1. FlexiBond Technology as Enabler for Darting in Absorbent Articles
Background
Like underwear and apparel, absorbent articles are often made of flat webs. Such flat webs can
perfectly wrap even parts of the body, but they fall short when more complex, sometimes intersecting
forms and shapes of the body are to be covered.
Since centuries, apparel is made using darting to cope with this problem. There is plenty of information
available, explaining how and where darting (german: Abnäher) is used.
Problem Description
Unlike in the apparel industry, manufacturers of absorbent disposable articles have chosen other,
more complex ways to achieve acceptable body fit of articles made of flat webs: they introduce elastic
elements to contract those portions of the product which need to be „shortened“ to make good contact
to the body of the wearer.
One reason for this approach may be the lack of an appropriate combining technique, by which abutting
nonwoven webs can reliably be bonded together at high speeds. The gold standard for such a bond
(line or region) has been defined by the textile industry: besides being soft, the bond should be as narrow
as a seam made of a sewing thread, and it should be at least as strong as the materials bonded together.
Proprietary Solution
„FlexiBond“ technology developed by Concepts for Success offers a robust approach to introduce
extremely reliable melt fusion seams in and between nonwoven materials, as has been demonstrated
in various tests. The shape of such seams can be readily changed as needed, the number of layers
to be bonded together can be varied easily, and the technology can bond materials of varying caliper
or basis weight. Bond lines can be very narrow, and the number of bond regions per cm is variable.
The photo shots below show samples with some of many executions possible.
Please see also WO (A1) for reference). WO2B shows a product using FlexiBond
technology.

2. Characteristics of the bonded webs
First, material webs bonded via FlexiBond technology show
extremely strong bonds. Typically, the bonded materials tear outside the bond areas when pulled too hard.
Second, the bond sites are very soft. There are no hard spots like often described when Ultra-Sonic Bonding
with traditional „anvils“ is employed.
Third, the shape and curvature of the narrow bond lines can be changed without changing hardware. This
allows to produce various product executions on the same equipment without changing parts.
Availability
FlexiBond technology has been sucessfully tested as combining technology in AI product making. When
these products are in use, the seams are pulled in a „Butt-type“ arrangement - which is much more demanding
than a „Lap-type“ arrangement. Results have been extremely positive. Many other applications are possible.
In order to use this technology on a broader base, Concepts for Success and Herrmann Ultraschall have
joined forces. If you have a need for a robust bonding technology - just contact either one.