ANU
`
`urrmmi.
`
`VKITSILANG
`BRANQH
`
`Petitioner Ex. 1026 Page 1
`
`Petitioner Ex. 1026 Page 1
`
`

`
`An illustrated Gui
`
`de to
`
`Product
`
`Manufacturing
`
`
`
`Jacqueline L. Longe, Editor
`
`
`
`\ \ '
`
`GALE GROUP
`
`
`G D
`
`Petitioner Ex. 1026 Page 2
`
`

`
`
`
`Chris Jery-an, Managing Editor
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`ISBN 0-7876-3642-8
`ISSN 1072-5091
`
`Printed in the United States of America
`10 9
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`Gale Group and Design is a trademark used herein under license.
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`Petitioner Ex. 1026 Page 3
`
`Petitioner Ex. 1026 Page 3
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`

`
` rrier
`
`in i997 alone, over
`
`Backgrounefi
`
`8,700 children were
`
`brought to the emergency
`
`room and treated for falls
`
`from carriers.
`
`Family members have carried babies in a va-
`riety of carriers since the beginning of human
`civilization. Baby carriers keep the baby
`close and provide the infant with comfort and
`security while allowing the carrier some free-
`dom to work and care for other members of
`
`the family. The most basic form of baby car-
`rier is the sling. In South America, woven
`shawls are used to carry babies in front of
`their mothers. The shawl is anchored over
`
`one shoulder, wrapped under the other arm,
`and tied around the back. The baby is free to
`nurse and sleep, and is cooled or warmed by
`the weave and wool of the shawl. In Asia, the
`sling is tied over one arm but carried lower
`on the opposite side so the baby rests on the
`hip. African cultures use the sling in this
`fashion or with the sling tied in front around
`the chest with the baby balanced behind. The
`front—tied sling is also practical for older ba-
`bies who need to nurse less often and are
`more settled in their routine.
`
`Other Asian cultures tie a woven cloth
`
`in a complex series of
`around the infant
`wraps and ties that isolate the chiid’s legs on
`the mother’s sides and allow the baby to
`move its arms freely against the mother. In
`cold climates where mothers wear hooded
`
`coats or parkas, the hood doubles as a sling
`that gives the baby room to see around its
`mother’s head or cuddle deep in the hood to
`nap. Hot climates feature baby carriers of
`loosely woven airy cloth and even net bags
`that can be hung from the shoulders or bal-
`anced on the head. The cradle boards used
`
`by many tribes of Native Americans are an-
`cient forerunners of today’s framed back-
`pack that provides rigid strength to carry the
`child and cloth wrapping for comfort.
`
`Side- and hip-balanced carriers are used by
`fathers and brothers who hunt and harvest
`
`with the baby. Other relatives can baby-sit,
`thanks to the convenience of baby carriers.
`The closeness of the baby carrier is not only
`a convenience but a way of nurturing the
`whole family.
`
`History
`
`The invention of the cloth infant carrier
`
`grew out of one woman’s service in the
`Peace Corps. Ann Moore, a pediatric nurse
`who worked in Togo, Africa, in the 1960s
`observed the native women carrying their
`babies in slings. After she returned to the
`United States, Moore and her mother, Lucy
`Aukerrnan, designed a fabric pouch to re-
`semble these slings but also to be rugged
`and to have adjustable shoulder and waist
`supports for the parent. Moore and Auker-
`man patented the Snugli in 1969.
`
`In 1978, a Nigerian child care professional
`named Toritse Onuwaje moved to the United
`States. She was dismayed at the amount of
`crying American babies did compared to
`their Nigerian counterparts. She patterned a
`carrier she called the Baby Wrap on the '
`ukpoma, a cloth carrier worn by members of
`her native ltshekiri tribe. The women of her
`
`tribe work all day with their babies wrapped
`on their backs, and the babies seldom cry be-
`cause the mothers’ closeness is comforting.
`
`The rigid, molded plastic carrier grew out of
`the invention of the child safety seat for use
`in automobiles (and, later, airplanes). The
`first child safety seats were patented in the
`late 1970s. In the period from 1982 through
`1985, a number of designs of molded plastic
`carriers were patented with varying configu-
`
`22
`
`
`
`Petitioner Ex. 1026 Page 4
`
`

`
`rations for carrying a reclining infant. The
`shape was contoured to support the child’s
`back and seat and incorporated an adjustable
`handle that could be raised and locked into
`
`
`
`place while the child is being carried and
`lowered to lift the baby in and out. Various
`types of fabrics cushion the child; some car-
`" riers use fabric mesh that is suspended in the
`frame to support the infant, while others are
`fitted out with padded cloth inserts that fas-
`- ten in the plastic carrier securely but can be
`emoved for cleaning.
`
`
`
`' Raw Materials
` Slings and cloth carriers are manufactured
`from fabrics and polyester fiber or foam for
`stuffing or padding. The fiber is purchased
`in S00-lb (227—kg) bales. Velcro fasteners,
`woven fabric webbing for straps, and meta}
`___u_ckles and fasteners for Supports around
`"parent are used to hold cloth carriers in
`place. Backpack—type carriers can be made
`tly of cloth, but a second type consists
`r1 aluminum frame with a cloth support
`of
`_fO1?_ the baby and padded cloth straps that ad-
`to the parent.
`
`Different types of baby carriers.
`
`flexible, and durable. Manufacturers receive
`
`the plastic in pellets. Metal components are
`made of steel by specialized metal fabrica-
`tors. These parts may include buckles, lock-
`ing clips, and hardware for adjusting har-
`nesses. Rivets and fabric fasteners may be
`made of other metals but are also supplied
`by specialty contractors.
`
`Fabrics used to make infant carriers include
`
`durable fabric like denim and nylon mesh
`and webbing for harnesses. All fabrics have
`to be specially treated to meet standards for
`flammability, but they also have to be wash-
`able. Chemical cleaning methods and even
`strong detergents can break down the treat-
`ments used to make the material flame—re—
`
`sistant, so these fabrics must be cleaned
`with water and mild soap. The fabrics are
`also chosen for their appeal, so color and
`fashion trends are observed by designers in
`selecting these materials.
`
`Foam padding and fiber fill are also required
`to be flame resistant. For manufacturers of
`
`molded plastic carriers, most of the cloth
`liners and pads are sewn by outside suppli-
`ers to the specifications of the carrier manu-
`facturers.
`
`
`
`All
`
`infant carriers bear manufacturers’ la-
`
`bels, and printers make paper and adhesive-
`
` __ypropylene, a medium-impact plastic. It
`'
`he advantages of being lightweight,
`
`
`
`
`
`Petitioner Ex. 1026 Page 5
`
`Petitioner Ex. 1026 Page 5
`
`

`
`There are three basic designs of infant carri-
`ers. The first is the sling of which the Snugli
`and Baby Wrap are best known. The second
`is a modification of an aluminum—framed
`
`backpack in which the pack portion is fitted
`to carry a baby and padded straps are pro»
`vided for the parents’ comfort. The third
`type is the molded plastic carrier that resem-
`bles an automobile safety seat with a plastic
`back, seat, and handle and a padded interior
`but without the devices needed to secure the
`carrier in an automobile.
`
`Factors influencing the design of infant car’
`riers are many and relate to how the individ-
`ual consumer is most comfortable carrying
`
`their child. Safety is, of course, the overrid-
`ing concern. The infant must be comfortably
`held or restrained in the carrier, a soft carrier
`
`must have openings for the chiid’s legs but
`not so large that the baby will fall out, and a
`rigid carrier designed to sit on solid surfaces
`must not tip over. Comfort for the baby is
`the second leading design factor. All forms
`of carriers have some type of cloth liner or
`insert to cushion the baby, and this must be
`comfortable as well as durable and easily
`cleaned. And, finally,
`the person carrying
`the child must also be comfortabie. Cloth in-
`
`fant carriers and backpack~type carriers
`have to adapt to different body types so the
`baby can be carried with equal comfort.
`This is usually accomplished with a set of
`straps that cross the shoulders and fit around
`the waist or on the hips. Carriers made of
`molded plastic rnust strike the right balance
`between the weight and strength needed to
`support
`the
`child adequately and light
`weight for the parent to carry.
`
`These combinations of characteristics have
`
`not been easy for manufacturers to produce
`successfully. Consumer protection groups
`like the Consumer Product Safety Commis
`sion list a number of carriers that have been
`
`recalled. The molded plastic carriers have
`had notable problems such as failure of the
`handle locks that can cause the carrier to re-
`
`lease and tip the baby out. But the cloth car-
`riers have also been made with leg openings
`that are too large and allow tiny babies to
`
`baby’s movements to tip the carrier over. In
`1997
`alone, over 8,700 children were '
`
`brought to the emergency room and treated
`for falls from carriers. Also, a number of
`
`medical reports show that infants are left in
`one position in the carriers for too long. In
`the supine or reclining position, the back of
`the baby’s head flattens as it rests against
`the carrier. Babies held upright in cloth car~
`riers or backpack-type carriers are subject to _
`spinal stress that complicates the natural de-
`velopment of curves in the spine. Sling—type
`carriers have been found to hold the baby in
`the best position for its growth.
`
`The Manufactu ring
`Process
`
`Cloth carriers
`
`Following initial design, prototypes are
`sewn by hand and checked for fit on both
`infants and parents of a range of sizes and
`weights. When the final design is approved,
`the pattern on blueprints or computerized
`drawings is transferred to paper patterns.
`The patterns are tacked to the fabric with
`pins and stacked together. A fabric cutter
`that looks much like a band saw is used to
`
`through all
`cut
`pieces for many carriers are produced at the
`same time.
`
`The fabric pieces are stitched together by
`workers
`operating
`sewing machines. Typically, each worker is
`responsible for one section of the carrier
`such as the back or the straps. The pieces are
`stitched together inside out with the seams
`exposed then turned right side out. Sections
`that will be padded are left with small open-
`ings in the seams where the padding can be .
`added.
`
`The sections to be padded are stuffed
`with polyester fiber or foam padding.
`The fiber is purchased by the manufacturer
`in tightly packed bales that are tluffed up
`with a machine called a picker. The fiber is
`selected for the packing by the quality of the
`fibers, and, when it is inserted into the ca1ri-
`er section as padding,
`
`Petitioner Ex. 1026 Page 6 -
`
`24
`
`Petitioner Ex. 1026 Page 6
`
`

`
`At the assembly line, the molded shells
`and all other parts are distributed to work
`stations. Each worker is responsible for fit-
`ting the carrier with one item or type of item
`and handing it to the next worker who adds
`another piece. The padded insert that forms
`the cushion for the baby is a completed item
`that has been sewn and stuffed. It is attached
`
`to the carrier by Velcro or other fasteners.
`Alternatively, the nylon mesh used to make
`a hammock—like support for the infant
`in
`some types of carriers is attached to sections
`of the plastic shell that were designed to trap
`the mesh and lock it in place. Straps, har-
`nesses, buckles, and labels are added in turn.
`
`the infant
`In the packing department,
`carriers are individually packed in car-
`tons. The cartons are significant sources of
`information for consumers and are preprint—
`ed with consumer data as well as company
`information and bright designs. The cartons
`are stacked and bulk—wrapped in plastic for
`storage and distribution.
`
`Qucaiii-y Confroi
`
`Hands—on assembly is key to the construc-
`tion of the three types of infant carriers de-
`scribed here. Workers are highly skilled in
`their own and related parts of manufacture
`of carriers, and they are rewarded for identi-
`fying errors and rejecting imperfect carriers.
`Molded plastic carriers are nominally the
`most complex to manufacture; the shell is
`carefully checked for uniform thickness and
`strength and compared to a master copy for
`correctness. Because manufacturers usually
`make several different
`lines or models of
`
`carriers, each product has a bill of materials
`listing the part numbers of all the parts mak-
`ing up that model. Assembly workers rnoni~
`tor
`these, and line managers periodically
`pull carriers from the assembly line to check
`the materials, review the overall quality, and
`test the products.
`
`Byproducis/Waste
`
`The making of infant carriers results in little
`waste because most of the materials used
`
`Petitioner Ex. 1026 Page 7
`
`
`
`_added are then stitched together.
`
`The sections of the carrier are assembled
`
`to create the finished product at another
`‘set of sewing machines. Any restraining
`raps and webbing are stitched securely in
`place. Hardware and fasteners (if any) are
`‘also stitched on or driven into place by spe-
`c_1al machines, and labels are sewn in place
`I _]0l1]S between two fabric sections. A final
`inspection is performed to check all
`the
`seams and fasteners, and the carrier
`is
`"acked in a plastic bag and boxed. Multiple
`boxes are packed in shipping cartons for
`_storage or transport.
`
`Bcrckpackdype carriers
`
`The cloth sections of the backpack-type
`"carriers are designed, cut, stitched, and
`padded like the cloth carriers described
`above.
`
`The aluminum frames used to support the
`carriers are made of tubing formed by
`aluminum fabricators to the sizes, shapes,
`"H curves specified by the carrier manufac-
`rer. They are received by the carrier manu-
`'fai:turer in bulk lots that are distributed to
`
`
`
`
`
`
`bins along the assembly line. Assembly line
`I orkers pair a cloth carrier to a metal frame
`
`and attach it; methods of attachment vary
`
`idely among makers but can include Vel-
`cro and metal buckles and fasteners. Some
`
`frames also have plastic feet or pads where
`they balance against the parent or so they can
`
`be stood on the ground or a solid surface
`
`
`while the infant
`is placed in the carrier.
`hese feet are inserted into holes in the
`
`fr me and fastened in place.
`
`
`The frame/carrier assembly is inspected
`and packaged like the cloth carrier.
`
` _ofded pfasfic carriers
`
`
`
`
`"Molding of the carrier’s plastic shell is
`he first step in manufacture of this type
`Of carrier. Plastic pellets stored in bulk are
`melted and injected into specially machined
`___ies or forms for the shell. The dies are the
`highly detailed product of
`the design
`
`
`
`
`
`
`
`
`Petitioner Ex. 1026 Page 7
`
`

`
`batch of new plastic. Sewn linings of the
`plastic shells are returned to the supplier and
`can often be resewn; similarly, cloth carriers
`can be resewn, assuming the error is not
`picked up and corrected immediately by the
`sewing machine operator. Metal parts are
`also recycled by suppliers.
`
`Safety concerns are important in several as
`pects of carrier manufacture. Sewing ma-
`chines, fabric cutters, and power hand tools
`have automatic emergency shutoffs, safety
`guards, and other protections. Operation of
`the injection molding machinery is automat-
`ed, and workers seldom have reason to ap-
`proach these machines with their high opera
`ating temperatures. Mold operators wear
`protective gloves. Fabric cutters, sewing
`machine operators, and those who handle
`the polyester fiber and foam padding wear
`masks over their mouths and safety glasses.
`
`The Future
`
`The concept of the infant carrier may be as
`old as civilization, yet the “modern” baby
`carrier is less than half a century old. De-
`spite this new or reborn acceptance, the car-
`rier has become an essential part of every
`baby’s layette. This is not surprising be-
`cause every parent’s first priorities are the
`safety and comfort of that new baby. The
`alarming aspect of infant carriers may be the
`number of product
`recalls. Perhaps this
`should not be surprising either, because the
`manufacture of carriers is an attempt for an
`industry to fit a standard to tiny babies and
`an even wider variety of sizes and shapes of
`parents and care givers.
`
`Manufacturers are conscientious about doing
`their part
`to keep improving and varying
`products to prevent child injury and provide
`security. Responsibility for proper use of in-
`fant carriers is beyond the manufacturers’
`purview, yet they try to design out opportu-
`nities for consumer error. Doctors are also
`adding to the information base by studying
`
`future, but all these negatives are strong mo-
`tivators toward the best possible products for -
`the most babies.
`
`Where ta Learn More
`
`Books
`
`Bernhard, Emery. A Ride on Mother’:
`Back.‘ A Day of Baby Carrying Around the
`World. New York: Gulliver Books, Har-
`court Brace & Company, 1996.
`
`Periodicals
`
`Karvonen, Karen. “Child Carriers.” Women’s
`Sports and Fimess 14, no. 5 (July—August
`1992): 112.
`
`Quindlen, Anna. “A Mother’s Nominees
`For
`the Nobel Prize." New York Times
`
`(September 21, 1986).
`
`Sommars, Jack. “Oh Baby!” Coiortido Busi-
`ness Magazine 23, no. 3 (March 1996): 16.
`
`Other
`
`Consumer Product Safety Commission.
`http://www.cpsc.gov (September 18, 2000).
`
`“43 Reasons to Carry Your Baby.” Natur-
`ing Magazine (1998). http://www.nurtur—
`ing.ca/'carrybaby.htm (January 200] ).
`
`Lemelson—MIT
`The
`Women’s History Month. http://web.mit.
`edu,/invent/www/'inventorsR-Z/wh1n3.html
`(September 27, 2000).
`
`Loving Attachment. Choosing a Carrier:
`Infirrir Carriers and Spinal Stress. http:/1’
`www.lovingattachment.eom (September 27,
`2000).
`
`The Mayo Clinic. Misshapen Infiant Heads:
`Not an Epidemic (May 22, 1999). http:/;’ -
`www.mayohealth.org/home?id=CC00010 .3.
`(September 27, 2000).
`
`
`
`26
`
`
`
`Petitioner Ex. 1026 Page 8
`
`Petitioner Ex. 1026 Page 8