Process to make boxer shorts having a contracted crotch region

Abstract

A method of making a boxer-style pant having side seams, a contracted crotch region and hanging legs. A flat web is provided. Portions are removed from the flat web to define leg openings. The flat web is then contracted either elastically or inelastically in selected areas along the flat web between the leg openings. The flat web is cut into separate pieces, folded and side seams are formed. The pant may include an absorbent.

What is claimed is:  
     
         1 . A method of making a pant having side seams and hanging legs, comprising: 
 providing a flat web;    removing at least one portion of the flat web to define two leg openings;    contracting the flat web in at least one selected area to define at least one contracted area, a first region and a second region; and    attaching the first region and the second region together to form the side seams.    
     
     
         2 . The method of  claim 1 , further including applying a strip in the at least one selected area.  
     
     
         3 . The method of  claim 2 , wherein contracting the flat web in the at least one selected area comprises contracting the strip.  
     
     
         4 . The method of  claim 2 , wherein the strip comprises a delayed retraction material.  
     
     
         5 . The method of  claim 1 , wherein contracting the flat web in the at least one selected area comprises corrugating the flat web.  
     
     
         6 . The method of  claim 5 , wherein corrugations are bonded together.  
     
     
         7 . The method of  claim 1 , further comprising attaching at least one waist elastic to the flat web.  
     
     
         8 . The method of  claim 1 , further comprising folding the flat web.  
     
     
         9 . The method of  claim 1 , wherein the pant is made using a machine direction assembly.  
     
     
         10 . The method of  claim 1 , wherein the pant is made using a cross-machine direction assembly.  
     
     
         11 . The method of  claim 1 , further comprising cutting the flat web into separate pieces.  
     
     
         12 . The method of  claim 11 , wherein the contracting occurs before the cutting.  
     
     
         13 . The method of  claim 11 , wherein the contracting occurs after the cutting.  
     
     
         14 . The method of  claim 1 , wherein the flat web comprises an integral elastic zone.  
     
     
         15 . A method of making an absorbent pant having side seams and hanging legs, comprising: 
 providing a flat web;    removing at least one portion of the flat web to define two leg openings;    contracting the flat web in at least one selected area to define at least one contracted area, a first region and a second region;    attaching an absorbent structure to the flat web; and    attaching the first region and the second region together to form the side seams.    
     
     
         16 . The method of  claim 15 , further including applying a strip in the at least one selected area.  
     
     
         17 . The method of  claim 15 , wherein contracting the flat web in the at least one selected area comprises contracting the strip.  
     
     
         18 . The method of  claim 15 , wherein the strip comprises a delayed retraction material.  
     
     
         19 . The method of  claim 15 , wherein contracting the flat web in the at least one selected area comprises corrugating the flat web.  
     
     
         20 . The method of  claim 19 , wherein corrugations are bonded together.  
     
     
         21 . The method of  claim 15 , further comprising attaching at least one waist elastic to the flat web.  
     
     
         22 . The method of  claim 15 , further comprising folding the flat web.  
     
     
         23 . The method of  claim 15 , wherein the pant is made using a machine direction assembly.  
     
     
         24 . The method of  claim 15 , wherein the pant is made using a cross-machine direction assembly.  
     
     
         25 . The method of  claim 15 , further comprising cutting the flat web into separate pieces  
     
     
         26 . The method of  claim 25 , wherein the contracting occurs before the cutting.  
     
     
         27 . The method of  claim 25 , wherein the contracting occurs after the cutting.  
     
     
         28 . The method of  claim 15 , wherein the flat web comprises an integral elastic zone.  
     
     
         29 . A pant made from a single flat web, the pant comprising: 
 a garment shell, the garment shell including a front region, a back region, a contracted crotch region, side seams connecting the front region to the back region, and hanging legs, at least a portion of each of the front region, the back region, the contracted crotch region and the hanging legs comprising portions of the single flat web.    
     
     
         30 . The pant of  claim 29 , further comprising a waist elastic extending along at least a portion of at least one of a front waist edge of the front region and a back waist edge of the back region.  
     
     
         31 . The pant of  claim 29 , further comprising an absorbent structure attached to the garment shell in at least one of the front region, the back region and the crotch region.  
     
     
         32 . The pant of  claim 31  wherein the absorbent structure is attached to the garment shell by one of ultrasonic bonding and adhesive bonding.  
     
     
         33 . The pant of  claim 31 , wherein the absorbent structure comprises a stretchable material.  
     
     
         34 . The pant of  claim 29 , wherein a ratio of a take up to twice an inseam length is in a range from about 1:1 to about 1.5:1.  
     
     
         35 . A method of making a pant having side seams and hanging legs, comprising: 
 providing a flat web;    removing at least one portion of the flat web to define two openings;    applying at least one strip to the flat web;    contracting the strip to provide at least one contracted area, a first region and a second region;    attaching the first region to the second region.