch elastic is selectively removed by a cutting unit that is already present in the production line. Accordingly, there is no need for any separate strip cut unit as used in the prior art which means that the machine construction is simplified and the risk of technical failure is reduced. Moreover, in comparison with the prior art using separate elastic supporting webs for safe removal of unwanted elastic segments, material waste is greatly reduced with the method according to the invention as no additional material layers are needed to support the cut-away elastic elements. A further advantage of the invention is that the chassis web which forms a support structure for all other components of the pant garment is a single coherent web which is held together by narrow connecting strips that are left extending in the CD between the openings formed after removing the cut-out pieces. Hence, in accordance with the invention there is only one chassis web that needs to be guided and synchronized with other components in the production process.

When severing the elastic elements in the crotch segments of the continuous base web, the stretched elastic elements will return to their relaxed state within the non-attached crotch parts of the elastic elements. The relaxed elastic elements will immediately retract from the crotch segments of the continuous base web so that the loose ends of the elastic elements formed by the non-attached crotch parts of the elastic elements are wholly brought away together with the cut-out pieces. Consequently, the method according to the invention will also not leave long unsightly retracted unattached ends in the crotch portions of the finished disposable garments.

The attachments between the continuous elastic elements and the continuous base web may be made in any suitable manner such as by means of adhesive, thermowelding or ultrasonic welding. Adhesive may be applied as a coating on the continuous base web or may be applied to the elastic elements or both. The adhesive may be applied by any suitable method such as spraying, extruding, slot-coating, gravure coating, melt-blowing, etc.

In a disposable garment produced using the elasticated web according to the invention as a chassis component, the elasticated web will extend the full length of the garment, from the front waist edge of the garment to the rear waist edge of the garment. The web will thus form front and rear portions of the chassis having front and rear leg elastic arranged along the leg edges of the front and rear portions. A narrow web portion remaining after removal of the elastic elements from the crotch portion will be connecting the front and rear portions in the garment crotch portion.

Severing of the unattached segments of the elastic elements in the crotch segments of the continuous base web will take place with a cut extending generally in the cross- machine direction, CD, of the continuous base web. The cutting line loop for each cut-out piece extends in the crotch segments generally perpendicular to the MD from one side of a crotch center line extending in the MD of the continuous base web to the opposite side of the crotch center line. Hence, the portions of the cutting line loop located in the crotch segments of the continuous base web may be parallel to the CD or may have a curved or partly curved configuration with a general direction of extension in the CD. in addition to severing of the elastic elements in the crotch segment, the elastic elements are also cut a second time to form the cut-away elastic crotch segments. The second cut in each of the elastic elements is made where the cutting loop crosses the elastic elements at a location between the first attachment sites and the leg opening part of the cut-out piece. This second cut is made generally in the machine direction, MD, and leaves the cut-away elastic crotch segments attached to the end part at the first attachment sites of the cut-out piece.

In the method according to the invention, a pair of second attachment sites of the first and second elastic elements may be located on the second end part of the cut-out piece so that when cutting out the cut-out piece from the continuous base web, the first and second stretched elastic elements will be severed by the cutting line once on a first side of the second attachment sites and once on a second side of the second attachment sites. In this embodiment, cut-away end segments of the first and second elastic elements will be attached also to the second end part of the cut-out piece and will be removed from the continuous base web together with the cut-out piece.

The attachment sites on either side of the unattached segments in the crotch segments of the continuous base web may be formed at an edge of a continuous attachment of the parts of the elastic elements that are attached in the leg opening segments. Alternatively, at least the first attachment sites may take the form of discrete attachment sites that are separate from the continuous attachment of the elastic elements in the leg opening segments. As used herein, a discrete attachment site is a delimited and well-defined attachment area having a relatively small MD size such as a maximum MD extension of 30 mm. The discrete attachment sites may have a shape such as square, rectangular, circular, or oval shape.

Discrete attachment sites can be placed in the crotch segment of the continuous base web. Such discrete attachment sites are particularly useful when the elastic elements are attached to the base web in the leg edge segments by means of continuous uniform band-shaped adhesive areas arranged along the side edges of the base web. The discrete attachment sites are placed at a distance from the inner edges of the band- shaped adhesive areas with a gap between the inner edges of the band-shaped adhesive areas and the discrete attachment sites. The second cut in the first and second elastic elements, severing the cut-away crotch elastic segments from the elastic elements in the leg opening segments may be made in the gap between the attachments of the leg elastic in the band-shaped adhesive areas and the discrete attachment sites or across the discrete attachment sites.

The purpose of attaching the elastic elements to discrete attachment sites arranged at a distance from the edge of a continuous adhesive area is to prevent the unattached tensioned parts of the elastic elements in the crotch segments of the base web from falling back all the way to the edge of the adhesive area. If the elastic elements are allowed to fall back to the edge of an adhesive area, there is a risk that the elastic elements adhere to the adhesive and that the severed ends of the elastic elements are prevented by the adhesive from completely retracting to a position inside of the cutting line loop.

An alternative way of prohibiting fall-back of the unattached parts of the elastic elements to the edges of continuous adhesive areas is to arrange continuous lines or narrow bands of adhesive at a distance from the edges of the continuous adhesive areas. A further way of prohibiting fall-back of the unattached parts of the elastic elements is by forming spacing attachments integral with band-shaped leg elastic adhesive areas along the side edges of the base web. When the spacing attachment is formed integral with the band- shaped leg elastic adhesive areas, the inner edges of the band-shaped leg elastic adhesive areas will be non-linear and the band-shaped adhesive areas will have a nonuniform width.

In accordance with the invention, the second attachment sites may also take the form of discrete attachment sites so that cut-away end segments of the first and second elastic elements will be attached also to the second end part of the cut-out piece and will be removed from the continuous base web together with the cut-out piece.

The minimum spacing in the cross-direction, CD, between the cut-out pieces in the crotch segment may be 10 mm - 150 mm, preferably 15 mm - 100 mm and most preferably 20 mm - 80 mm. The spacing between the cut-out pieces defines the minimum width of the narrow web portion remaining in the crotch segment after removal of the elastic elements from the crotch segment and is the portion of the web that connects the front and rear web portions in the finished garment according to the invention.

The first and second stretched elastic elements are preferably attached to the continuous base web by means of adhesive. The adhesive may be applied to the continuous base web in a first band-shaped area along a first of the parallel side edges of the continuous base web and in a second band-shaped area along a second of the parallel side edges of the continuous base web. The first and second band-shaped areas are spaced apart in the cross-machine direction CD of the continuous base web so that an attachment-free area extending continuously in the CD is formed between the adhesive areas.

Alternatively, adhesive may be applied as a single band-shaped area to which both stretched elastic elements are attached. The single band-shaped area has adhesive free areas arranged intermittently in the MD within the crotch segments of the continuous base web. The adhesive free areas may have rectangular, square, circular, oval, hourglass shape or other suitable shape and are positioned in the crotch segments of the continuous base web so that unattached elastic segments of the stretched elastic elements are formed in the crotch segments of the continuous base web.

The band-shaped adhesive areas may be uniformly coated by adhesive or may have adhesive applied in a pattern such as a dot pattern, a spiralized pattern or a pattern of closely spaced parallel lines, preferably extending generally in the CD. The first and second band-shaped areas may have a width in the cross-machine direction, CD, of the continuous base web that is smaller than the width in the cross-machine direction, CD, of the first and second regularly undulating wave-shaped curves of the stretched continuous elastic elements, the first and second stretched continuous elastic elements being attached to the continuous base web with said wave crests completely within the first and second band-shaped areas and with a portion of each the wave- troughs extending in the cross-machine direction, CD, away from said first and second band-shaped areas to form the unattached segments in the crotch segments. Alternatively, the first and second band-shaped areas may have portions in the leg edge segments of the continuous base web having a width in the cross-machine direction, CD, of the continuous base web greater than or equal to the width in the cross-machine direction, CD, of the first and second regularly undulating wave-shaped curves of the stretched continuous elastic elements, and portions in the crotch segments of the continuous base web having a width in the cross-machine direction, CD, of the continuous base web smaller than the width in the cross-machine direction, CD, of the first and second regularly undulating wave-shaped curves of the stretched continuous elastic elements, the first and second stretched continuous elastic elements being attached to the continuous base web with the wave crests completely within the first and second band-shaped areas and with a portion of each of the wave-troughs extending in the cross- machine direction, CD, away from the first and second band-shaped areas to form the unattached segments in the crotch segments.

In accordance with the invention, adhesive may be applied to the continuous base web in first and second attachment areas generally coinciding with the first and second regularly undulating wave-shaped curves within the leg edge segments of the continuous base web.

The first and second stretched elastic elements may be attached between the base web and a covering web in order to lock the elastic elements in the desired curve shape.

In most cases, the narrow strip of material remaining between the cut-out pieces and connecting the two halves of the base web will be too narrow to provide a pant garment with a sufficiently wide crotch portion. In accordance with the invention, a supplementary piece material may be attached to the continuous base web in the crotch segment after cutting out and removing the cut-out pieces. A supplementary piece of material may be attached to the crotch segment of the continuous base web also in instances where the width of the narrow strip of material is adequate for the intended purpose but where specific additional properties different from those of the base web material are desired such as absorbency, cushioning, different colouring, etc.

The supplementary piece of crotch material may be comprised in a core pack which is a prefabricated component comprising a topsheet layer, a backsheet layer and an absorbent core between the topsheet layer and the backsheet layer.

The method according to the invention may further include applying waist elastic along at least one of the side edges of the continuous base web. The waist elastic may be intermittently applied but is preferably applied continuously along the side edges. The method may also include application of body elastic between the leg elastic curves and the waist elastic.

The continuous base web may be further processed by being folded along the longitudinal centre line of the base web and by connecting the two halves of the base web in edge seams formed in the cross machine direction, CD, centrally across each wave crest segment and subsequently cutting the continuous base web into individual pant garments in the cross machine direction by cutting through the edge seams.

The invention also relates to an improved disposable pant garment having front and rear waist edges and leg edges, a front body portion, a rear body portion and a crotch portion between the front and rear body portions and comprising a coherent chassis layer extending continuously from the front waist edge to the rear waist edge and having elastic elements attached along the leg edges. The front body portion and the rear body portion are connected in the crotch portion by a strip of the chassis layer having a minimum width of 10 - 50 millimeters.

The minimum width of the connecting strip is defined as the shortest distance between the side edges of the strip. Accordingly, a strip having a minimum width of 10 - 15 millimeter has a shortest distance between its side edges of 10 - 15 mm. A minimum width of the crotch portion of a pant garment is defined as the shortest distance between the leg edges of the pant garment and is generally determined by the width of a supplementary piece of material arranged in the crotch portion, such as a supplementary chassis layer, an absorbent insert or an outer backsheet layer of a core pack.

The disposable pant garment according to the invention may be an absorbent pant garment. The absorbent pant garment may comprise a core pack arranged in the crotch portion, the core pack comprising a topsheet layer, a backsheet layer and an absorbent core arranged between the layers.

The pant garment may be a pant diaper having closed side seams connecting the front body portion with the rear body portion to form a panty having leg openings and a waist opening.

The pant garment according to the invention has a narrow strip of the chassis web connecting the front portion with the rear portion in the crotch portion. Hence, the chassis web constitutes a continuous and coherent supporting structure carrying all other components of the pant garment. The method for producing an elasticated chassis web according to the invention, comprising the steps of attaching two continuous elongated leg elastic elements along curvilinear paths to a continuous base web as the base web is moved in a machine direction, MD, and forming leg openings in the base web while in the same operation cutting out and completely removing pieces of the base web together with parts of the leg elastic elements extending across segments of the base web intended to form part of a crotch portion in the disposable pant garment results in that the pant garment has no elastic elements extending transversely across the crotch portion. In this way, the pant garment is provided with a smooth clothes-like outer surface and an aesthetically pleasing appearance. The absence of elastic elements or cut-off elastic ends in the crotch portion reduces the risk of chafing when the pant garment is worn.

DEFINITIONS

As used herein a "pant garment" or "pant type garment" is any type of garment that is worn in a pant-like fashion around the lower trunk of a user's body. The pant garment may be a pair of disposable, non-absorbent underpants that may be worn with or without an absorbent insert. Other disposable articles that are considered to be pant garments are disposable absorbent sanitary pants and pant diapers and open diapers and diaper covers having fastening means for fastening the diaper or diaper cover in a pant-like configuration on a user's body.

A "layer" or a "web" as used herein is a generally two-dimensional structure that may comprise one or more plies and may be in the form of a laminate made from plies of the same or different materials.

An "elastic" material as used herein is to be understood in the conventional way as being a material that after stretching resiliently returns to a less extended state, ideally to its original, unstretched state. By an elongated elastic means of the invention being "continuously attached" along a segment thereof is meant that the elastic means is bonded to a base web with sufficiently closely spaced bonds to maintain a functional curvature of the elastic means after attachment to the base web. Consequently, a continuous attachment may be achieved by closely spaced intermittent bonds, such as bonds with a maximum spacing along the elongated elastic means of 7 mm or by a true continuous bond extending unbroken over the full length of the continuously attached segment of the elastic means.

By "snap back" as used herein is meant the sudden and vigorous relaxation and retraction of a tensioned elastic element that takes place when the tensioned elastic element is severed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in greater detail below with reference to the figures shown in the appended drawings. The figures are schematic illustrations of the invention.

Figure 1 shows an elasticated base web according to a first embodiment of the invention;

Figure 2 shows the elasticated base web of Fig. 1 at a later stage in the

production process with cut-out pieces of the web removed; Figure 3 shows a detail of the elasticated base web in Fig. 1 during snap-back of severed elastic elements; Figure 4 shows a detail of the elasticated base web in Fig. 2 during removal of cut-out pieces;

Figure 5 shows an elasticated base web according to a second embodiment of the invention;

Figure 6 shows an elasticated base web according to a third embodiment of the invention;

Figure 7 shows an elasticated base web according to a fourth embodiment of the invention;

Figure 8 shows a detail of the elasticated base web in Fig.7 in a first stage of the production process during snap-back of severed elastic elements; Figure 9 shows a detail of the elasticated base web in Fig. 7 in a second stage of the production process during removal of cut-out pieces;

Figure 10 shows an elasticated base web according to the invention during

production of an absorbent garment;

Figure 1 1 shows a segment of an elasticated base web according to the invention;

and

Figure 12 shows a pant diaper made from a segment of an elasticated base web as shown in Fig. 1 1 and comprising an integrated absorbent body.

DETAILED DESCRIPTION OF EMBODIMENTS

The base web 1 for production of a disposable pant-shaped garment that is schematically shown in Figs. 1 and 2 is continuously moved in a machine direction, MD and has a cross machine direction, CD, perpendicular to the MD. The base web 1 has a longitudinal crotch centre line 2 in the MD and is divided in the CD into leg edge segments 3 and crotch segments 4 extending transversely across the base web 1 in the CD, and arranged in alternating sequence in the MD. The base web 1 has first and second parallel side edges 5, 6 in the MD. The crotch centre line 2 is a line extending in the MD of the base web 1 , between the side edges 5,6 of the base web 1 . In the base web 1 shown in Figs. 1 and 2, which will form a garment chassis having front and rear portions of equal length, the crotch centre line 2 coincides with the centre line of the base web. However, the crotch centre line 2 may be offset towards one of the side edges 5,6, as shown in Fig. 10.

Normally, the crotch centre line 2 will be offset towards the side edge being placed at the front waist edge of the finished pant garment.

The base web 1 can consist of any flexible web material as commonly used in the art, such as a layer of nonwoven material, a plastic film or a laminate of two or more sheets of the same or different materials. The base web 1 may be elastic or inelastic and will preferably comprise or consist of at least one nonwoven layer. Suitable nonwoven materials are carded bonded nonwovens, spunbond nonwovens, spunlaced nonwovens, meltblown nonwovens, etc. The nonwoven webs may comprise or consist of

thermoplastic fibres. The base web according to the invention will form part of a chassis for a disposable pant-type garment and is commonly incorporated in joins in the garment. For this reason, it is highly desirable that the base web comprises thermoplastic material and is weldable by heat or by ultrasonic welding processes. Examples of suitable polymers for use in the base webs according to the invention are polyethylene, polyesters, polypropylene and other polyolefin homopolymers and copolymers. A weldable nonwoven web preferably has a high content of thermoplastic fibres and may contain at least 50% thermoplastic fibres and preferably at least 80% thermoplastic fibres.

The base web 1 is coated with an adhesive, such as a hot melt adhesive that is applied to the base web 1 within in a first band-shaped attachment area 7 along the first side edge 5 of the continuous base web 1 and in a second band-shaped attachment area 8 along the second of side edge of the continuous base web 1 . The first and second attachment areas 7,8 are spaced apart in the cross-machine direction CD of the continuous base web so that a band-shaped area 9 is free of adhesive.

As the base web 1 is moved in the MD, first and second continuous elastic elements 10, 1 1 are stretched and attached in the stretched state to the base web 1 . Typical stretch rates are around 200% which means that the base web has been stretched to three times its original unstretched length. Lower or higher stretch rates may be used as desired within the scope of the invention. The elastic elements 10, 1 1 may be stretched to different degrees resulting in a finished pant garment having differently tensioned front and rear parts of the leg elastic.

The elastic elements 10,1 1 will form leg elastic in a finished disposable pant garment and may be in the form of elastic threads or bands. Each elastic element 10,1 1 may consist of one or more strings or bands of elastic material such as natural or synthetic rubber, elastic foam, elastic film, elastic nonwoven, etc. Elastic strings may have an outer layer of inelastic textile threads spun around an elastic core.

The first and second continuous elastic elements 10, 1 1 are fed in the MD along first and second regularly undulating wave-shaped curves 12, 13 and are attached to the base web 1. In the schematic illustrations in Figs, l and 2, the first and second curves 12, 13 have identical shape. However, depending on the desired shape of the leg elastic in the finished pant garment, the first and second curves may have different shapes such as for example a shape as illustrated in Fig. 10. It is common that the leg openings in a pant garment have different curvatures in the front half and in the rear half of the garment in order to obtain better anatomical fit. However, the first and second curves 12, 13 must always have equal wave length, I, and have wave crests 14, 15 directed towards the side edges 5,6 of the base web 1 and wave troughs 16, 17 directed away from the side edges 5,6 of the base web 1 . The wave crests 14 and wave troughs 16 of the first wave-shaped curve 12 are arranged in register with the wave crests 15 and wave troughs 17 of the second wave-shaped curve 13. Accordingly, the elastic elements 10, 1 1 are attached to the base web 1 at a maximum distance di from each other within the leg edge segments 3 of the base web 1 and at a minimum distance d₂ from each other within the crotch segments 4.

In a garment made with the elasticated base web 1 , the leg edge segments 3 of the base web 1 are portions of the web that will form or be part of side portions of the garment. These portions will have leg openings encircled by leg elastic elements and will be placed over a user's hips when the garment is being worn, The crotch segments 4 are portions of the web that will form a component of the garment's crotch portion and will be located centrally between the side portions. When the garment is worn, the crotch portion is placed in the user's crotch. If the pant garment is an absorbent garment an absorbent core will be placed in the crotch portion of the garment. After the elastic elements 10, 1 1 have been stretched, they are attached in the stretched state to the base web 1 along the first and second regularly undulating wave-shaped curves 12,13 within the leg edge segments 3 of the base web 1.

In the embodiment shown in Figs. 1 and 2, the first and second stretched elastic elements 10, 1 1 are attached to the base web 1 by means of adhesive, that has been applied to the base web 1 in first and second band-shaped attachment areas 7,8 along the side edges 5,6 of the base web 1. However, other means of attachment such as ultrasonic or thermal welding or adhesive applied in a contoured pattern following the elastic curves or directly to the elastic elements are contemplated within the scope of the invention.

In order to lock the elastic elements 10,1 1 in the desired curve shape in particular in the case when the elastic elements are adhesively attached to the base web, the elastic elements may be covered by a covering web that is attached to the base web 1 . The covering web may be a single web applied over both elastic elements 10, 1 1 or may be made from two parts, each covering one of the elastic elements 10, 1 1 at least within the parts of the elastic element 10, 1 1 that are attached to the base web 1. In the latter case, the parts of the covering web may have a shape corresponding to the curve shape of the elastic elements or may be bands of uniform width. The covering web may be chosen from the same materials as the base web. Nonwoven webs are preferred as covering webs. The covering web is not shown in the figures.

The first and second band-shaped attachment areas 7,8 are shown in Figs. 1 and 2 to have a CD extension, or width, that is smaller than the CD extension, or width, of the first and second wave-shaped curves 12, 13 of the stretched elastic elements 10, 1 1. This means that the elastic elements 10, 1 1 cannot be completely attached along their full length within the attachment areas 7,8. The first and second stretched elastic elements 10, 1 1 are attached to the base web 1 with the wave crests 14, 15 of the wave-shaped curves 12, 13 placed completely inside the first and second band-shaped attachment areas 7,8 so that those segments of the elastic elements 10, 1 1 placed closest to the side edges 5,6 of the base web 1 are attached to the base web 1 within the attachment areas 7,8. The attached segments of the elastic elements 10,1 1 are located in the leg edge segments 3 of the base web.

Due to the band-shaped attachment areas 7,8 having smaller CD width than the wave- shaped curves 12, 13, a portion of each wave-trough 16, 17 extends in the CD away from the first and second band-shaped attachment areas 7,8 into the adhesive free area 9 between the band-shaped attachment areas 7,8 when the elastic elements 10, 1 1 are attached to the base web 1. The unattached segments 18,19 of the elastic elements 10,1 1 outside of the band-shaped attachment areas 7,8 are located in the crotch segments 4 of the base web 1. Each unattached elastic segment 18, 19 extends in the MD between a first attachment site 20,21 on a first side of each of the wave troughs 16, 17 of the first and second elastic elements 10, 1 1 and a second attachment site 22,23 on a second side of each of the wave troughs of the first and second elastic elements 10,1 1 as the base web 1 is fed in the MD. In the embodiment shown in Figs. 1 and 2, the first and second attachment sites 20,21 ,22,23 are the points where the curved elastic elements 10,1 1 leave the band-shaped attachment areas 7,8 along the side edges 5,6 of the base web 1. As shown in Figs. 1 and 2, the elastic elements 10, 1 1 are attached to the base web 1 along their full length in the leg edge segments 3 and are free from attachments to the base web 1 in the crotch segments 4. The tension in the stretched elastic elements 10, 1 1 causes the unattached segments 18, 19 of the elastic elements 10, 1 1 to contract and fall back to a less tensioned state where they assume a straight configuration along the edges of the band-shaped attachment areas 7,8. Falling back to a straight configuration will only cause a slight relaxation of the elastic elements 10,1 1 so that they will still be under tension as the web is moved in the MD to the next step in the manufacturing process.

After the elastic elements 10, 1 1 have been attached to the base web 1 , identically shaped cut-out pieces 25 are cut out from the base web 1. The cut-out pieces 25 are spaced apart in the crotch segments 4 so that when the cut-out pieces 25 have been removed, only a narrow strip 26 of the base web 1 remains between the holes 50 left by the cut-out pieces 25. The narrow strips 26 of the base web 1 connect the two halves of the base web 1 on either side of the crotch center line 2 that will form front portions and rear portions when the garment is fully assembled. This means that a finished pant garment incorporating the base web 1 will have a continuous chassis layer extending from a front end edge of the garment through the garment crotch portion and to a rear end edge of the garment.

The contour of each cut-out piece 25 is rounded and is defined by a cutting line 27 extending along each elastic element 10, 1 1 , between the elastic elements 10, 1 1. The cutting line 27 crosses the crotch center line 2 of the base web 1 twice, in first and second neighbouring crotch segments 4 and forms a closed loop. In a finished disposable pant garment, the cutting line 27 defines at least part of the edges of the leg openings in the pant garment. One part of the cutting line on one side of the base web 1 crotch center line 2 will form a front leg edge in the garment and a corresponding part of the cutting line on the opposite side of the crotch center line 2 will form a rear leg edge in the garment.

As is shown in Fig. 2, the cut-out pieces 25 have a generally rounded shape with each cut-out piece 25 having a central leg opening part 28 being located within a leg edge segment 3 of the base web 1 and a leading end part 29 and a trailing end part 30 resembling ears extending forward and rearward in the machine direction, MD, from the leg opening part 28 in the leg edge segment 3 into adjoining crotch segments 4 on the leading and trailing sides of the leg edge segment 3. The first attachment sites 20,21 of the first and second elastic elements10, 1 1 are located inside of the cutting line 27 on the leading end part 29 of the cut-out piece 25. Likewise, the second attachment sites 22,23 of the first and second elastic elements 10, 1 1 are located inside of the cutting line 27 on the trailing end part 30 of the cut-out piece 25. Simultaneously with forming the cut-out pieces 25, crotch segments 31 ,32 of the stretched elastic elements 10, 1 1 are also cut away from the base web 1 .

The first and second stretched elastic elements 10, 1 1 are severed once within the unattached segment 18,19 of each elastic element 10, 1 1 , releasing the tension in the elastic elements 10, 1 and causing the cut-off non-attached ends of the elastic elements 10, 1 1 to relax and snap-back to the first attachment sites 20,21 so that the cut-off ends become located inside of the contour of the following cut-out piece 25. These cuts are made generally in the cross machine direction, CD, where the cutting line 27 crosses over the crotch center line 2 of the base web 1 from one half of the base web 1 to the other half of the base web 1 . Discrete cut-off elastic segments 31 ,32 of the first and second stretched elastic elements 10,1 1 are formed by means of the cutting line 27 additionally severing each of the elastic elements 10, 1 1 between each of the first attachment sites 20,21 and the leg opening part 28 of the cut-out piece 25. The elastic elements are then cut a further time between each of the second attachment sites 22,23 and the leg opening part 28 of the cut-out piece 25. These cuts are made generally in the machine direction, MD, at the end parts 29,30 of the cut-out pieces 25 at the border between the leg edge segment 3 and the crotch segment 4 of the base web 1 or in a transition area between the leg edge segment 3 and the crotch segment 4.

In the process shown in Figs. 1 and 2, the order of the cuts in the elastic elements 10,1 1 as the base web 1 is moved in the machine direction, MD, is from right to left in Figs. 1 and 2. Accordingly, if a first cut is considered to be that which severs the elastic elements 10, 1 1 in the unattached segments 18, 19, this first cut will be made at the trailing end part 30 of a first cut-out piece and will cause the ends of the severed elastic elements 10, 11 to retract to a position in the vicinity of the first attachment sites 20,21 in the leading end part 29 of a second cut-out piece 25 following on the first cut-out piece 25 in the MD.

Relaxation and retraction of the severed elastic ends will take place before the web is cut again at the leading end part 29 of the following cut-out piece 25. Accordingly, when the following cut-out piece 25 begins to form, the CD cut in the crotch section 4 will only be made through the base web 1 and not through the retracted elastic elements 10, 1 1. As the following cut-out piece 25 continues to be formed second cuts through the elastic elements 10, 1 1 are made, severing the elastic elements 10, 1 1 downstream of the first attachment sites 20, 21 so that cut-off crotch elastic segments 31 ,32 are severed from the parts of the elastic elements 10, 1 1 that are attached along the leg edge segments 3. The cut-off crotch elastic segments 31 ,32 including the retracted portions of the elastic elements 10, 1 1 are attached to the cut-out pieces 25 at the first attachment sites 20, 21 which are formed by a small area of the first and second band-shaped attachment areas 7,8 that is inside of the cutting line contour in the leading end parts 29 of the cut-out piece 25. Small cut-off crotch elastic segments 31 ,32 of the elastic elements 10, 11 are again formed as the base web 1 moves in the MD and the trailing end part 30 of the second cutout piece 25 is being formed. The cutting line 27 will then cut the elastic elements 10, 1 1 a first time before reaching the second attachment sites 22, 23 and a second time when the cutting cycle begins again with the CD cut at the trailing end part 30 of the second cut-out piece 25 severing the unattached crotch segments 8,19 of the elastic elements 10, 1 in an attached area.

The cut-out 25 pieces are finally removed from the base web 1 together with the cut-off crotch segments 31 ,32 of the elastic elements. Removal of the cut-out pieces 25 may be carried out in any suitable way such as by using suction means.

The cut-out pieces 25 may be formed by means of any cutting method known in the art. A suitable means of forming the cut-out pieces 25 may be by using a rotary die cutter (RDC) as is well known in the art. An RDC comprises a rotating cutting roll having cutting edges on the peripheral surface. The cutting roll works against an anvil roll and continuously cuts a web in the nip between the rolls. Other cutting methods that may be used are water jet or laser cutting. Figs. 3 and 4 show detailed views of a multi-string elastic element 1 1 being cut away by the method according to the invention. The continuous elastic element 1 1 is attached to a base web 1 in a band-shaped adhesive attachment area 8 and has an unattached segment 19 between a first attachment site 21 and a second attachment site 23 where the elastic element 1 1 leaves and reenters the band-shaped adhesive attachment area 8. The section of the base web 1 that is shown in Figs. 3 and 4 is taken from the lower half of a continuous base web 1 such as that shown in Figs. 1 and 2 and includes a wave trough 17 part of the elastic element curve arranged in a crotch segment 4 of the base web 1. The section of the base web 1 also includes a corner section of a trailing end part 30 of a first cut-out piece 25' and a corner section of a leading end part 29 of a second cut-out piece 25" which are separated in the machine direction, MD, by a narrow strip 26 of the base web 1 .

When the base web 1 is moved in the MD, a first cutting line 27' is made in the web 1 , the first cutting line 27' having a final CD cut segment 34' at the trailing end portion 30 of the first cut-out portion 25'. The first cutting line 27' severs the tensioned elastic element 1 1 on a leading side of the narrow strip 26 of base web 1 between the first and second cutout pieces 25', 25", as is shown in Fig. 3. A second cutting line 27" having a beginning CD cut segment 34" at the leading end portion 29 of the second cut-out portion 25" is indicated by a dashed line in Fig. 3. Fig. 3 shows the situation immediately after the elastic element 1 1 has been cut at the first cutting line 27' and before the severed ends 35 of the elastic element 1 1 have been relaxed and retracted inside of the contour of the second cutting line 27". In the time it takes for the base web 1 to move in the MD to a position where the initial CD cut segment 34" of the second cutting line 27" is created, the severed ends 35 of the elastic element 1 1 will have retracted inside of the contour of the second cutting line 27" as shown in Fig. 4. As the second cutting line 27" continues in the MD, the elastic element 1 1 is cut by the cutting line 27" within the band-shaped attachment area 8, downstream of the first attachment site 21 on the leading end portion 29 of the second cut-out piece 25". The second cut results in cut-off crotch elastic segments 32 being formed. The cut-off crotch elastic segments 31 ,32 include the severed and retracted unattached ends 35 of the elastic element 1 1 and a portion of the elastic element 1 1 that is attached to the second cut-out piece 25" at the first attachment site 21. Fig. 4 shows the same section of the base web 1 as in Fig. 3 after both the first and the second cutting lines 27', 27" have been formed and the cut-out pieces 25', 25" are being removed from the base web 1. From Fig. 4 it can be seen that the major part of the unattached segment 19 of the elastic element 1 1 is removed together with the second cutout piece 25" while shorter unattached ends 36 of the elastic element 1 1 are left on the first cut-out piece 25'. There are no parts of the elastic element 1 1 left in the crotch segment 4 of the base web 1 or any loose elastic pieces that may interfere with the production process.

The elastic element 1 1 in Figs. 3 and 4 includes three elastic strings. It is to be

understood that the elastic elements as disclosed herein may consist of any suitable number of elastic sub elements ranging from a single elastic string or band up to 20 or more strings or bands. In particular, the elastic elements may consist of 10 or more thin, closely spaced elastic filaments. Fig. 5 shows a production method according to the invention which is a slightly modified version of the method shown in Figs. 1 and 2. The only difference between the method in Fig. 5 and that in Figs. 1 and 2 is that the band-shaped attachment areas 7,8 have different widths in the cross machine direction, CD, in different parts of the base web 1 with corresponding variations in the CD width of the adhesive free area 9 between the band-shaped attachment areas 7,8. As shown in Fig. 5, the adhesive free area 9 has a greater CD width in the crotch segments 4 than in the leg edge segments 3 of the base web 1 . The continuous elastic elements 10, 1 1 are applied to the base web 1 in first and second sinusoidal curve paths 12,13 arranged on either side of the longitudinal crotch center line 2 through the base web 1. Immediately after application of the elastic elements 10, 1 1 to the base web 1 , the unattached curved portions of the curved elastic elements 10, 1 1 loose some of their tension and fall back from a first curved configuration shown at (a) to the straight configuration shown at (b) in alignment with the inner edges 37,38 of the band-shaped attachment areas 7,8. Within the unattached elastic segments 18, 19, in the crotch segments 4 of the base web 1 where the adhesive free area 9 has a greater CD width, the elastic elements 0,1 1 extend at a distance from the inner edges 37,38 of the band-shaped attachment areas 7,8. Accordingly, within this part 39 of the unnatached portion, the elastic elements 10, 1 1 run completely free from the attachment areas 7,8.

By having the elastic elements 10, 1 1 arranged at a distance from the inner edges 37,38 of band-shaped adhesive attachment areas 7,8, the unattached tensioned parts of the elastic elements 10, 1 1 in the crotch segments 4 of the base web 1 are prevented from falling back all the way to the inner edges 37,38 of the adhesive areas 7,8. If the elastic elements 10, 1 1 are allowed to fall back to the edge of an adhesive area, there is a risk that the elastic elements adhere to the adhesive or that friction between the elastic elements 10, 1 1 and the adhesive cause the severed ends of the elastic elements to be prevented from completely retracting to a position inside of the cutting line loop.

After application of the elastic elements 10, 1 1 , the continuous base web 1 is cut along a cutting line 27 in the same way as shown in Figs. 1 -4 and the cut-out pieces 25 are removed from the base web 1 together with the cut-away elastic segments 31 ,32.

The method illustrated in Fig. 6 differs from the method in Figs. 1 and 2 in that the first attachment sites 20, 21 are in the form of discrete attachment sites 40,41 that do not form parts of the first and second band-shaped attachment areas 7,8. In Fig. 6, the base web 1 is moved in the machine direction, MD, in the same way as in the methods in Figs. 1 , 2 and 5. The base web 1 is provided with adhesive band-shaped attachment areas 7,8 arranged along the side edges 5,6 of the base web and placed at a distance from each other on either side of the longitudinal crotch center line through the base web 1 so that an attachment free band shaped area 9 is formed between the band=shaped attachment areas 7,8. Stretched continuous elastic elements 10, 1 1 are fed along sinusoidal curves 12, 13 and are attached in the stretched state to the band-shaped attachment areas 7,8 in the same manner as in the Figs.1 and 2 method.

After the elastic elements 10, 1 1 have been attached to the base web 1 , identically spaced apart cut-out pieces 25 are cut out from the base web 1 , leaving only a narrow strip 26 of the base web 1 remaining between the holes 50 left by the cut-out pieces 25 and connecting the two halves of the base web 1 on either side of the crotch center line 2.

The contour of each cut-out piece 25 is defined by a cutting line 27 extending along each elastic element 10,1 1 , between the elastic elements 10, 11. The cutting line 27 crosses the crotch center line 2 of the base web 1 twice to form a closed loop.

The cut-out pieces 25 have a generally rounded shape with each cut-out piece 25 having a central leg opening part 28 and a leading end part 29 and a trailing end part 30 extending forward and rearward in the machine direction, MD.

The discrete attachment sites 40,41 of the first and second elastic elements10, 1 1 are located inside of the cutting line 27 on the leading end part 29 of the cut-out piece 25. The second attachment sites 22,23 of the first and second elastic elements 10, 1 1 which are located at the inner edges 37,38 of the band shaped attachment areas 7,8 are shown to be inside of the cutting line 27 at the trailing end part 30 of the cut-out piece 25. However, if the cutting line 27 is arranged between the inner edges 37,38 of the band shaped attachment areas 7,8 and the discrete attachment sites 40,41 or within the discrete attachment sites 40,41 at the leading end part of the cut-out piece 25, the cutting line 27 may be arranged such that the second attachment sites 22,23 of the first and second elastic elements 10 are outside of the cutting line 27 at the trailing end part 30 of the cutout piece 25.

As in the previously described embodiments, crotch segments 31 ,32 of the stretched elastic elements 0,1 1 are cut away from the base web 1 in the cutting operation when the cut-out pieces 25 are formed.

The first and second stretched elastic elements 10,1 1 are severed once within the unattached segment 18, 19 of each elastic element 10, 1 1 , releasing the tension in the elastic elements 10, 1 1 and causing the cut-off ends of the elastic elements 10, 1 1 to snap-back to the discrete attachment sites 40,41 inside of the contour of the cut-out piece 25. Due to the sudden relaxation of the non-attached ends of the elastic elements 10, 1 1 between the attachment sites 40,41 and the cut, the ends of the elastic elements retract completely inside of the contour of the cut-out piece, As in the previously described embodiments of the invention, these cuts are made generally in the cross machine direction, CD, where the cutting line 27 first crosses the elastic elements 10, 1 1 in the unattached segment, 18,19 near the inner edges 37,38 of the band shaped attachment areas 7,8. The discrete attachment sites 40, 41 are small areas of adhesive or small thermally or ultrasonically bonded areas where the elastic elements 10,1 1 are attached to the base web 1. The discrete attachment sites have a delimited and well-defined attachment area with a relatively small MD size such as a maximum MD extension of 30 mm. The discrete attachment sites may have a shape such as square, rectangular, circular, or oval. In the example shown in Fig. 6, one discrete attachment site 40, 41 is used for each elastic element 10,1 1 at each leading end part 29 of each cut-out piece 25. Although the discrete attachment sites 40,41 are shown as individual attachment sites in Fig. 6, the discrete attachment sites may be in the form of a single adhesive area extending in the CD and providing first attachment sites for both elastic elements 10, 1 1. The discrete attachment sites 40,41 are shown placed at a distance from the inner edges 37,38 of the band- shaped attachment areas 7,8 so that a small gap 45 is formed between each band- shaped attachment area 7,8 and the corresponding discrete attachment site 40,41.

The purpose of the discrete attachment sites 40,41 is to keep the unattached segments 18, 19 of the elastic elements 10, 1 1 at a distance from the inner edges 37,38 of the band- shaped attachment areas 7,8 in order to prevent the band shaped attachment areas 7,8 from interfering with the snap-back effect when severing the elastic elements 10, 1 1. Instead of discrete attachment sites placed at a distance from the inner edges 37,38 of the band-shaped attachment areas 7,8, the unattached segments 18, 19 of the elastic elements 10, 1 1 may be held away from the inner edges of the band-shaped attachment areas 7,8 by means of attachment sites arranged as adhesive protrusions extending without a gap from the inner edges 37,38 towards the crotch centre line 2 or connecting the band-shaped attachment areas 7,8 in the CD. Discrete cut-off elastic segments 31 ,32 of the first and second stretched elastic elements 10, 1 1 are formed by means of the cutting line 27 additionally severing each of the elastic elements 10,11 once inside the band-shaped attachment areas 7,8. These cuts are made generally in the machine direction, MD, at the leading end parts 29 of the cut-out pieces.

As in the process shown in Figs. 1 and 2, the order of the cuts in the elastic elements 10, 1 1 as the base web 1 is moved in the machine direction, MD, is from right to left in Figs. 6. If a first cut is considered to be that which severs the elastic elements 10, 1 1 in the unattached segments 18, 19, this first cut will be made in the band-shaped attachment free area 9 at the trailing end part 30 of a first cut-out piece 25 and near each inner edge 37,38 of the band shaped attachment areas 7,8. The first cut will cause the ends of the severed elastic elements 10, 1 1 to snap back and retract to a position in the vicinity of the discrete attachment sites 40,41 in the leading end part 29 of a second cut-out piece 25 following on the first cut-out piece 25 in the MD. Relaxation and retraction of the severed elastic ends will take place before the web is cut in the CD at the end of the trailing end part 30 of the first cut-out piece 25. When the following cut-out piece 25 begins to form, the CD cut in the crotch section 4 will also only be made through the base web 1 and not through the retracted elastic elements 10, 1 1. As the following cut-out piece 25 continues to be formed, second cuts through the elastic elements 10, 1 1 are made, severing the elastic elements 10, 1 1 downstream of the discrete attachment sites 40,41 so that cut-off crotch elastic segments 31 ,32 10, 1 1 are removed from the parts of the elastic elements 10, 1 1 that are attached along the leg edge segments 3. The cut-off crotch elastic segments 31 ,32 including the retracted portions of the elastic elements 0, 1 1 are attached to the cut-out pieces 25 at the discrete

attachment sites 40, 41. The second cut in the elastic elements 10, 1 1 , which forms the cut-off crotch elastic segments 31 ,32 is shown in Fig. 6 to be made in the band shaped attachment areas but may alternatively be made in the small gap 45 between each inner edge 37,38 of the band shaped attachment areas 7,8 and the discrete attachment sites 40,41 or within the discrete attachment sites 40,41.

Fig. 7 is similar to Fig. 6 but differs in that both the first attachment sites 20,21 and the second attachment sites 22,23 delimiting the unattached segments 18,19 of the elastic elements 10, 1 1 in the crotch segments 4 of the base web 1 are in the form of discrete attachment sites 40,41 ,42,43. The contour of each cut-out piece 25 is defined by a closed loop cutting line 27 as previously described. Each cut-out piece 25 has a central leg opening part 28, a leading end part 29 and a trailing end part 30. The first discrete attachment sites 40,41 are placed on the leading end part 29 inside of the contour of the cut-out piece 25 and the second discrete attachment sites 42,43 are placed on the trailing end part 30 inside of the contour of the cut-out piece 25.

The sequence of the cuts is from right to left in Fig. 7 as the base web 1 moves in the machine direction, MD. The first cut severs the elastic elements 10, 1 1 at the trailing end part 30 of a first cut-out piece 25 and causes the unattached end parts of the severed elastic elements 10, 1 1 to snap back to the first discrete attachment sites 40,41 in the leading end part 29 of a second cut-out piece 25 following on the first cut-out piece 25 in the MD. During retraction of the severed end parts of the elastic elements 10, 1 1 the ends move to a position in the vicinity of the first discrete attachment sites 40,41 which is inside the contour of the cut-out piece 25.

Relaxation and retraction of the severed elastic ends will take place before the web is cut again at the leading end part 29 of the second cut-out piece 25. This means that when the second cut-out piece 25 begins to form, the CD cut in the crotch section 4 will only be made through the base web 1 and not through the retracted elastic elements 10,1 1. As the following cut-out piece 25 continues to be formed second cuts through the elastic elements 10,1 are made, severing the elastic elements 10, downstream of the first discrete attachment sites 40, 41 on the second cut-out piece so that cut-off crotch elastic segments 31 ,32 are severed from the parts of the elastic elements 10, 1 that are attached along the leg edge segments 3. As in the embodiment shown in Fig. 6, this second cut may be made in the band-shaped attachment areas 7,8, in the small gap 45 between each inner edge 37,38 of the band shaped attachment areas 7,8 and the discrete attachment sites 40,41 or within the discrete attachment sites.

The cut-off crotch elastic segments 31 ,32 including the retracted portions of the elastic elements 10, 1 1 are attached to the cut-out pieces 25 at the first discrete attachment sites 40, 41 inside of the cutting line contour in the leading end parts 29 of the second cut-out piece 25. Small portions of the elastic elements 10, 1 1 are again cut off from the leg edge elastic as the base web 1 moves in the MD and the trailing end part 30 of the second cut-out piece 25 is being formed. The cutting line 27 will then cut the elastic elements 10, 1 1 either as shown in Fig. 7 in the band-shaped attachment areas 7,8, in the small gap 45 between each inner edge 37,38 of the band shaped attachment areas 7,8 and the discrete attachment sites 42,43 before reaching the second discrete attachment sites 42, 43 or within the second discrete attachment sites 42,43. The elastic elements 10, 1 1 are then cut a second time when the cutting cycle begins again with the CD cut at the trailing end part 30 of the second cut-out piece 25 where the unattached crotch segments 18, 19 of the elastic elements 10, 1 1 are severed.

Instead of making discrete attachment sites 40,41 ,42,43 intermittently arranged in the MD, the attachment sites may be made as continuous strings or bands of adhesive arranged in the MD at a distance from the inner edges 37, 38 of the band-shaped attachment areas 7,8. Such continuous strings or bands of adhesive will have keep the unattached crotch segments 18, 19 of the elastic elements 10, 1 1 away from the inner edges 37,38 of the band-shaped attachment areas 7,8. However, there is a risk that the snap-back function will be somewhat hindered by friction and adhesion between the cut elastic ends and a continuous adhesive string or band.

Figs. 8 and 9 show detailed views of a multi-string elastic element 1 1 being cut and partly removed in a method according to the invention, similar to the method shown in Fig 7 with unattached elastic segments 19 being defined by discrete attachment sites 41 ,43. The continuous elastic element 1 1 is attached to a base web 1 in a band-shaped adhesive attachment area 8 and has an unattached segment 19 between a first discrete attachment site 41 and a second discrete attachment site 43 as in the method in Fig 7. The section of the base web 1 that is shown in Figs. 8 and 9 is taken from the lower half of a continuous base web 1 such as that shown in Fig. 7 and includes an unattached segment 19 of the elastic element 1 1 arranged in a crotch segment 4 of the base web 1 . The section of the base web 1 also includes a corner section of a trailing end part 30 of a first cut-out piece 25' and a corner section of a leading end part 29 of a second cut-out piece 25" which are separated in the machine direction, MD, by a narrow strip 26 of the base web .

When the base web 1 is moved in the MD, a first cutting line 27' is made in the web 1 , the first cutting line 27' having a final CD cut segment 34' at the trailing end portion 30 of the first cut-out portion 25'. The first cutting line 27' severs the tensioned elastic element 1 1 on a leading side of the narrow strip 26 of base web 1 between the first and second cutout pieces 25', 25", as is shown in Fig. 8. A second cutting line 27" having an initial CD cut segment 34" at the leading end portion 29 of the second cut-out portion 25" is indicated by a dashed line in Fig. 8. Fig. 8 shows the situation immediately after the elastic element 1 1 has been cut at the first cutting line 27' and before the severed ends 35 of the elastic element 1 1 have been relaxed and retracted inside of the contour of the second cutting line 27". In the time it takes for the base web 1 to move in the MD to a position where the initial CD cut segment 34" of the second cutting line 27" is created, the severed ends 35 of the elastic element 11 will have retracted inside of the contour of the second cutting line 27" as shown in Fig. 9.

As the second cutting line 27" continues in the MD, the elastic element 1 1 is cut by the cutting line 27" in the band-shaped adhesive attachment area 8, upstream of where the unattached segment 19 of the elastic element 1 1 ends at the discrete attachment site 41 on the leading end portion 29 of the second cut-out piece 25". The second cut results in cut-off crotch elastic segments 32 being formed.

The cut-off crotch elastic segments 32 at the leading and trailing ends parts 29,30 include the severed and retracted unattached ends 35,36 of the elastic element 1 1 and portions of the elastic element 1 1 that are attached to the cut-out pieces 25', 25" at the first and second discrete attachment sites 41 ,43.

Fig. 9 shows the same section of the base web 1 as in Fig. 8 after both the first and the second cutting lines 27', 27" have been completely formed and the cut-out pieces 25', 25" are being removed from the base web 1. From Fig. 9 it can be learned that the major part of the unattached segment 19 of the elastic element 1 1 is removed together with the second cut-out piece 25" while shorter unattached ends 36 of the elastic element 1 1 are left on the first cut-out piece 25'. There are no parts of the elastic element 1 1 left in the crotch segment 4 of the base web 1 or any loose cut-off elastic pieces that may interfere with the production process.

An elasticated base web 1 such as the base webs shown in Figs. 1 -9, may be further processed into elasticated disposable pant garments such as disposable underpants, disposable absorbent pants, disposable pant diapers having closed side seams or disposable diapers with closure means for securing the diaper in a pant-like configuration about the waist of a wearer. Fig. 10 shows a base web 1 having continuous leg elastic elements 10, 1 1 attached along first and second regularly undulating curves 12, 13 to the base web, as disclosed herein. The undulating curves 12, 13 in Fig.10 have the same wavelength, i, but differ in amplitude and shape in order for the resulting leg elastic to conform to the curvature of an anatomically shaped leg-opening in a finished pant garment.

The base web in Fig. 10 is provided with waist elastic 54,55 along the side edges 5,6. The waist elastic is shown as a number of regularly spaced elastic elements. However, any elastic waist feature as known in the art may be used. Such waist features include continuous or discrete elastic elements that may be single or multiple bands or strings arranged with different tension and/or different spacing at one or both of the side edges 5,6 of the base web 1 . The waist elastic elements may be applied only in an area in the vicinity of the side edges, or may be applied all the way to the leg elastic elements 10, 1 1 to form body elastic in the finished pant garment.

After the leg elastic elements 10, 1 1 and the waist elastic 54,55 have been applied to the base web 1 , leg holes 50 are formed in the base web 1 by cutting out and removing cut- out pieces 25 together with cut-off crotch elastic segments of the leg elastic elements 10, 1 1 being attached to end parts 29,30 of the cut-out pieces 25, as herein disclosed. The crotch center line 2 is closer to the upper side edge 5 than to the lower side edge 6 so that the leg holes 50 are cut out from the base web 1 slightly offset from the longitudinal center line of the base web towards the upper side edge 5 as shown in Fig 10. When the pant garment is fully assembled, the upper side edge 5 in Fig. 10 will be at the front waist edge of the garment while the lower side edge 6 in Fig. 10 will be at the rear waist edge of the garment.

A core pack 56 is subsequently attached over the narrow strip 26 of the base web 1 remaining between the leg holes 50. A "core pack", as used herein is a separately produced component that is integrated with the base web 1 and includes an absorbent core enclosed between a topsheet and a liquid impermeable backsheet. The core pack 56 may be attached by any suitable means such as by adhesive or thermo bonding or ultrasonic bonding. Although the core pack 56 is shown in Fig. 10 to have a rectangular shape, the core pack may take other forms such as hourglass shape, trapezoidal shape, etc.

The various components included in the core pack 56 can be connected to one another in a conventional manner, for example by adhesive bonding, ultrasonic bonding or thermobonding. The core pack can of course contain further components in addition to those described here, such as a liquid transport sheet, elastic members, shape-stabilizing members, shaping elements, side barriers, etc. The liquid-permeable topsheet can consist of any material known for the purpose, such as a layer of nonwoven material, a perforated plastic film, net material, tow, or the like. The topsheet can, of course, also consist of a laminate of two or more sheets of the same or different material. The liquid-impervious barrier sheet can consist of a liquid-impermeable plastic film, a nonwoven sheet which has been coated with a liquid barrier material, or some other flexible material sheet which has the ability to withstand liquid penetration. However, it may be advantageous if the liquid-impervious barrier sheet has some degree of breathability, i.e. permits the passage of water vapour through the sheet.

The absorption core can be made up of absorbent material, such as cellulose fluff pulp, tissue, absorbent foam, etc. It is also possible for the absorption core to contain superabsorbents, i.e. polymer materials which are able to absorb body fluid corresponding to many times their own weight and form a hydrogel. Such superabsorbents are usually present in the form of particles, but fibres, flakes, granules and films are also available. Moreover, the absorption core can comprise non-absorbent components such as stiffening elements, shaping elements, binders, etc. Various types of liquid-receiving porous structures such as fibre waddings, open-cell foam or the like can also be included in the core.

A section 60 of a base web corresponding to a chassis for a disposable pant is shown in Fig. 1 1 . The base web section 60 comprises a base web 1 having leg elastic elements 10, 1 1 , waist elastic 54,55 and body elastic 61 ,62 applied thereto. The leg elastic elements 10, 1 1 are applied along a front leg elastic curve 12 and a rear leg elastic curve 13 as shown in Fig. 10. The leg elastic elements 10, 1 1 are attached to the base web 1 as shown in Figs. 7 and 8-9 with discrete attachment sites 40-43 defining unattached segments 18, 19 of the elastic elements 10, 1 1 therebetween. In the machine direction, MD, the base web section 60 comprises a crotch segment 4 located between one half of a first leg edge segment 3 and one half of a second leg edge segment 3. In the cross machine direction, CD, the base web section 60 comprises a front body portion 67, a rear body portion 68 and a crotch portion 69 located between the front body portion 67 and the rear body portion 68.

The base web section 60 is shown before leg openings have been formed in the base web by removing the cut-out pieces 25', 25" that are to be cut out along cutting lines 27', 27". When the cut-out pieces 25', 25" have been removed, the base web section 60 will have first and second leg openings separated in the MD by a narrow strip 26 of the base web 1 remaining in the crotch portion 69. The leg elastic elements 10, 1 1 are removed from the crotch portion 69 together with the cut-out pieces 25', 25", so that the only remaining parts of the leg elastic elements 10, 1 1 are the segments that are attached along the leg openings forming front and rear leg elastic, 71 ,72.

The base web section 60 shown in Fig. 1 1 may be converted into a disposable pant or a disposable absorbent pant, the base web section 60 forming a chassis component that extends as a continuous base web from a front waist edge 75 to a rear waist edge 76 of the pant without any seams or joins in the web.

For most purposes, the narrow strip 26 in the crotch portion 69 needs to be supplemented with a broader piece of material to replace the material that was cut away from the crotch portion when removing the crotch elastic segments. The supplementary piece of material may be a nonwoven material, a plastic film, a nonwoven/film laminate or a core pack as shown in Fig. 10. When the supplementary piece of material is a non-absorbent layer of material it may be applied on an outer garment-facing side of the base web section 60 to create a smooth outer surface in the crotch portion of the finished pant garment. However, it is generally preferred to apply the supplementary piece of material to the inner, wearer- facing side of the base web section 60. In a finished pant garment, the supplementary piece of material will define the width of the crotch portion 69 between the leg openings formed by removing the cut-out pieces 25', 25". The supplementary piece of material may have curved or straight edges in the CD, i.e. in the longitudinal direction of the assembled pant garment. The base web section 60 will constitute a continuous chassis layer in the pant garment and the narrow strip 26 will connect a front body portion of the chassis layer with a rear body portion of the chassis layer and will have a smaller maximum width than the minimum width of the crotch portion as defined by the width of the supplementary piece of material.

After the cut-out pieces 25', 25" have been removed from the base web 1 , the base web is folded along the longitudinal centre line through the base web 1 and edge seams are formed in the CD at the garment side edges 77,78 to join the front and rear body portions 67,68. The fold along the longitudinal centre line may coincide with the crotch centre line 2 as in the embodiment shown in Fig. 1 1 or may be placed at a distance from the crotch centre line as would be the case in the embodiment shown in Fig. 10. Subsequently, base web sections 60 are cut off from the continuous base web 1 by cutting through the edge seams in the cross machine direction, CD, so that individual pant garments are formed. One example of a fully assembled pant garment that may be produced from a base web section such as that in Fig. 1 1 is shown in Fig. 12. The Fig. 12 garment comprises an integrated absorbent core. However, the invention is also directed to the production of chassis webs for non-absorbent or slightly absorbent pant garments. Side seams are often arranged in a pant garment to connect the front body portion to the rear body portion and to form a pant having a waist opening and leg openings. The side seams are intended to be arranged at the user's hips during use of the disposable pant, The side seams are preferably designed so that they can withstand the tensile forces which arise when the pant is being put on and is being worn, but such that they can be torn apart or opened in a controlled manner when the disposable pant is taken off or to check if the pant needs changing. In the latter instance, the side seams are preferably reclosable seams, as known in the art. Side seams may be formed by any suitable means known in the art such as adhesively, by ultrasonic bonding, by thermobonding or by stitching or needling. As the person skilled in the art is well aware, if thermobonding or ultrasonic bonding is being used, the base web material needs to comprise a sufficient amount of thermoplastic material in order to obtain sufficient bond strength.

An assembled pant diaper 100 is shown in Fig. 12. The pant diaper 100 has a front body portion 107, a rear body portion 108 and a crotch portion 109 between the front body portion 107 and the rear body portion 108. The pant diaper 100 has front and rear waist edges 175, 176 encircling a waist opening 180 and leg edges 127 encircling two leg openings 150 and side seams 178 extending between the leg openings 150 and the waist opening 180 and connecting the front body portion 107 and the rear body portion 108. The leg openings have leg elastic 170 arranged at the leg edges 127 around the leg openings 150. Each leg elastic 170 is formed by a front elastic segment 1 10 and a rear elastic segment 1 1 which are separated by a gap, g, in the crotch portion 109. The leg elastic may be one or more elastic strings, bands, etc as herein described. Front and rear waist elastic 154, 155 is arranged around the waist opening 180 and body elastic 61 is arranged on the front body portion 07 and the rear body portion 08 in an area between the waist elastic 154, 155 and the leg openings 150. The waist elastic 154, 155 may be in the form of a waist band formed from plies of substantially non-elastic nonwoven material that is elasticized by one or more elongate elastic members, such as elastic threads or bands that are arranged between the plies. The plies can be formed from a single layer of material such as an edge portion of the base web 101 that is folded over onto itself or can be made from separate materials such as a portion of the base web 101 and a layer of another material. The elastic members are arranged in the waist band in a tensioned state such that they contract and gather the nonwoven material in the waist band when they are allowed to relax, as shown in Fig 2. The waist elastic 154, 155 may be a prefabricated component that is attached to the side edges 5,6, of a base web 1 during manufacturing according to any one of the methods disclosed herein. A disposable pant according to the invention need not have waist elastic with the configuration shown in Fig. 12. The waist elastic may be arranged on only one of the front body portion 107 and the rear body portion 108. The waist elastic may extend along only a part of the waist opening 180 such as along a central section of the front waist edge 175 and/or the rear waist edge 176.

The body elastic 161 is shown as multiple elongated elastic members extending between the side edges 178 across the front body portion 107 and the rear body portion 108. The elastic members may be elastic strings or bands that may be uniformly or non-uniformly spaced over the body portions 107, 108 and that may have been applied with the same or different tensioning. The body elastic is not a necessary feature of the invention and may be omitted or designed in other ways as found suitable for a specific purpose.

Accordingly, body elastic may be applied to only one of the front and rear body portion 107, 108 and may include or consist of curved elastic elements or elastic panels formed from elastic or elasticated nonwoven material.

There are no elastic elements extending across the crotch portion 109 between the leg openings 50.

The diaper 100 is formed with a chassis layer 101 extending continuously from the front waist edge 175 over the front body portion 107, through the crotch portion 109 and the rear body portion 108 to the rear waist edge 176 without any seams or joins in the chassis layer 101.

The front body portion 107 and the rear body portion 108 are connected in the crotch portion 109 by a narrow strip 126 of the chassis layer 101 that was formed when cutting away elastic elements from the crotch portion in the method according to the invention.

A core pack 156 is attached to the inside of the chassis layer 101 in the crotch portion 109. The core pack 156 comprises an absorbent core 190 being sandwiched between an inner topsheet layer 191 and an outer backsheet layer 192. In the pant diaper shown in Fig. 12, the backsheet layer 192 is exposed and visible in the crotch portion 109 on both sides of the narrow strip 26 of the chassis layer 101 .

The liquid-permeable topsheet 191 may consist of or comprise a layer of nonwoven material, a perforated plastic film, net material, tow, or the like. The topsheet 191 can consist of a laminate of two or more sheets of the same or different material and may have different composition or different properties within different portions of the topsheet.

The backsheet 192 may consist of a liquid-impermeable plastic film, a nonwoven sheet which has been coated with a liquid barrier material, or some other flexible sheet material having the ability to resist liquid penetration. The backsheet is preferably breathable, allowing passage of air and water vapour. As the backsheet 192 is exposed to the outside of the pant diaper in the crotch portion 109 and may come into contact with a wearer's skin when the diaper is worn, the backsheet 192 preferably has a textile or textile-like outer surface in order to avoid the stickiness that may be felt in contact with a plastic film surface. A textile or textile-like outer surface is also preferred for the reason that it enhances the likeness of the pant diaper or other pant garments to regular underwear. The absorption core 190 comprises absorbent material, such as absorbent fibres e.g. cellulose fluff pulp, tissue, absorbent foam, superabsorbents, absorbent composites, etc. Superabsorbents are polymer materials which are able to absorb and retain body fluid corresponding to many times their own dry weight under formation of a hydrogel.

Superabsorbents are usually present in the form of particles or granules, but fibres, flakes, and films are also available. The absorption core 190 may further comprise non-absorbent components such as non-absorbent fibres, stiffening elements, shaping elements, barrier material, binders, etc. Various types of liquid-receiving porous structures such as fibre wads, open-cell foam or the like can also be included in the core.

In the pant diaper shown in Fig. 12, the core pack 156 includes side elastic 193 arranged at the side edges of the absorbent core 190. The side elastic 193 contributes to form the core into a curve shape and to form barriers against side leakage. The side elastic 193 may be applied on the core edges or may be applied outside of the core in side flaps formed from one or both of the topsheet and the backsheet to create elasticated raised barriers along the side edges of the core.

Claims

1. Method for producing an elasticated chassis web for use as a continuous and coherent layer in a disposable garment, comprising the steps of: a) feeding a continuous base web (1 ) along a production path in a machine direction, (MD), the continuous base web (1) having a cross machine direction, (CD), transverse to the machine direction, (MD), and parallel side edges (5,6) in the machine direction, (MD), and having leg edge segments (3) and crotch segments (4) extending in the cross machine direction, (CD), and alternating in the machine direction, (MD); b) stretching first and second continuous elastic elements (10,1 1 ); c) feeding said first and second continuous elastic elements (10, 1 1 ) in said machine direction, (MD), along first and second regularly undulating wave-shaped curves (12, 13), said curves (12, 13) having equal wave length, I, and having wave crests (14, 15) directed towards said side edges (5,6) of said continuous base web (1 ) and wave troughs (16, 17) directed away from said side edges (5,6) of said continuous base web (1 ), said wave crests (14) and wave troughs (16) of said first wave-shaped curve (12) being in register with said wave crests (15) and wave troughs (17) of said second wave-shaped curve (13) with said elastic elements (10, 1 1 ) being at a maximum distance (d₂) from each other within said leg edge portions (3) of said continuous base web (1 ) and with said elastic elements (10, 1 1 ) being at a minimum distance (d-i ) from each other within said crotch segments (4) of said continuous base web (1 ); characterised by the further steps of: d) attaching said first and second stretched elastic elements (10, 1 1 ) to said continuous base web (1 ) along said first and second regularly undulating wave- shaped curves (12, 13) within said leg edge segments (3) of said continuous base web (1 ), leaving said first and second elastic elements (10, 1 1 ) free from attachments to said continuous base web (1 ) within said crotch segments (4) along unattached elastic segments (18, 19) located between a first attachment site (20,21 ) on a first side of each of said wave troughs (16, 17) of said first and second elastic elements (10, 1 1 ) and a second attachment site (22,23) on a second side of each of said wave troughs (16, 17) of said first and second elastic elements (10, 1 1 ) as said continuous base web (1 ) is fed in said machine direction, (MD) ; e) cutting out identically shaped cut-out pieces (25) from said continuous base web (1 ), wherein,

- said cut-out pieces (25) are spaced apart in said crotch segments (4);

- a contour of each said cut-out piece (25) is defined by a cutting line (27) extending along each elastic element (10, 1 1 ), between said elastic elements (10, 1 1 ) and forming a closed loop;

- each said cut-out piece (25) has a leg opening part (28) being located within a leg edge segment (3) of said continuous base web (1 ) and a leading end part (29) and a trailing end part (30) extending from said leg opening part (28) in said leg edge segment (3) into adjoining crotch segments (4) on a leading and a trailing side of said leg edge segment (3);

- a pair of first attachment sites (20,21) of said first and second elastic elements

(10,1 1 ) are located on said leading end part (29) of said cut-out piece (25); f) forming cut-off crotch segments (31 ,32) of said stretched and attached elastic elements (10, 1 1 ) by means of said cutting line (27) severing each said first and second stretched elastic element (10, 1 1 ) once within said unattached segment

(18, 19) of each said elastic element (10,1 1 ) on a first side of said first attachment sites (20,21 ), causing said severed unattached segments (18,19) to snap-back inside of said contour of said cut-out pieces (25), and severing each said elastic element (10, 1 1 ) once on a second side of said first attachment sites (20,21 ) such that said cut-off crotch elastic segments (31 ,32) are attached to said cut-out pieces

(25); and g) removing said cut-out pieces (25) and said cut-off crotch elastic segments (31 ,32). from said continuous base web (1 ).

2. Method according to claim 1 , wherein a pair of second attachment sites (22,23) of said first and second elastic elements (10, 1 1 ) are located on said trailing end part (30) of said cut-out piece (25); and wherein said first and second stretched elastic elements (10,1 1 ) are severed by said cutting line (27) once on a first side of said second attachment sites (22,23), and once on a second side of said second attachment sites (22,23).

3. Method according to claim 1 or 2, wherein the first attachment sites (20,21 ) take the form of discrete attachment sites (40,41 ).

5 4. Method according to claim 1 , 2 or 3, wherein the second attachment sites (22,23) take the form of discrete attachment sites (42,43).

5. Method according to any one of the preceding claims, wherein the minimum spacing in the machine direction, (MD), between the cut-out pieces (25) in the crotch segment (4) is

10 10 mm - 150 mm, preferably 15 mm - 100 mm and most preferably 20 mm - 80 mm.

6. Method according to any one of the preceding claims, wherein said first and second stretched elastic elements (10, 1 1 ) are attached to said continuous base web (1 ) by means of adhesive.

15

7. Method according to claim 6, wherein said adhesive is applied to said continuous base web (1 ) in a first band-shaped attachment area (7) along a first of said parallel side edges (5) of said continuous base web (1 ) and in a second band-shaped attachment area (8) along a second of said parallel side edges (6) of said continuous base web (1 ), said first

20 and second band-shaped areas (7,8) being spaced apart in the cross-machine direction (CD) of the continuous base web (1 ).

8. Method according to claim 6, wherein said adhesive is applied to said continuous base web (1 ) in first and second attachment areas generally coinciding with said first and

25 second regularly undulating wave-shaped curves (12, 13) within said leg edge segments (3) of said continuous base web (1 ).

9. Method according to any one of the preceding claims, wherein said first and second stretched elastic elements (10, 1 1 ) are attached between the base web (1 ) and a covering 0 web.

10. Method according to claim 7, wherein said first and second band-shaped attachment areas (7,8) have a width in the cross-machine direction, (CD), of the continuous base web (1 ) smaller than the width in the cross-machine direction, (CD), of said first and second 5 regularly undulating wave-shaped curves (12, 13) of said stretched continuous elastic elements (10, 1 1 ), said first and second stretched continuous elastic elements (10, 1 1 ) being attached to said continuous base web (1 ) with said wave crests (14, 15) completely within said first and second band-shaped attachment areas (7,8) and with a portion of each said wave-troughs (16, 17) extending in the cross-machine direction, (CD), away from said first and second band-shaped attachment areas (7,8) to form said unattached segments (18,19) in said crotch segments (4).

1 1. Method according to claim 7, wherein said first and second band-shaped attachment areas (7,8) have portions in said leg edge segments of said continuous base web (1 ) having a width in the cross-machine direction, (CD), of the continuous base web (1 ) greater than or equal to the width in the cross-machine direction, (CD), of said first and second regularly undulating wave-shaped curves (12,13) of said stretched continuous elastic elements (10, 1 1 ), and portions in said crotch segments (4) of said continuous base web (1 ) having a width in the cross-machine direction, (CD), of the continuous base web (1 ) smaller than the width in the cross-machine direction, (CD), of said first and second regularly undulating wave-shaped curves (12, 13) of said stretched continuous elastic elements (10, 1 1 ), said first and second stretched continuous elastic elements (10,1 1 ) being attached to said continuous base web (1 ) with said wave crests (14, 15) completely within said first and second band-shaped attachment (7,8) areas and with a portion of each said wave-troughs (16, 17) extending in the cross-machine direction, (CD), away from said first and second band-shaped attachment areas (7,8) to form said unattached segments (18,19) in said crotch segments (4).

12. Method according to any one of the preceding claims, wherein a supplementary piece of crotch material is attached to said continuous base web (1 ) in said crotch segment (4) after cutting out and removing said cut-out pieces (25).

13. Method according to claim 12, wherein said supplementary piece of crotch material is comprised in a core pack (56), said core pack comprising a topsheet layer, a backsheet layer and an absorbent core between said topsheet layer and said backsheet layer.

14. Method according to any one of the preceding claims, wherein waist elastic (54,55) is applied along at least one of said side edges (5,6) of said continuous base web (1 ).

15. Method according to claim 14, wherein said continuous base web (1 ) is folded along a longitudinal centre line through said base web (1 ), edge seams are formed in the cross machine direction, (CD), centrally across each wave crest segment (14, 15) and said continuous base web (1 ) is cut into individual pant garments in the cross machine direction, (CD), by cutting through said edge seams.

16. A disposable pant garment (100) having front and rear waist edges (175, 176) and leg edges (127), a front body portion (107), a rear body portion (108) and a crotch portion (109) between said front and rear body portions (107, 108) and comprising a coherent chassis layer (101 ) extending continuously from said front waist edge (175) to said rear waist edge (176) and having elastic elements (1 10, 1 1 1 ) attached along said leg edges (127), characterised by said front body portion (107) and said rear body portion (108) being connected in said crotch portion (109) by a strip (126) of said chassis layer (101 ) having a minimum width of 10 - 50 millimeters.

17. A disposable pant garment according to claim 16, wherein said pant garment (100) is an absorbent pant garment (100).

18. A disposable pant garment according to claim 17, wherein said absorbent pant garment (100) comprises a core pack (156) arranged in said crotch portion (109), said core pack comprising a topsheet layer (191 ), a backsheet layer (192) and an absorbent core (190) between said topsheet layer (191 ) and said backsheet layer (192).

19. A disposable pant garment according to claim 17 or 18, wherein said pant garment is a pant diaper (100) having side seams (178) connecting said front body portion (107) with said rear body portion (108).