Composite method for fabricating garments

A method for use in constructing a garment including elastic, in a processing system, as one of a series of consecutive workpieces in a continuous web, each respective workpiece having front and back body portions, separated by a crotch portion, the method including, with respect to respective workpieces, the steps of:

• (a) stretching first and second leg elastics;
• (b) incorporating the first and second stretched leg elastics into the continuous web in stretched condition;
• and
• (c) stretching third leg elastic, orienting the third leg elastic in a direction transverse to the longitudinal dimension of the web, and, while maintaining the stretched third leg elastic in the transverse orientation, incorporating the stretched third leg elastic along opposing edges of the crotch portion such that opposing portions of the third leg elastic are disposed on opposing sides of the crotch adjacent respective ones of the first and second leg elastics, to thereby provide effective continuity of stretching capacity at the respective leg openings between the third leg elastic and respective ones of the first and second leg elastics.

A method for use in constructing a garment including elastic therein, in a processing system, as one of a series of consecutive workpieces in a continuous web having a width dimension, the method including, with respect to respective workpieces, the steps of:

• (a) stretching elastic;
• (b) incorporating the elastic into the continuous web in stretched condition on a first rotary transport device having a first outer working surface effective to inhibit shrinkage of the web in the width dimension on the first rotary transport device without use of suction;
• and
• (c) relieving stretch in the elastic at a first portion of each respective workpiece in the web, while maintaining stretch in the elastic at a second portion of each respective workpiece.

A method for use in constructing a garment including elastic therein, in a processing system, as one of a series of consecutive workpieces in a continuous web, the method including, with respect to respective workpieces, the steps of:

• (a) stretching a continuous elastic;
• (b) incorporating the stretched continuous elastic into the continuous web;
• and
• (c) relieving stretch in the elastic at a first portion of each respective workpiece in the web, the relieving of stretch comprising using a dancer roll to control tension in the continuous elastic as the continuous elastic is being incorporated into the continuous web, including applying a first active force to the dancer roll in a first direction, and a second active force in a second opposite direction, in cycles, each cycle corresponding to the advance of one of the workpieces in the continuous web into the processing system, each cycle thus causing movement of the dancer roll, including (i) corresponding relieving of tension in the continuous elastic as the continuous elastic is incorporated into the web at the first portion of the corresponding workpiece, and (ii) imposing of tension as the continuous elastic is incorporated into the web at a second portion of the workpiece.

A method for use in constructing a garment including elastic, in a processing system, as one of a series of consecutive workpieces in a continuous web, the workpieces having front and back body portions separated by a crotch portion, the method including, with respect to respective workpieces, the steps of:

• (a) stretching an elastic;
• (b) incorporating the stretched elastic into the continuous web in stretched condition;
• and
• (c) subsequently relieving stretch in the elastic at the crotch portion of each respective workpiece in the web, while maintaining the stretch in the elastic at the front and back body portions of each respective workpiece, by applying ultrasonic energy to the outer surface of the workpiece at at least one selected locus at the crotch portion, sufficient to effect severing of the elastic without corresponding severing of the continuous web.