Staggered cutting knife

Abstract

A method and apparatus for producing disposable undergarments having areas of defined elastic material is disclosed. The method provides for staggered cutting knives for severing the elastic material, which results in less necessary material used in the construction of the undergarments.

1 . A method of making a garment, said garment including a fit-gather laminated area, said method including the steps of: 
 a. providing a laminate defining said fit gather area extending widthwise of said garment, said laminate having two layers of non-woven material and an intermediate layer of a plurality of longitudinally widthwise stretchable elastic elements laterally spaced lengthwise relative to said garment;    b. adhering a first portion of said intermediate layer of elastic elements to facing sides of said layers of non-woven material and further defining a non-adhesive portion of said intermediate layer;    c. severing selected ones of said stretchable elastic elements lying in a first common plane traversing the width of said garment in said non-adhering second portion; and    d. severing remaining of said stretchable elastic elements lying in a second common plane spaced lengthwise relative to said first common plane.    
   
   
       2 . The method according to  claim 1 , further including the steps of: 
 a. providing a backing sheet of material; and    b. adhering said backing sheet of material to one of said non-woven layers of material.    
   
   
       3 . The method according to  claim 1  further including the step of attaching an adsorbent layer to said garment.  
   
   
       4 . A knife assembly for an apparatus used in the manufacture of a garment having a fit gather laminate area extending widthwise of said garment, said area comprising a plurality of layers, said layers including a layer of non-woven material and an adjacent layer of a plurality of longitudinally widthwise stretchable elastic elements laterally spaced lengthwise relative to said garment, said knife assembly comprising: 
 a plurality of knife blades having cutting edges extending lengthwise across said fit gather laminate area, said plurality of blades including:    a first pair of spaced apart knife blades located in a common plane; and    a second pair of spaced apart knife blades located in a second common plane and being in an alternatively staggered relationship to a respective knife blade lying in said first common plane; and    support means securing said knife blades in said staggered relationship.    
   
   
       5 . The knife assembly according to  claim 4  wherein said support means comprises a roll bar.  
   
   
       6 . A severing station in a continuous garment production assembly for severing elastic material in said garment having a fit gather laminate area, the station comprising: 
 a cutting roll;    a plurality of knife blades located on said cutting roll, said knife blades having cutting edges extending lengthwise across said fit gather laminate area, said plurality of blades including:    a first pair of spaced apart knife blades located in a common plane; and    a second pair of spaced apart knife blades located in a second common plane and being in an alternatively staggered relationship to a respective knife blade lying in said first common plane; and    an anvil roller.    
   
   
       7 . The severing station according to  claim 7 , wherein said anvil roller further comprises at least one carbide insert, said carbide insert providing an area for said knife blades to act against.