Method for manufacturing shaped components from web materials

A method for manufacturing multi-directional shaped components from web materials, the method comprising the steps of:

• providing a first web of material in a machine direction, the first web having longitudinal edge portions;
• making at least a first shaping cut to sever the first web into at least a first shaped strip and a second shaped strip, the first shaping cut having a pattern extending in the machine direction and alternately extending in a cross machine direction to alternate distal points located between the longitudinal edge portions of the first web, the first shaped strip and the second shaped strip having alternating nested projecting portions defined by the first shaping cut, the first shaped strip having an axial orientation substantially identical to an axial orientation of the second shaped strip;
• separating the first shaped strip and the second shaped strip;
• providing a second web of material in the machine direction;
• joining at least the first shaped strip to the second web;
• reorienting the second web such that the axial orientation of the first shaped strip differs from the axial orientation of the second shaped strip;
• repositioning the second web in the cross machine direction such that at least a portion of the second shaped strip is aligned to at least partially overlap a portion of the first shaped strip in the cross machine direction;
• phasing the second web in the machine direction such at least a portion of the second shaped strip is aligned to at least partially overlap a portion of the first shaped strip in the machine direction;
• joining at least a portion of the second shaped strip to a portion of the first shaped strip;
• and
• making at least one separating cut to separate the multi-directional shaped components, the separating cut having a pattern defining edges of the shaped components, each of the shaped components comprising at least a portion of the joined portions of the first shaped strip and the second shaped strip.

A method for manufacturing multi-directional shaped components from web materials, the method comprising the steps of:

• providing a first web of material in a machine direction;
• making at least one dividing cut in the machine direction to sever the first web into at least a first panel and a second panel having longitudinal edge portions;
• making at least a first shaping cut through the first panel to sever the first panel into at least a first shaped strip and a second shaped strip, the first shaping cut having a pattern extending in the machine direction and alternately extending in a cross machine direction to alternate distal points located between the longitudinal edge portions of the first panel, the first shaped strip and the second shaped strip having alternating nested projecting portions defined by the first shaping cut, the first shaped strip and the second shaped strip having an axial orientation;
• making at least a second shaping cut through the second panel to sever the second panel into at least a third shaped strip and a fourth shaped strip, the second shaping cut having a pattern extending in the machine direction and alternately extending in a cross machine direction to alternate distal points located between the longitudinal edge portions of the second panel, the third shaped strip and the fourth shaped strip having alternating nested projecting portions defined by the second shaping cut, the third shaped strip and the fourth shaped strip having an axial orientation differing from the axial orientation of the first shaped strip and the second shaped strip;
• separating at least the first shaped strip and at least one of the third shaped strip or the fourth shaped strip;
• providing a second web of material in the machine direction;
• joining at least the first shaped strip to the second web;
• repositioning the second web in the cross machine direction such that at least a portion of the one of the third shaped strip or the fourth shaped strip is aligned to at least partially overlap a portion of the first shaped strip in the cross machine direction;
• phasing the second web in the machine direction such at least a portion of the one of the third shaped strip or the fourth shaped strip is aligned to at least partially overlap a portion of the first shaped strip in the machine direction;
• joining at least a portion of the one of the third shaped strip or the fourth shaped strip to a portion of the first shaped strip;
• and
• making at least one separating cut to separate the multi-directional shaped components, the separating cut having a pattern defining edges of the shaped components, each of the shaped components comprising at least a portion of the joined portions of the first shaped strip and the one of the third shaped strip or the fourth shaped strip.