Method and apparatus for bonding elastic parts under tension to an advancing carrier

The present disclosure relates to methods and apparatuses for stretching, transferring, and bonding elastic parts under tension to an advancing carrier substrate during the assembly of absorbent articles. A continuous carrier substrate may be advanced in a machine direction at a first speed, and a discrete elastic part may be cut from a continuous elastic substrate having a direction of stretch in a cross direction. The speed of the discrete elastic part is changed from a second speed to the first speed, and the central region of the discrete elastic part is stretched in the cross direction. The discrete elastic part is bonded with the continuous carrier substrate such that the stretched central region extends in the cross direction between the first and second longitudinal edges of the continuous carrier substrate. The discrete elastic part may also be bonded with the carrier substrate with adhesive and/or mechanical bonds.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses for manufacturing absorbent articles, and more particularly, to apparatuses and methods for stretching, transferring, and bonding elastic parts to an advancing carrier during the assembly of absorbent articles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example, diapers and other absorbent articles, may be assembled by adding components to and/or otherwise modifying an advancing, continuous web of material. For example, in some processes, advancing webs of material are combined with other advancing webs of material. In other examples, individual components created from advancing webs of material are combined with advancing webs of material, which in turn, are then combined with other advancing webs of material. In some cases, individual components created from an advancing web or webs are combined with other individual components created from other advancing webs. Webs of material and component parts used to manufacture diapers may include: backsheets, topsheets, leg cuffs, waist bands, absorbent core components, front and/or back ears, fastening components, and various types of elastic webs and parts such as leg elastics, barrier leg cuff elastics, stretch side panels, and waist elastics. Once the desired component parts are assembled, the advancing web(s) and component parts are subjected to a final knife cut to separate the web(s) into discrete diapers or other absorbent articles.

Some absorbent articles have components that include elastic parts, such as for example, waistbands. In some configurations, waistbands may be provided as a single layer of elastic material, such as an elastic film. In some configurations, the waistbands may be provided as an elastic laminate that may include elastic material bonded to one or more substrates such as nonwovens, wherein the elastic material may include an elastic film and/or elastic strands. In some assembly operations, the waistbands are joined to an advancing carrier web, such as a continuous topsheet or backsheet web, while the waistbands are in a stretched condition. As such, when the waistbands relax, the carrier web gathers to form corrugations. The resulting laminate is stretchable to the extent that the corrugations allow the waistband to elongate.

When manufacturing absorbent articles, the waistband may be provided as a continuous length of waistband material that may be stretched; cut into discrete waistbands; and bonded with the advancing carrier web while the waistband is in a stretched state. In addition, the carrier web may be advanced in a machine direction and the waistband may be applied to the carrier web such that direction of stretch of the waistband is oriented in a cross direction. For example, some manufacturers may stretch a continuous waistband material in a machine direction and cut the continuous waistband material into stretched discrete waistbands. The stretched discrete waistbands may be turned 90 degrees before placement on and bonding to the advancing carrier web such that direction of stretch is oriented in the cross direction with respect to the carrier web. However, such assembly operations involving the handling and bonding of discrete waistbands in a stretched state can present various challenges.

For example, with reference to a waistband and topsheet bonding operation as an example illustration, adhesive may be applied to either or both the discrete waistband and the topsheet. When applying adhesive to the discrete waistband prior to combining with the topsheet, applied adhesive may migrate from the waistband and contaminate material handling equipment, such as knives, drums, and conveyance devices utilized to place the waistband on the topsheet. Such contaminating adhesive may also migrate to other substrates and components of the assembled article. Instead of applying adhesive to the waistband, adhesive may be applied to the topsheet before combining with the waistband. As such, the adhesive may be applied to the topsheet in discrete patches that are sized to correlate or match with the size of the waistband. Such an operation requires very precise placement of the waistband on the discrete patches of adhesive. Misplacement of the waistbands on the adhesive may lead to portions of the waistbands being unbonded and may also lead to areas of exposed adhesive. In turn, exposed adhesive that remains tacky can act to unintentionally bond other components together. For example, in subsequent assembly operations, the combined waistband and topsheet may be combined with other advancing substrates and/or components to create discrete absorbent articles that are folded and packaged. As such, the absorbent article may become bonded to itself in the folded configuration.

In an attempt to avoid the above described negative affects resulting from exposed tacky adhesive in an assembled product, adhesives may be applied in areas that are smaller than the discrete part to be bonded. For example, adhesive may be applied to only central portions of discrete waistband before combining with a topsheet. In another scenario, adhesive may be applied to the topsheet in discrete patches that are relatively smaller than the size of the waistband. In turn, only the central region of a waistband may be bonded with the topsheet. As such, perimeter edges of the waistband may remain unbonded and loose. Such unbonded edges may be aesthetically unpleasing and may lead to undesired tearing and/or separation of the waistband during product use.

In addition, difficulties associated with precisely placing the discrete waistband in a desired location may be exacerbated in assembly processes that require turning the discrete waistbands 90 degrees before combining with an advancing topsheet. Manufacturers may also encounter various difficulties associated with close coupled handovers of stretched waistbands between conveyance devices while maintaining the stretched condition of the waistbands. Further, components of the apparatuses associated with waistband application processes may be relatively inflexible with respect to making absorbent articles of different sizes. For example, existing assembly operations may be configured to place waistbands at fixed pitch distances that cannot be altered without changing several apparatus components when needed to make articles of different sizes that require changes in pitch distances.

Consequently, it would be beneficial to provide methods and apparatuses for bonding waistbands to carrier webs while helping to increase the size of bonded areas and reducing the chances of having exposed adhesives during subsequent assembly operations; providing flexibility to accommodate desired speed and/or pitch changes; eliminating the need for 90 degree turn operations of stretched waistbands; and/or improving abilities to transfer stretched waistbands between close coupled conveyance devices while helping to maintain the stretched condition of the waistbands.

SUMMARY OF THE INVENTION

In one form, a method of assembling absorbent articles comprises steps of: advancing a carrier substrate at a first speed in a machine direction, the carrier substrate comprising a first longitudinal edge and a second longitudinal edge separated from the first longitudinal edge in a cross direction; advancing a continuous elastic substrate at a second speed in the machine direction, the continuous elastic substrate comprising a first longitudinal edge and a second longitudinal edge separated from the first longitudinal edge in the cross direction, wherein the continuous elastic substrate is stretchable in the cross direction; cutting an elastic part from the continuous elastic substrate, the elastic part comprising a first end region and a second end region separated from the first end region in the cross direction by a central region; changing a speed of the elastic part from the second speed to the first speed; stretching the central region of the discrete elastic part in the cross direction; positioning the elastic part on the carrier substrate such that the stretched central region extends in the cross direction between the first and second longitudinal edges of the carrier substrate; adhesively bonding the stretched central region of the elastic part with the carrier substrate; and mechanically bonding the first end region and the second end region of the elastic part with the carrier substrate.

In another form, a method of assembling absorbent articles comprises steps of: providing an elastic part comprising a first surface and an opposing second surface, the elastic part further comprising a first end region and a second end region separated from the first end region in a cross direction by a central region; providing a zone of adhesive positioned on the second surface of the elastic part; advancing the elastic part in a machine direction on a first roll, wherein the second surface is facing radially outward; transferring the first end region and the second end region of the elastic part from the first roll to a rotatable transfer device, wherein the second surface of the elastic part is facing radially inward; stretching the central region of the elastic part in the cross direction while rotating the transfer device; transferring the stretched elastic part to a second roll, wherein the second surface of the elastic part is facing radially outward; advancing a carrier substrate adjacent the second roll, the carrier substrate comprising a first longitudinal edge and a second longitudinal edge separated from the first longitudinal side in the cross direction; advancing the elastic part from the second roll to the carrier substrate such that the stretched central region extends in the cross direction between the first and second longitudinal edges of the carrier substrate; adhesively bonding the stretched central region of the elastic part with the carrier substrate; and mechanically bonding the first end region and the second end region of the elastic part with the carrier substrate.

In yet another form, a method of assembling absorbent articles comprises steps of: advancing a continuous elastic substrate in a machine direction between a rotating knife roll and anvil roll; cutting an elastic part from the continuous elastic substrate, the elastic part comprising a first end region and a second end region separated from the first end region in the cross direction by a central region; advancing the elastic part in a machine direction on the knife roll or the anvil roll; transferring the first end region of the elastic part onto a first canted disk and transferring the second end region of the elastic part onto a second canted disk; stretching the central region of the elastic part in the cross direction by rotating the first canted disk and the second canted disk; transferring the stretched elastic part from the first and second canted disks to a rotating pattern roll; and advancing a carrier substrate adjacent the pattern roll; and bonding the stretched elastic part with the carrier substrate while the stretched elastic part is positioned between the carrier substrate and the pattern roll.

In still another form, a method of assembling absorbent articles comprises steps of: advancing a continuous elastic substrate in a machine direction, the continuous elastic substrate comprising a first surface and an opposing second surface, the continuous elastic substrate comprising a first longitudinal edge and a second longitudinal edge separated from the first longitudinal edge in a cross direction to define a first width, wherein the continuous elastic substrate is stretchable in the cross direction and comprises corrugations oriented to define corrugation lines extending in the machine direction; applying adhesive to corrugations on the first surface of the continuous elastic substrate, wherein the adhesive extends in the cross direction for a second width, wherein the second width is less than the first width; cutting an elastic part from the continuous elastic substrate, the elastic part comprising a first end region and a second end region separated from the first end region in the cross direction by a central region, wherein a zone of adhesive is positioned on the central region and not the first and second end regions; separating the zone of adhesive into individual stripes of adhesive by stretching the central region of the elastic part in the cross direction; adhesively bonding the stretched central region of the elastic part to a carrier substrate with the stripes of adhesive; and mechanically bonding the first end region and the second end region of the elastic part with the carrier substrate.

In still another form, a method of assembling absorbent articles comprises steps of: advancing the elastic part in a machine direction on a first roll; providing a first disk and a second disk, wherein the first disk and the second disk are canted relative to each other, and wherein the first disk and the second disk each comprise an outer rim comprising a pick-up surface and a drop-off surface, wherein the pick-up surface is angularly offset from the drop-off surface; transferring the first end region of the elastic part from the first roll onto pick-up surface of the first disk and transferring the second end region of the elastic part from the second roll onto the pick-up surface of the second disk; stretching the central region of the elastic part in the cross direction by rotating the first disk and the second disk; transferring the first end region of the elastic part from the drop-off surface of the first disk to a second roll and transferring the second end region of the elastic part from the drop-off surface of the second disk to the second roll; and advancing a carrier substrate adjacent the second roll; and bonding the stretched elastic part with the carrier substrate while the stretched elastic part is positioned between the carrier substrate and the second roll.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding the present disclosure:

“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. Absorbent articles can comprise sanitary napkins, tampons, panty liners, interlabial devices, wound dressings, wipes, disposable diapers including taped diapers and diaper pants, inserts for diapers with a reusable outer cover, adult incontinent diapers, adult incontinent pads, and adult incontinent pants. The term “disposable” is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

The term “feminine hygiene articles” refers to disposable absorbent articles used by women for catamenial protection. Such feminine hygiene articles may include sanitary napkins, tampons, interlabial products, incontinence devices, and pantiliners. Non-limiting examples of panty liners and sanitary napkins include those disclosed in U.S. Pat. Nos. 4,324,246; 4,463,045; 4,342,314; 4,556,146; 4,589,876; 4,687,478; 4,950,264; 5,009,653; 5,267,992; and 6,004,893, which are all incorporated by reference herein.

An “elastic,” “elastomer” or “elastomeric” refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than 10% greater than its initial length and will substantially recover back to about its initial length upon release of the applied force.

“Consolidation,” “consolidating,” and “consolidated” refers to a material undergoing a reduction in elongation from a first stretched length to a second stretched length that is less than the first stretched length and greater than zero.

“Relaxed state” defines a length of material when not stretched by an applied force.

In the context of the present description, an elongation of 0% refers to a material in relaxed state having a relaxed length of L, and elongation of 150% represents 2.5× the relaxed length, L, of the material. For example, an elastic film having a relaxed length of 100 millimeters would have a length of 250 millimeters at 150% elongation. And an elastic film having a relaxed length of 100 millimeters would have a length of 180 millimeters at 80% elongation.

As used herein, the term “joined” encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. 1/10 or less) in comparison to its length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers or fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may comprise two or more layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. In some configurations, a nonwoven may comprise a polyolefin based nonwoven, including but not limited to nonwovens having polypropylene fibers and/or polyethylene fibers and/or bicomponent fibers comprising a polyolefin. Nonlimiting examples of suitable fibers include spunbond, spunlaid, meltblown, spunmelt, solvent-spun, electrospun, carded, film fibrillated, melt-film fibrillated, air-laid, dry-laid, wet-laid staple fibers, and other nonwoven web materials formed in part or in whole of polymer fibers as known in the art, and workable combinations thereof. Nonwovens do not have a woven or knitted filament pattern. It is to be appreciated that nonwovens having various basis weights can be used in accordance with the methods herein. For example, some nonwovens may have a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm, 30 gsm, 40 gsm, or 65 gsm. Some nonwovens may have basis weight of about 8 gsm to about 65 gsm, specifically reciting all 1 gsm increments within the above-recited ranges and all ranges formed therein or thereby.

It is to be appreciated that films having various basis weights can be used in accordance with the methods herein. For example, some films may have a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm, 30 gsm, 40 gsm, or 60 gsm. Some films may have basis weight of about 5 gsm to about 150 gsm, specifically reciting all 1 gsm increments within the above-recited ranges and all ranges formed therein or thereby.

It is to be appreciated that elastic films discussed herein may comprise various materials and/or components. Some elastomeric compositions may comprise thermoplastic elastomers selected from the group consisting of Styrenic block copolymers, poly-esters, polyurethanes, polyether amides, and combinations thereof. Suitable styrenic block copolymers may be diblock, triblock, tetrablock, or other multi-block copolymers having at least one styrenic block. Exemplary styrenic block copolymers include styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene/butylenes-styrene, styrene-ethylene/propylene-styrene, and the like. Commercially available styrenic block copolymers include KRATON (styrenic block copolymer; available from the Kraton Chemical Company, Houston, TX), SEPTON (styrenic block copolymer; available from Kuraray America, Inc., New York, NY), VECTOR (styrenic block copolymer; available from TSRC Dexco Chemical Company, Houston, TX) can be used. Additinal commercially available elastomers include ESTANE (polyurethane; available from Lubrizol, Inc., Ohio), PEBAX (polyether block amide; available from Arkema Chemicals, Philadelphia, PA), and HYTREL (polyester; available from DuPont, Wilmington, DE).

Semi-crystalline, or metallocene polyolefins may be used in disposable absorbent products. The polyolefin elastomer materials herein may include, but are not limited to, any polymers or copolymers of polyolefins such as polyethylene and polypropylene. Examples of elastomeric polypropylenes include an elastic random poly(propylene/olefin) copolymer, an isotactic polypropylene containing stereo-irregularity, an isotactic/atactic polypropylene block copolymer, an isotactic polypropylene/random poly(propylene/olefin) copolymer block copolymer, a stereoblock elastomeric polypropylene, a syndiotactic polypropylene block poly(ethylene-co-propylene) block syndiotactic polypropylene triblock copolymer, an isotactic polypropylene block regioirregular polypropylene block isotactic polypropylene triblock copolymer, a polyethylene random (ethylene/olefin) copolymer block copolymer, a reactor blend polypropylene, a very low density polypropylene (or, equivalently, ultra low density polypropylene), a metallocene polypropylene, and blends or combinations thereof. Some homopolyolefins and random copolymers, as well as blends of such random copolymers, known by tradenames Vistamaxx™ available from ExxonMobil and VERSIFY™ from Dow, tend to show elastic performance. In some embodiments, two or more elastomers may be blended to achieve the desired elastic performance. For example, Styrenic block copolymer can be blended with polyolefin based elastomers, or polypropylene based elastomer can be blended with other polyolefin based elastomers.

Components of the disposable absorbent articles (i.e., diaper, disposable pant, adult incontinence article, sanitary napkin, pantiliner, etc.) described in this specification can at least partially be comprised of bio-sourced content as described in U.S. 2007/0219521A1 Hird et al published on Sep. 20, 2007, U.S. 2011/0139658A1 Hird et al published on Jun. 16, 2011, U.S. 2011/0139657A1 Hird et al published on Jun. 16, 2011, U.S. 2011/0152812A1 Hird et al published on Jun. 23, 2011, U.S. 2011/0139662A1 Hird et al published on Jun. 16, 2011, and U.S. 2011/0139659A1 Hird et al published on Jun. 16, 2011. These components include, but are not limited to, topsheet nonwovens, backsheet films, backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens, super absorbent, nonwoven acquisition layers, core wrap nonwovens, adhesives, fastener hooks, and fastener landing zone nonwovens and film bases. In at least one embodiment, a disposable absorbent article component comprises a bio-based content value from about 10% to about 100% using ASTM D6866-10, method B, in another embodiment, from about 25% to about 75%, and in yet another embodiment, from about 50% to about 60% using ASTM D6866-10, method B. In order to apply the methodology of ASTM D6866-10 to determine the bio-based content of any disposable absorbent article component, a representative sample of the disposable absorbent article component must be obtained for testing. In at least one embodiment, the disposable absorbent article component can be ground into particulates less than about 20 mesh using known grinding methods (e.g., Wiley® mill), and a representative sample of suitable mass taken from the randomly mixed particles.

The term “machine direction” (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

The term “cross direction” (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.

Aspects of the present disclosure relate to methods and apparatuses for bonding substrates used in absorbent articles, and in particular, methods and apparatuses for stretching, transferring, and bonding elastic parts under tension to an advancing carrier substrate during the assembly of absorbent articles. With regard to the assembly processes described herein, a continuous carrier substrate may be advanced in a machine direction at a first speed, the carrier substrate comprising a first longitudinal edge and a second longitudinal edge separated from the first longitudinal side in a cross direction. A continuous elastic substrate may also be advanced in the machine direction at a second speed with at least one direction of stretch extending in the cross direction, wherein the second speed is slower than the first speed. A discrete elastic part is separated from the continuous elastic substrate, wherein the discrete elastic part comprises a first end region and a second end region separated from the first end region in the cross direction by a central region. The speed of the discrete elastic part is changed from the second speed to the first speed, and the central region of the discrete elastic part is stretched in the cross direction. The discrete elastic part is bonded with the continuous carrier substrate such that the stretched central region extends in the cross direction between the first and second longitudinal edges of the continuous carrier substrate.

As discussed in more detail below, the discrete elastic parts are cut from a continuous elastic substrate having a direction of stretch in the cross direction, which eliminates the necessity of a 90 degree turn operations of stretched elastic parts before bonding with the carrier substrate. The methods and apparatuses herein also provide the ability to bond the discrete elastic part with the carrier substrate with adhesive and/or mechanical bonds. In some configurations, adhesive may be applied so as to help maximize bonded areas between the elastic part and the carrier substrate while mechanical bonds may also be used to help reduce perimeter edges of the elastic part that may otherwise remain unbonded and loose. Consecutively arranged conveying components of the apparatus may also be configured with intermeshing nubs and bonding elements and/or contoured outer rims that help improve abilities to transfer of discrete elastic parts while maintaining the elastic parts in a stretched condition. In addition, conveying components may also be configured with variable rotational velocities that help provide operational flexibility by reducing the necessity to change components to accommodate desired changes in speeds and/or pitching in manufacturing operations.

It is to be appreciated that the systems and methods disclosed herein are applicable to work with various types of converting processes and/or machines, such as for example, absorbent article manufacturing and assembly processes. The methods and apparatuses are discussed below in the context of manufacturing diapers that may be configured as taped diapers or pant diapers.

The term “taped diaper” (also referred to as “open diaper”) refers to disposable absorbent articles having an initial front waist region and an initial back waist region that are not fastened, pre-fastened, or connected to each other as packaged, prior to being applied to the wearer. A taped diaper may be folded about the lateral centerline with the interior of one waist region in surface to surface contact with the interior of the opposing waist region without fastening or joining the waist regions together. Example taped diapers are disclosed in various suitable configurations U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016, 6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887 A1; 2013/0211356 A1; and 2013/0306226 A1, which are all incorporated by reference herein.

The term “pant” (also referred to as “training pant”, “pre-closed diaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can be configured with a continuous or closed waist opening and at least one continuous, closed, leg opening prior to the article being applied to the wearer. A pant can be preformed or pre-fastened by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be preformed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed). Example diaper pants in various configurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861; 5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489; 7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764 A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1; 2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which are incorporated by reference herein.

For the purposes of a specific illustration,FIGS.1A and1Bshow an example of an absorbent article100that may be assembled in accordance with the methods and apparatuses disclosed herein. In particular,FIG.1Ashows one example of a plan view of an absorbent article100configured as a taped diaper100T, with the portion of the diaper that faces away from a wearer oriented towards the viewer. AndFIG.1Bshows a plan view of the diaper100with the portion of the diaper that faces toward a wearer oriented towards the viewer. The taped diaper100T shown inFIGS.1A and1Bincludes an absorbent chassis102, first and second rear side panels104and106; and first and second front side panels108and110.

As shown inFIGS.1A and1B, the diaper100and the chassis102each include a first waist region116, a second waist region118, and a crotch region119disposed intermediate the first and second waist regions. The first waist region116may be configured as a front waist region, and the second waist region118may be configured as a back waist region. In some embodiments, the length of each of the front waist region, back waist region, and crotch region may be ⅓ of the length of the absorbent article100. The absorbent article may also include a laterally extending front waist edge120in the front waist region116and a longitudinally opposing and laterally extending back waist edge122in the back waist region118. To provide a frame of reference for the present discussion, the diaper100T inFIGS.1A and1Bis shown with a longitudinal axis124and a lateral axis126. The longitudinal axis124may extend through a midpoint of the front waist edge120and through a midpoint of the back waist edge122. And the lateral axis126may extend through a midpoint of a first longitudinal or right side edge128and through a midpoint of a second longitudinal or left side edge130.

As shown inFIGS.1A and1B, the diaper100includes an inner, wearer facing surface132, and an outer, garment facing surface134. As such, it is also to be appreciated that the various components of the diaper described below may each include inner, wearer facing surfaces132, and an outer, garment facing surfaces134. The chassis102may include a backsheet136and a topsheet138. The chassis102may also include an absorbent assembly140, including an absorbent core142, disposed between a portion of the topsheet138and the backsheet136. As discussed in more detail below, the diaper100may also include other features, such as leg elastics and/or leg cuffs, an elastic waist region, and/or flaps, e.g., side panels and/or ears, to enhance the fits around the legs and waist of the wearer, to enhance the fit around the legs of the wearer.

As shown inFIGS.1A and1B, the periphery of the chassis102may be defined by the first longitudinal side edge128, a second longitudinal side edge130, a first laterally extending end edge144disposed in the first waist region116, and a second laterally extending end edge146disposed in the second waist region118. Both side edges128and130extend longitudinally between the first end edge144and the second end edge146. As shown inFIG.1A, the laterally extending end edges144and146may form a portion of the laterally extending front waist edge120in the front waist region116and a portion of the longitudinally opposing and laterally extending back waist edge122in the back waist region118. The distance between the first lateral end edge144and the second lateral end edge146may define a pitch length, PL, of the chassis102. When the diaper100is worn on the lower torso of a wearer, the front waist edge120and the back waist edge122may encircle a portion of the waist of the wearer. At the same time, the side edges128and130may encircle at least a portion of the legs of the wearer. And the crotch region119may be generally positioned between the legs of the wearer with the absorbent core142extending from the front waist region116through the crotch region119to the back waist region118.

It is to also be appreciated that a portion or the whole of the diaper100may also be made laterally extensible. The additional extensibility may help allow the diaper100to conform to the body of a wearer during movement by the wearer. The additional extensibility may also help, for example, the user of the diaper100, including a chassis102having a particular size before extension, to extend the front waist region116, the back waist region118, or both waist regions of the diaper100and/or chassis102to provide additional body coverage for wearers of differing size, i.e., to tailor the diaper to an individual wearer. Such extension of the waist region or regions may give the absorbent article a generally hourglass shape, so long as the crotch region is extended to a relatively lesser degree than the waist region or regions, and may impart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper100may include a backsheet136. The backsheet136may also define the outer surface134of the chassis102. The backsheet136may be impervious to fluids (e.g., menses, urine, and/or runny feces) and may be manufactured in part from a thin plastic film, although other flexible liquid impervious materials may also be used. The backsheet136may prevent the exudates absorbed and contained in the absorbent core from wetting articles which contact the diaper100, such as bedsheets, pajamas and undergarments. The backsheet136may also comprise a woven or nonwoven material, polymeric films such as thermoplastic films of polyethylene or polypropylene, and/or a multi-layer or composite materials comprising a film and a nonwoven material (e.g., having an inner film layer and an outer nonwoven layer). The backsheet may also comprise an elastomeric film. An example backsheet136may be a polyethylene film having a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplary polyethylene films are manufactured by Clopay Corporation of Cincinnati, Ohio, under the designation BR-120 and BR-121 and by Tredegar Film Products of Terre Haute, Ind., under the designation XP-39385. The backsheet136may also be embossed and/or matte-finished to provide a more clothlike appearance. Further, the backsheet136may permit vapors to escape from the absorbent core (i.e., the backsheet is breathable) while still preventing exudates from passing through the backsheet136. The size of the backsheet136may be dictated by the size of the absorbent core142and/or particular configuration or size of the diaper100.

Also described above, the diaper100may include a topsheet138. The topsheet138may also define all or part of the inner surface132of the chassis102. The topsheet138may be compliant, soft feeling, and non-irritating to the wearer's skin. It may be elastically stretchable in one or two directions. Further, the topsheet138may be liquid pervious, permitting liquids (e.g., menses, urine, and/or runny feces) to penetrate through its thickness. A topsheet138may be manufactured from a wide range of materials such as woven and nonwoven materials; apertured or hydroformed thermoplastic films; apertured nonwovens, porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Woven and nonwoven materials may comprise natural fibers such as wood or cotton fibers; synthetic fibers such as polyester, polypropylene, or polyethylene fibers; or combinations thereof. If the topsheet138includes fibers, the fibers may be spunbond, carded, wet-laid, meltblown, hydroentangled, or otherwise processed as is known in the art.

Topsheets138may be selected from high loft nonwoven topsheets, apertured film topsheets and apertured nonwoven topsheets. Apertured film topsheets may be pervious to bodily exudates, yet substantially non-absorbent, and have a reduced tendency to allow fluids to pass back through and rewet the wearer's skin. Exemplary apertured films may include those described in U.S. Pat. Nos. 5,628,097; 5,916,661; 6,545,197; and 6,107,539, which are all incorporated by reference herein.

As mentioned above, the diaper100may also include an absorbent assembly140that is joined to the chassis102. As shown inFIGS.1A and1B, the absorbent assembly140may have a laterally extending front edge148in the front waist region116and may have a longitudinally opposing and laterally extending back edge150in the back waist region118. The absorbent assembly may have a longitudinally extending right side edge152and may have a laterally opposing and longitudinally extending left side edge154, both absorbent assembly side edges152and154may extend longitudinally between the front edge148and the back edge150. The absorbent assembly140may additionally include one or more absorbent cores142or absorbent core layers. The absorbent core142may be at least partially disposed between the topsheet138and the backsheet136and may be formed in various sizes and shapes that are compatible with the diaper. Exemplary absorbent structures for use as the absorbent core of the present disclosure are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,888,231; and 4,834,735, which are all incorporated by reference herein.

Some absorbent core embodiments may comprise fluid storage cores that contain reduced amounts of cellulosic airfelt material. For instance, such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even 1% of cellulosic airfelt material. Such a core may comprise primarily absorbent gelling material in amounts of at least about 60%, 70%, 80%, 85%, 90%, 95%, or even about 100%, where the remainder of the core comprises a microfiber glue (if applicable). Such cores, microfiber glues, and absorbent gelling materials are described in U.S. Pat. Nos. 5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. Patent Publication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper100may also include elasticized leg cuffs156and an elasticized waistband158. It is to be appreciated that the leg cuffs156can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. The elasticized leg cuffs156may be configured in various ways to help reduce the leakage of body exudates in the leg regions. Example leg cuffs156may include those described in U.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115; and U.S. Patent Publication No. 2009/0312730 A1, which are all incorporated by reference herein.

As shown inFIG.1B, the chassis102may include longitudinally extending and laterally opposing leg cuffs156that are disposed on the interior surface132of the chassis102that faces inwardly toward the wearer and contacts the wearer. Each leg cuff may have a proximal edge. The leg cuffs may also overlap the absorbent assembly140, wherein the proximal edges extend laterally inward of the respective side edges of the absorbent assembly152and154. In some configurations, the leg cuffs may not overlap the absorbent assembly. It is to be appreciated that the leg cuffs may be formed in various ways, such as for example, by folding portions of the chassis102laterally inward, i.e., toward the longitudinal axis124, to form both the respective leg cuffs and the side edges128and130of the chassis102. In another example, the leg cuffs may be formed by attaching an additional layer or layers to the chassis at or adjacent to each of the respective side edges and of the chassis. Each of the leg cuffs may be joined to the interior surface132of the chassis and/or the absorbent assembly in leg cuff attachment zones in the front waist region116and in leg cuff attachment zones in the back waist region118. The leg cuffs may extend to the same longitudinal extent as the absorbent article or alternatively the leg cuffs may have a longitudinal extent that is less than the absorbent article.

The elasticized waistband158may provide improved fit and containment and may be a portion or zone of the diaper100that may elastically expand and contract to dynamically fit a wearer's waist. It is to be appreciated that the elasticized waistband158may be located in various positions relative to various diaper components. For example, the elasticized waistband158may be positioned longitudinally inwardly from the waist edges120,122of the diaper and/or toward the lateral edges148,150of the absorbent core142. In some configurations, the elasticized waistband158may be positioned with a lateral edge that is coterminous with the waist edges120,122. In some configurations, the elasticized waistband158may be positioned such that laterally opposing end regions of the waistband158are located laterally inward from the leg cuffs156. In some configurations, the elasticized waistband158may be positioned such that laterally opposing end regions of the waistband158overlap the leg cuffs156. In some configurations, the elasticized waistband158may be positioned on the wearer facing surface132of the topsheet138. In some configurations, the waistband158may be positioned on the wearer facing surfaces132of the topsheet138and the leg cuffs156. In some configurations, the waistband158may be positioned on the wearer facing surfaces132of the topsheet138and laterally opposing end regions of the waistband158may be positioned between the leg cuffs156and the topsheet138. In some configurations, the elasticized waistband158may be positioned between the garment facing surface132of the topsheet138and the wearer facing surface132of the backsheet136. And in some configurations, the elasticized waistband158may be positioned on the garment facing surface134of the backsheet136. The diaper100may also include more than one elasticized waistband158, for example, having one waistband158positioned in the back waist region118and one waistband158positioned in the front wait region116, although other embodiments may be constructed with a single elasticized waistband158. The elasticized waistband158may be constructed in a number of different configurations including those described in U.S. Pat. Nos. 4,515,595 and 5,151,092.

Taped diapers may be manufactured and provided to consumers in a configuration wherein the front waist region and the back waist region are not fastened, pre-fastened, or connected to each other as packaged, prior to being applied to the wearer. For example, the taped diaper100may be folded about a lateral centerline with the interior surface132of the first waist region116in surface to surface contact with the interior surface132of the second waist region118without fastening or joining the waist regions together. The rear side panels104and106and/or the front side panels108and110may also be folded laterally inward toward the inner surfaces132of the waist regions116and118.

The diaper100may also include various configurations of fastening elements to enable fastening of the front waist region116and the back waist region118together to form a closed waist circumference and leg openings once the diaper is positioned on a wearer. For example, as shown inFIGS.1A and1B, the diaper100may include first and second fastening members162,164, also referred to as tabs, connected with the first and second rear side panels104,106, respectively. The diaper may also include first and second front side panels108,110, that may or may not include fastening members.

With continued reference toFIGS.1A and1B, each side panel104,106and/or fastening member162and164may form a portion of or may be permanently bonded, adhered or otherwise joined directly or indirectly to the chassis102laterally inward from the side edge128and130, in one of the front waist region116or the back waist region118. Alternatively, the fastening members162,164may form a portion of or may be permanently bonded, adhered or otherwise joined directly or indirectly to the first and second rear panels104,106at or adjacent the distal edge of the panel and/or the first and second front side panels108and110at or adjacent the distal edge of the side panel. It is to be appreciated that the fastening members and/or side panels may be assembled in various ways, such as disclosed for example, in U.S. Pat. No. 7,371,302. The fastening members162,164and/or side panels104,106,108,110may also be permanently bonded or joined at or adjacent the side edges128and130of the chassis102in various ways, such as for example, by adhesive bonds, sonic bonds, pressure bonds, thermal bonds or combinations thereof, such as disclosed for example, U.S. Pat. No. 5,702,551, which is incorporated by reference herein.

Referring now toFIG.1B, the first fastening member162and/or the second fastening member164may include various types of releasably engageable fasteners. The first and second fastening members162and/or164may also include various types of refastenable fastening structures. For example, the first and second fastening members162and164may include mechanical fasteners,166, in the form of hook and loop fasteners, hook and hook fasteners, macrofasteners, buttons, snaps, tab and slot fasteners, tape fasteners, adhesive fasteners, cohesive fasteners, magnetic fasteners, hermaphroditic fasteners, and the like. Some examples of fastening systems and/or fastening members162,164are discussed in U.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; 5,221,274; 6,251,097; 6,669,618; 6,432,098; and U.S. Patent Publication Nos. 2007/0078427 A1 and 2007/0093769 A1, which are all incorporated by reference herein.

As previously mentioned, the fastening members162and164may be constructed from various materials and may be constructed as a laminate structure. The fastening members162and164may also be adapted to releasably and/or refastenably engage or connect with another portion of the diaper100. For example, as shown inFIG.1A, the diaper100may include a connection zone168, sometimes referred to as a landing zone, in the first waist region116. As such, when the taped diaper100is placed on a wearer, the fastening members162and164may be pulled around the waist of the wearer and connected with the connection zone168in the first waist region116to form a closed waist circumference and a pair of laterally opposing leg openings. It is to be appreciated that the connection zone may be constructed from a separate substrate that is connected with the chassis102of the taped diaper. In some embodiments, the connection zone may be integrally formed as part of the backsheet136of the diaper100or may be formed as part of the first and second front panels108,110, such as described in U.S. Pat. Nos. 5,735,840 and 5,928,212, which are both incorporated by reference herein.

As previously mentioned, absorbent articles may be assembled with various components that may constructed with the substrates described herein. Thus, in the context of the previous discussion, the apparatuses and methods herein may be used to bond discrete elastic parts under tension to an advancing carrier substrate during the assembly of an absorbent article100. For example, the apparatuses and methods herein may be utilized to bond elastic parts that may be configured as waistbands158to carrier substrates that may be configured as topsheets138or backsheets136during the manufacture of absorbent articles100. It is to be appreciated that the systems and methods disclosed herein are applicable to work with various types of converting processes and/or machines. For example,FIG.2shows a schematic representation of a converting process including an apparatus or system300that bonds discrete elastic parts200with an advancing carrier substrate202to form a laminate204.

As shown inFIGS.2and3, the carrier substrate202may advance in a machine direction MD at a first speed S1. The carrier substrate comprises a first longitudinal edge206and a second longitudinal edge208separated from the first longitudinal edge206in a cross direction CD to define a width WCS. The carrier substrate202also includes a first surface210and an opposing second surface212. As discussed in more detail below, discrete elastic parts200are bonded with the first surface210of the carrier substrate202.

In the context of components of absorbent articles100discussed above and assembly processes thereof, the elastic parts200may be configured as waistbands158and the carrier substrate202may be configured as a continuous topsheet138, backsheet136, or continuous laminate of a combined topsheet138and backsheet136. As such, the first surface210of the carrier substrate202may correspond with the wearer facing surface132or the garment facing surface134of the topsheet138or backsheet136. In some configurations, the elastic part200may be bonded between a topsheet138and a backsheet136. For example, the elastic part200may be bonded with the wearer facing surface132of the backsheet136, which is subsequently bonded with a topsheet138. In another example, the elastic part200may be bonded with the garment facing surface134of the topsheet138, which is subsequently bonded with a backsheet136. In yet another example, the elastic part200may be bonded with the garment facing surface134of the backsheet136, wherein the wearer facing surface132of the backsheet136may have been previously bonded with a topsheet138or may be subsequently bonded with a topsheet138. In another example, the elastic part200may be bonded with the wear facing surface132of the topsheet136, wherein the garment facing surface134of the topsheet138may have been previously bonded with a backsheet136or may be subsequently bonded with a backsheet136.

As shown inFIG.3A, the carrier substrate202may also include leg cuffs156positioned on the first surface210adjacent the first longitudinal edge206and the second longitudinal edge208. As such, portions of the discrete elastic parts200may also be bonded with the leg cuffs156. In some configurations, the discrete elastic parts200may be bonded with the carrier substrate202and leg cuffs156may subsequently be bonded with the carrier substrate202. The leg cuffs156may be positioned relative the elastic part200such that the leg cuffs156may or may not partially cover or overlap opposing end portions of the elastic part200. In some configurations, the leg cuffs156may be sandwiched between the elastic parts200and the carrier substrate202. And in some configurations, the elastic parts200may be sandwiched between the leg cuffs156and the carrier substrate202.

Referring now toFIGS.2and4, a continuous elastic substrate200aadvanced at a second speed S2in a machine direction MD, wherein the second speed S2is less than the first speed S1. The continuous elastic substrate200acomprises a first longitudinal edge214and a second longitudinal edge216separated from the first longitudinal edge214in the cross direction CD to define a width WES. The continuous elastic substrate200aalso includes a first surface218and an opposing second surface220. The continuous elastic substrate200ais stretchable in at least one direction and is oriented such that the continuous elastic substrate200ais stretchable in the cross direction CD. As such, the width WESof the continuous elastic substrate may be an unstretched width. In some configurations, the width WESof the continuous elastic substrate200amay be a partially stretched width.

With continued reference toFIGS.2,4, and5, the system300may include an adhesive applicator device302that deposits adhesive222onto the second surface220of the continuous elastic substrate200a. It is to be appreciated that the adhesive applicator device302may be configured in various way, such as for example, as a spray nozzle and/or a slot coating device. In some configurations, the adhesive applicator device302may be configured in accordance with the apparatuses and/or methods disclosed in U.S. Pat. Nos. 8,186,296; 9,265,672; 9,248,054; and 9,295,590 and U.S. Patent Publication No. 2014/0148773 A1, which are all incorporated by reference herein.

It is to be appreciated that the adhesive222may be applied to the continuous elastic substrate200ato define regions of adhesive222on the second surface220having various shapes and sizes relative to the continuous elastic substrate200a. For example, as shown inFIG.5, the adhesive222may be applied to the second surface220of the continuous elastic substrate200ato define a region224of adhesive222extending continuously in the machine direction MD and the cross direction CD. The adhesive222may extend in the cross direction CD define a width WADH. In some configurations, the width WADHof adhesive222may be less than the width WESof the continuous elastic substrate200a, and in some configurations, the width WADHmay be equal to the width WESof the continuous elastic substrate200a.

As shown inFIGS.2,5, and6, the continuous elastic substrate200amay advance in the machine direction MD from the adhesive applicator device302to a cutting device304that cuts and separates discrete elastic parts200from the continuous elastic substrate200a. As such, the discrete elastic parts200each include a leading edge230and a trailing edge232and defines a length LEPin the machine direction MD extending from the leading edge230to the trailing edge232. The elastic part200also includes first and second longitudinal edges214,216that correspond with the longitudinal edges214,216of the continuous elastic substrate200aextending between the leading and trailing edges230,232. In addition, the elastic part200includes first and second surfaces218,220that correspond with the first and second surfaces218,220of the continuous elastic substrate200a.

As shown inFIG.6, the discrete elastic part200also includes a first end region234adjacent the first longitudinal edge214and a second end region236adjacent the second longitudinal edge216, wherein the second end region236is separated from the first end region234in the cross direction CD by a central region238. As discussed above, adhesive222may be applied to the second surface220of the continuous elastic substrate200a. As such, the discrete elastic part200may include a zone240of adhesive222on the second surface220. It is to be appreciated that the zone240of adhesive222may define various sizes and shapes relative to the elastic part200. For example, as shown inFIG.6, the zone240of adhesive may extend in the cross direction CD for less than the entire width W1of the discrete elastic part200. In some configurations, the zone240of adhesive222may be positioned only on the central region238of the discrete elastic part200such that the first end region234and the second end region236of the second surface220of the discrete elastic part200may not include any adhesive222.

As shown inFIGS.2and7, the cutting device304may include a knife roll306positioned adjacent an anvil roll308to define a nip310therebetween. The knife roll306may include an outer circumferential surface312and one or more blades314adapted to rotate about an axis316in a first direction Dir1. The anvil roll308may include an outer circumferential surface318adapted to rotate about an axis320in a second direction Dir2opposite the first direction Dir1such that the outer circumferential surface318advances at a third speed S3, wherein the third speed S3is greater than the second speed S2. With continued reference toFIG.2, as the continuous elastic substrate200aadvances through the nip310between the knife roll306and the anvil roll310, the blade314operates to cut the discrete elastic part200from the continuous elastic substrate200a. Because the outer circumferential surface318of the anvil roll308advances at the third speed S3, the cut discrete elastic part200may then accelerate from the second speed S2to the third speed S3on the outer circumferential surface318of the anvil roll308.

In some configurations, the third speed S3may be equal to the first speed S1of the advancing carrier substrate202. In some configurations, the third speed S3may be less than or greater than the first speed S1of the advancing carrier substrate202, and as such, the discrete elastic part may be accelerated or decelerated downstream of the anvil roll308from the third speed S3to the first speed S1before being combined with the carrier substrate202. Because the first speed S1of the carrier substrate is greater than the second speed S2, the discrete elastic parts200are accelerated from the second speed S2to the first speed S1before bonding with the carrier substrate202. By accelerating discrete elastic parts200from the second speed S2to the first speed S1, trailing edges232(or leading edges230) of consecutively cut discrete elastic parts200may be separated from each other in the machine direction MD by a pitch distance PD, such as shown inFIG.12, which may correspond with the pitch length PL described above with reference toFIGS.1A and1B. The anvil roll308may also be configured to apply vacuum pressure to the discrete elastic parts200to help hold the discrete elastic parts200on the outer circumferential surface318as the anvil roll308rotates.

It is to be appreciated that the cutting device304may be configured in various ways. For example, in some configurations, the blade314may be configured such that resulting cut lines and corresponding leading edges230and trailing edges232of the discrete elastic parts200may be straight and/or curved. The cutting device304may also be adapted to cut the discrete elastic parts200such that material along the cut line adjacent leading edges230and trailing edges232is fused and/or pressure bonded together. It is also to be appreciated that the positions of the knife roll306and anvil roll308may be opposite to that which is illustrated inFIG.2, and as such, the discrete elastic parts200may remain on the outer circumferential surface312of the knife roll306as opposed to the anvil roll308. It is also to be appreciated that the cutting device304may be configured to convey and/or cut the discrete elastic parts200in different ways. For example, the cutting device304may be adapted to advance the continuous elastic substrate200aand/or the discrete elastic parts200on a conveyor belt. In another example, the cutting device304may include a laser adapted to cut the discrete elastic parts200from the continuous elastic substrate200a. It is also to be appreciated that one or more components of the cutting device304may be configured to operate at constant and/or variable speeds. For example, the knife roll306and/or the anvil roll308may be connected with various types of motors, such as servo motors for example, that may rotate the knife roll306and/or the anvil roll308at constant and/or variable angular velocities.

With reference toFIG.2, the apparatus300may include a rotatable transfer device322that transfers the discrete elastic parts200from the cutting device304to a bonding device324, which in turn, combines the elastic parts200with the carrier substrate202. The transfer device322may also be configured to stretch the discrete elastic parts200in the cross direction CD. As such, the transfer device322may be configured as a spreader mechanism326, such as shown inFIGS.7and8. With continued reference toFIGS.2,7, and8, the transfer device322may be positioned adjacent the anvil roll308to define a nip328therebetween. In some configurations, the anvil roll308may be configured to apply positive air pressure, sometimes referred to as blow-off air, to the discrete elastic parts200adjacent the nip328to help remove the discrete elastic parts200from the anvil roll308during transfer to the transfer device322. As discussed in more detail below, the discrete elastic parts200are received from the anvil roll308and the spreader mechanism326operates to stretch discrete elastic parts200in the cross direction CD. The stretched discrete elastic parts200are then advanced from the spreader mechanism326onto a rotating component of the bonding device324, which in turn, bonds the stretched discrete elastic parts200onto the carrier substrate202.

As shown inFIGS.7and8, the spreader mechanism326may include a first disk330and a second disk332, wherein the first disk330is displaced from the second disk332in the cross direction CD. The first disk330is adapted to rotate about an axis of rotation330aand the second disk332is adapted to rotate about an axis of rotation332a, wherein the first and second disks330,332may rotate in a third direction Dir3that is opposite the second direction Dir2. As shown inFIG.9, the first disk330includes an outer rim330bextending axially between an inner edge330cand an outer edge330d, and the second disk332includes an outer rim332bextending axially between an inner edge332cand an outer edge332d.

As shown inFIGS.7-9, the first disk330and the second disk332are canted relative to each other such that the outer rims330b,332bare separated from each other by a distance D that increases from a minimum distance Dmin at a first location to a maximum distance Dmax at a second location. As discussed below, the discrete elastic parts200are transferred from the cutting device304onto the outer rims330b,332bduring operation. Because the first and second disks330,332are canted, rotation of the disks330,332causes the rims330b,332bto pull on first end region234and the second end region236of discrete elastic parts200and stretch the central regions238of the discrete elastic parts200in the cross direction CD before the discrete elastic parts200are transferred to the bonding device324. As shown inFIGS.2,6, and10, the spreader mechanism326may operate to stretch the discrete elastic parts200in the cross direction from a first width W1to a second width W2that is greater than the first width W1.

With reference toFIGS.2,7, and8, the disks330,332may also be configured to help grip the opposing first and second end regions234,236of the discrete elastic parts200during operation. For example, the first disk330and the second disk332may each be fluidly connected with a vacuum pressure source334. As such, vacuum air pressure may be used to help hold the discrete elastic parts200onto the rims330b,332bduring operation. As shown inFIGS.9and9A, the disks330,332may also include nubs336that protrude radially outward from the rims330b,332b. As such, the nubs336may also help prevent the first and second end regions234,236of the discrete elastic parts200from sliding along the rims330b,332bwhile stretching the central region238of the discrete elastic parts200. It is also noted that because the first and second end regions234,236of the discrete elastic part200are held on the rims330b,332bduring the stretching operation, the central region238of the discrete elastic part200is stretched while the first and second end regions234,236may not be stretch or may be stretched to a much lesser degree than the central region238.

As previously discussed with reference toFIG.6, the elastic part200may include a zone240of adhesive222that is positioned only on the central region238of the discrete elastic part200and wherein the first end region234and the second end region236of the second surface220of the discrete elastic part200may not include any adhesive222. As shown inFIGS.2,7, and8, once transferred to the transfer device322, the elastic parts200may be oriented such that the first surface218may be facing radially outward, and the second surface220and the zone240of adhesive222may be facing radially inward. As such, the arrangement of disks330,322of the spreader mechanism326provide the ability to rotatably convey the elastic parts200from the cutting device304to the bonding device324with a zone240of adhesive222that faces radially inward without having to contact the adhesive222with the disks330,332.

It is to be appreciated that the transfer device322may be configured in various ways to help ensure a relatively smooth and consistent transfer of the discrete elastic parts200from the cutting device304to the transfer device322as well as a relatively smooth and consistent transfer of the discrete elastic parts200from the transfer device322to the bonding device324. For example, as discussed above, the transfer device322may include a first disk330and a second disk332that are canted relative to each other. Thus, as discussed below with reference toFIGS.9B and9C, the first and second disks330,332may be configured to compensate for the canted orientations so as to define a relatively constant gap between the rims330b,332band the outer circumferential surface318of the anvil roll308at or near the nip328as well as a relatively constant gap between the rims330b,332band the outer circumferential surface346of the pattern roll340at or near the nip338.

As shown inFIGS.9B and9C, the first disk330may be oriented such that the rotation axis330ais angularly offset from the rotation axis320of anvil roll308and the rotation axis348of the pattern roll340to define a canting angle θ therebetween. In addition, the second disk332may be oriented such that the rotation axis332ais angularly offset from the rotation axis320of anvil roll308and the rotation axis348of the pattern roll340to define a canting angle θ therebetween. It is to be appreciated that the rotation axis320of anvil roll308is shown inFIG.9Brelative to the rotation axes330a,332aof the first and second disks330,332only to illustrate the canting angle θ therebetween and does not represent the actual physical position of the rotation axis320. Similarly, it is to be appreciated that the rotation axis348of pattern roll340is shown inFIG.9Crelative to the rotation axes330a,332aof the first and second disks330,332only to illustrate the canting angle θ therebetween and does not represent the actual physical position of the rotation axis348.

With continued reference toFIGS.9B and9C, the respective rims330b,332bof the first and second disks330,332may each be contoured to define a pick-up surface368and a drop-off surface370. In turn, the pick-up surfaces368may be oriented to define a relatively constant gap G1extending for a distance along the cross direction CD between the pick-up surface368and the outer circumferential surface318of the anvil roll308at or near the nip328. In some configurations, the pick-up surfaces368may be parallel or substantially parallel with the outer circumferential surface318of the anvil roll308at or near the nip328. In addition, the drop-off surfaces370may be oriented to define a relatively constant gap G2extending for a distance along the cross direction CD between the drop-off surfaces370and the outer circumferential surface346of the pattern roll340at or near the nip338. In some configurations, the drop-off surfaces370may be parallel or substantially parallel with the outer circumferential surface346of the pattern roll340at or near the nip338. It is to be appreciated that the rims330b,332bof the disks330,332may be configured such that the pick-up surfaces368may be positioned axially inboard or outboard in the cross direction of the drop-off surfaces370. In addition, the pick-up surface368may be angularly offset from the drop-off surface370by an offset angle Φ. In some configurations, the offset angle may be defined such that:
Φ=[180°−2×(canting angle θ)].

In operation, the discrete elastic part200may be transferred from the anvil roll308at the nip328to position the first end region234of the discrete elastic part200on the pick-up surface368of the first disk330and to position the second end region236of the discrete elastic part200on the pick-up surface368of the second disk332. As the disks330,332rotate, the first end region234of the discrete elastic part200will become positioned on the drop-off surface370of the first disk330and the second end region236of the discrete elastic part200will become positioned on the drop-off surface370of the second disk332due to the canted orientations of the disks330,332. Thus, the discrete elastic part200is transferred from the drop-off surfaces370of the disks330,332to the outer circumferential surface346of the pattern roll340at the nip338.

It is to be appreciated that the contoured features of the rims330b,332bof the disks330,332described above may be incorporated as integrated features of the disks330,332or may be incorporated into discrete parts, such as shoes, that may be connected with disks330,332. In addition, it is to be appreciated that the rims330b,332band/or shoes may be constructed from compliant materials, such as polyurethane or silicone. In some configurations, the rims330b,332band/or shoes may, and may also include holding pins and/or may be constructed from materials with a relatively high coefficient of friction relative the discrete elastic parts200.

It is also to be appreciated that aspects of the spreader mechanism326may be configured to be independently controlled. For example, the cross direction CD position of the spreader mechanism326relative to cutting device304and/or the bonding device324. In addition, the cross direction CD positions of the disks330,332of the spreader mechanism326may be adjustable relative to each other. In addition, canting angles of the disks330,332of the spreader mechanism326may be adjustable. In some configurations, radial clearances between components of the cutting device304and/or the bonding device324and the outer rims of the first and second disks330b,332bof the spreader mechanism326may be adjustable, wherein the positions of the disks330,332may be configured to be independently or collectively adjustable.

It is to be appreciated that various drives may be used to control the rotation of the disks330,332of the spreader mechanism326. For example, the disks330,332of the spreader mechanism326may be driven by one or more motors, such as a servo motor. In some configurations, motors may be directly connected with the disks330,332, and in some configurations, motors may be indirectly connected with the disks330,332, such as through belts, pulleys, and/or gears. The disks330,332may be driven as a pair through the use of a common driveshaft with a coupling between the disks. In some configurations, a common jackshaft may be used to drive both disks330,332together with a single motor. In some configurations, drives of components of the cutting device304and/or the bonding device324and spreader mechanism326may be operatively connected, and may be configured with a single motor.

As discussed above, the cut discrete elastic parts200accelerate from the second speed S2to the third speed S3on the outer circumferential surface318of the anvil roll308, and in some configurations, the third speed S3may be less than or greater than the first speed S1of the advancing carrier substrate202. Thus, the transfer device322may be configured to rotate at a variable angular velocity to accelerate or decelerate the discrete elastic parts200to the first speed S1. For example, if the third speed S3is less than the first speed S1, the transfer device322may be configured to receive the discrete elastic part200from the anvil roll308while the rims330b,332bof the first and second disks330,332are moving through the nip328at the third speed S3. The angular velocity of the disks330,332may then be changed to accelerate the discrete elastic part200to the first speed S1before transferring the discrete elastic part200to the bonding device324. In another example, if the third speed S3is greater than the first speed S1, the angular velocity of the disks330,332may be changed to decelerate the discrete elastic part200to the first speed S1before transferring the discrete elastic part200to the bonding device324. In situations where the third speed S3is equal to the first speed S1, the disks330,332may rotate at a constant angular velocity. It is to be appreciated that the spreader mechanism326may be configured in various ways to accommodate a need to rotate at variable angular velocities, such as, for example, disclosed in European Patent Publication No. EP 2260813 B1, which is incorporated by reference herein. The ability to rotate at the transfer device326at variable angular velocities may help reduce the need to replace components of the apparatus300when assembling absorbent articles100of smaller or larger sizes, which in turn, may require a reduction or increase in the pitch distances between consecutively cut discrete elastic parts200.

As previously mentioned, the rotatable transfer device322may be configured to transfer the discrete elastic parts200from the cutting device304to a bonding device324. As shown inFIGS.2,7, and8, the bonding device324may be positioned adjacent the first and second disks330,332of the spreader device326to define a nip338therebetween. In some configurations, the first and second disks330,332may be configured to apply positive air pressure, sometimes referred to as blow-off air, to the discrete elastic part200adjacent the nip338to help remove the discrete elastic parts200from the disks330,332during transfer to the bonding device324. As discussed in more detail below, the discrete elastic parts200are received from the spreader mechanism326with the central regions238stretched in the cross direction CD, and the bonding device324transfers and bonds the discrete elastic parts200in the stretched state to the advancing carrier substrate202.

It is to be appreciated that the bonding device324may be configured in various ways. For example, as shown inFIGS.2,7, and8, the bonding device324may be configured with a pattern roll340and a pressing surface342adjacent the pattern roll340to define a nip344therebetween. The pattern roll340includes an outer circumferential surface346and rotates about an axis of rotation348, wherein the pattern roll340may rotate in a fourth direction Dir4that is opposite the third direction Dir3. In addition, pattern roll340may rotate such that the outer circumferential surface346advances at or about the first speed S1. During operation, discrete elastic parts200in a stretched state are transferred from the first and second disks330,332to the outer circumferential surface346of the pattern roll340. The pattern roll340rotates to advance the stretched elastic parts200between the outer circumferential surface346of the pattern roll and the advancing carrier substrate202. In particular, the first surface218of the discrete elastic part200may be positioned in a facing relationship with and in direct contact with the outer circumferential surface346of the pattern roll340. As such, the zone240of adhesive222and the second surface of the discrete elastic part200may be facing radially outward from the rotation axis348. The carrier substrate202advances to the pattern roll340such that the first surface210of the carrier substrate200is in direct contact with and in a facing relationship with the outer circumferential surface346of the pattern roll340. As the pattern roll340rotates, the second surface220of the discrete elastic part200is positioned in direct contact with and in a facing relationship with the first surface210of the carrier substrate200. The combined discrete elastic part200and the carrier substrate202advance through the nip344between the pattern roll340and the pressing surface342to mechanically bond the discrete elastic part200and the carrier substrate202together.

For example, as shown inFIG.2, the bonding device324may be configured as a mechanical bonding device that includes an anvil roll350. The anvil roll350may include an outer circumferential surface352and rotates about an axis of rotation354, wherein the anvil roll350may rotate in a fifth direction Dir5that is opposite the fourth direction Dir4. The outer circumferential surface352of the anvil roll350may define the pressing surface342operating in conjunction with the pattern roll340. As shown inFIGS.11and11A, the outer circumferential surface346of the pattern roll340may also comprise one or more bonding surfaces356defined by bonding elements358extending radially outward. As the pattern roll340rotates, the discrete elastic parts200and the carrier substrate200are advanced between the bonding surfaces356and the pressing surface342to mechanically bond or weld the elastic part200and the carrier substrate202together to create bonds242between the elastic part200and the carrier substrate202. Heat and/or pressure between the pressing surface342and the pattern roll340may melt and bond the carrier substrate202and the elastic part200together in areas supported by the bonding surfaces356on the pattern roll340. As shown inFIG.12, the mechanical bonds and/or bond regions242may have shapes that correspond with and may mirror shapes of the bonding surfaces356.

Thus, as the laminate204advances through the nip344, the carrier substrate202and the discrete elastic part200are mechanically bonded or welded together. It is to be appreciated that the bonding device324herein may be configured in various ways with various features described herein to bond the discrete elastic parts200with the carrier substrate202. As such, the pattern roll340and/or anvil roll350may be configured to apply heat and pressure in various ways to perform mechanical bonding, such as for example, the mechanical bonding devices and methods disclosed in in U.S. Pat. Nos. 4,854,984; 6,248,195; 8,778,127; 9,005,392; 9,962,297; and 10,052,237. It is also to be appreciated that the positions of the pattern roll340and anvil roll350may be opposite to that which is illustrated inFIG.2, and as such, the discrete elastic parts200may be transferred from the transfer device322to the outer circumferential surface352of the anvil roll350as opposed to the pattern roll340. It is also to be appreciated that one or more components of the bonding device324may be configured to operate at constant and/or variable speeds. For example, the pattern roll340and/or the anvil roll350may be connected with various types of motors, such as servo motors for example, that may rotate the pattern roll340and/or the anvil roll350at constant and/or variable angular velocities.

In some configurations, the carrier substrate202may be partially wrapped around the outer circumferential surface346of the pattern roll340. As such, the bonding device324may include one or more rolls that help guide the carrier substrate202to and/or from the pattern roll340. For example, as shown inFIG.2, the bonding device may include a guide roll360that helps to guide the carrier substrate202onto the outer circumferential surface346of the pattern roll340downstream of the nip338where the elastic parts202are received from the transfer device322and upstream of the nip344between the pattern roll340and the pressing surface342. The guide roll360may also be configured to apply pressure against the carrier substrate202and the elastic part200to help enhance the bonding of the adhesive222of the adhesive zone240and the carrier substrate202.

It is to be appreciated that the bonding device324may be configured in various ways, such as with heated or unheated pattern rolls, anvil rolls and/or ultrasonic bonding devices. For example, the bonding device324schematically shown inFIG.2Amay include the pattern roll340and the pressing surface342that comprises an energy transfer surface362of an ultrasonic bonding device364. As such, the bonding device364may include a horn366and may be configured to impart ultrasonic energy to the combined elastic part200and the carrier substrate202on the pattern roll340.

It is to be appreciated that aspects of the ultrasonic bonding device364may be configured in various ways, such as for example linear or rotary type configurations, and such as disclosed for example in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and 6,645,330. In some configurations, the ultrasonic bonding device364may be configured as a linear oscillating type sonotrode, such as for example, available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode may include a plurality of sonotrodes nested together in the cross direction CD. It is also to be appreciated that rotary horns may also be configured to rotate at constant and/or variable angular velocities.

As discussed above, the pattern roll340includes bonding elements358that extend radially outward to define bonding surfaces356. In turn, the bonds and/or bond regions242between the discrete elastic part200and the carrier substrate202may have shapes that correspond with and may mirror shape of the bonding surfaces356. It is to be appreciated that the pattern roll340may have various quantities and/or shapes of bonding surfaces356and that such bonding surfaces356may be positioned in various locations on the pattern roll340. For example, as shown inFIGS.11,11A,12, and13, the bonding elements358and bonding surfaces356may be positioned to correspond with the first end region234and the second end region236of the discrete elastic part200. Thus, the bonding device340may operate to mechanically bond the first and second end regions234,236of the elastic part200without mechanically bonding the stretched central region238. In some configurations, the bonding elements358and bonding surfaces356may be positioned such that mechanical bonds242are also applied to bond the central region238of the discrete elastic part200and the carrier substrate202together.

The pattern roll340may also be configured to apply vacuum pressure to the discrete elastic parts200to help hold the discrete elastic parts200on the outer circumferential surface346as the pattern roll340rotates. The vacuum pressure may also help hold the discrete elastic parts200in the stretched state while positioned on the pattern roll340. In addition, the bonding elements358and bonding surfaces356may also help grip the elastic parts200and help hold the elastic parts200in the stretched state. In addition, the pattern roll340may be configured such to also apply vacuum pressure through the bonding surfaces356of the bonding elements358. Further, the pattern roll340may be configured to interface with the first and second disks330,332of the spreader mechanism326to help maintain the stretched state of the discrete elastic part200during the transfer to the pattern roll340at the nip338. For example, as discussed above, the disks330,332of the spreader mechanism326may include various quantities of nubs336that protrude radially outward from the rims330b,332b, wherein the nubs336may help prevent the first and second end regions234,236of the elastic parts200from sliding toward each other along the rims330b,332bwhile stretching the discrete elastic parts200. It is to be appreciated that the nubs336may be configured in various shapes and sizes, spacing, and may be constructed from various types of materials. In some configurations, the bonding elements358on the pattern roll340may be configured to intermesh with the nubs336protruding from the rims330b,332bof the first and second disks330,332. The intermeshing between the nubs336and the bonding elements358may help the apparatus300maintain the stretched state of the discrete elastic part200when transferring from the transfer device322to the bonding device324.

As shown inFIG.2, after the discrete elastic part200is bonded with the carrier substrate202to create the laminate204, the laminate204may continue to advance in the machine direction MD from the bonding device324and may be subjected to additional converting operations, such as cutting, folding, and/or packaging operations. In some configurations, the laminate204may define a continuous length of absorbent articles or may be combined with additional substrates and/or components to define a continuous length of absorbent articles. In turn, the continuous length of absorbent articles may be subjected to a final knife cut that separates discrete absorbent articles from the continuous length of absorbent articles. As previously mentioned, the discrete elastic parts200may correspond with waistbands158on the absorbent articles100and the carrier substrate202may correspond with a topsheet substrate138or backsheet substrate136. In some configurations, the apparatuses and methods herein may be configured to apply discrete elastic parts200as discrete front and/or back waistbands158. In some configurations, the discrete elastic parts200may be applied to the carrier substrate202, and the discrete elastic parts200are subsequently cut during the final knife cut operation into a front waistband158positioned in the front waist region116and a back waistband158positioned in the back waist region118. It is to be appreciated that such final knife cut operation may be configured to apply straight and/or curved cut lines through the carrier substrate202and discrete elastic parts200. It is also to be appreciated that the carrier substrate202may include parts, such as laterally extending side panels for example, attached thereto upstream of the bonding device324. As such, the system300may also include devices, such as rails and/or conveyors, to help guide and control the carrier substrate202, and specifically such laterally extending features, into the bonding device324to help prevent unintentional bonding of such features.

As discussed above, the discrete elastic parts may be combined with the carrier substrate with adhesive and/or mechanical bonds. It is to be appreciated that the adhesive and mechanical bonds may be configured in various ways. For example, as discussed above with reference toFIGS.2,4,5, and6, the continuous elastic substrate200amay define a width WESin the cross direction CD, and the discrete elastic part200may also define a first width W1in the cross direction CD upstream of the nip328between the cutting device304and the transfer device322. And the respective widths WES, W1of the continuous elastic substrate200aand the elastic part200may be unstretched widths or partially stretched widths. Thus, as shown in for exampleFIGS.4Aand4A1, the continuous elastic substrate200amay comprise corrugations244oriented so as to define corrugation lines246extending in the machine direction MD. As discussed above with reference toFIG.2and as shown inFIG.5A, adhesive222may be applied to the second surface220of the continuous elastic substrate200a. The cutting device304separates the discrete elastic part200from the continuous elastic substrate200a. Thus, as shown inFIGS.6Aand6A1, the discrete elastic part200may also comprise corrugations244oriented to define corrugation lines246extending in the machine direction MD. In addition, the elastic part200includes a zone240of adhesive222that may cover corrugations244on the second surface220of the discrete elastic part200, such as shown inFIGS.6Aand6A1. Thus, the zone240of adhesive222may be separated into individual stripes248of adhesive222when the central region238of the discrete elastic part200is stretched in the cross direction CD, as shown inFIGS.10Aand10A1. The individual stripes248of adhesive222may extend in the machine direction MD and may be separated from each other in the cross direction CD by areas of the second surface220of the elastic part200the do not include adhesive222. In turn, the stretched central region238of the discrete elastic part200may then be bonded with the carrier substrate202with the stripes248of adhesive222.

It is also to be appreciated that the zone240of adhesive222may be applied to define various different shapes and sizes with respect to the discrete elastic part200and/or the carrier substrate202. For example, as shown inFIG.12, the zone240of adhesive222may extend in the cross direction CD to be coterminous with both the leading edge230and the trailing edge232of the elastic part200, and the zone240of adhesive222may define a length LAZin the machine direction MD and a width WAZin the cross direction CD. As such, the length LAZof the zone240of adhesive222may extend the entire length LEPof the discrete elastic part200extending from the leading edge230to the trailing edge232. In some configurations such as shown inFIG.12A, the length LAZof the zone240of adhesive222may extend for less than the entire length LEPof the discrete elastic part200. As such, the zone240of adhesive222may extend in the cross direction CD to be coterminous with the leading edge230and/or the trailing edge232of the elastic part200and may extend for length LAZextending from either the leading edge230or the trailing edge232of the elastic part200.

In some examples, the zone240of adhesive222may not extend to either the leading edge230or the trailing edge232of the elastic part200. In some configurations, more than one zone240of adhesive222may bond the elastic part200with the carrier substrate202. For example, as shown inFIG.12B, the laminate204may include a first zone240aof adhesive and a second zone240bof adhesive240bthat bond the elastic part200with the carrier substrate202. Such zones240a,240bof adhesive222may be separated from each other in the cross direction CD and/or the machine direction MD.

It is to be appreciated that the elastic part200, carrier substrate202, the zone240of adhesive222, and the mechanical bonds and/or bond regions242may define various features with various sizes relative to each other. For example, as shown inFIG.12, the elastic part200bonded with the carrier substrate202may define a width WEPextending in the cross direction CD from the first longitudinal edge214to the second longitudinal edge216. As such, the width WEPof the elastic part200may equal to or less than the WCSof the carrier substrate. The width WAZof the zone240of adhesive222may be equal to or less than the width WEPof the elastic part200.

As previously mentioned, the bonding device340may operate to mechanically bond the first and second end regions234,236of the elastic part200with the carrier substrate202. As such, the mechanical bonds242may define bond zones wherein the laminate204of the elastic part200and carrier substrate202may or may not be elastic. For example, as shown inFIG.12, a first bond zone BZ1may extend from the mechanical bonds242located in the first end region234of the elastic part200to first longitudinal edge214of the elastic part200, and a second bond zone BZ2may extend from the mechanical bonds242located in the second end region236of the elastic part200to second longitudinal edge216of the elastic part200. The first bond zone BZ1may define a width WBZ1in the cross direction CD, and the second bond zone BZ2may define a width WBZ2in the cross direction CD, wherein the widths WBZ1and WBZ2may be equal or different. As shown inFIG.12, a corrugation zone CZmay be defined in the cross direction CD between the first bond zone BZ1and the second bond zone BZ2wherein the laminate204of the elastic part200and carrier substrate202is elastic. The corrugation zone CZmay define a width WCZin the cross direction CD when in a fully stretched state, such as shown inFIG.12.

In some configurations, the first bond zone BZ1and/or the second bond zone BZ2may be separated in the cross direction CD from the zone240of adhesive222. For example, as shown inFIG.12, the first bond zone BZ1may be separated in the cross direction CD from the zone240of adhesive222to define a first gap zone GZ1, and the second bond zone BZ2may be separated in the cross direction CD from the zone240of adhesive222to define a second gap zone GZ2. The first gap zone GZ1may define a width WGZ1in the cross direction CD, and the second gap zone GZ2may define a width WGZ2in the cross direction CD, wherein the widths WGZ1and WGZ2may be equal or different. In some configurations, the first width WGZ1and/or the second width WGZ2may be from about 2 mm to about 4 mm. In some configurations, the first bond zone BZ1and/or the second bond zone BZ2may be coterminous with the zone240of adhesive222, wherein the first width WGZ1and/or the second width WGZ2may be 0 mm. In some configurations, portions of the first bond zone BZ1and/or the second bond zone BZ2may be located inside the zone240of adhesive222. In some configurations, portions of the first bond zone BZ1and/or the second bond zone BZ2may be located laterally outward from the first longitudinal edge214and/or the second longitudinal edge216.

As discussed above with reference toFIG.2, the system300may include an adhesive applicator device302that may be configured to apply adhesive222to the continuous elastic substrate200aupstream of the nip310between the knife roll306and anvil roll308. In turn, the discrete elastic parts200separated from the continuous elastic substrate200amay include a zone240of adhesive222that is adapted to adhesively bond the elastic part200with the carrier substrate202. It is to be appreciated that the zone240of adhesive222may comprise adhesive222applied to the continuous elastic substrate200a, the elastic part200, and/or the carrier substrate202in various configurations and/or positions in the assembly process. For example, as shown inFIG.2, the system300may include an adhesive applicator device302athat may be configured to apply adhesive222to the discrete elastic part200at a position downstream of the nip310between the knife roll306and anvil roll308. In another example, shown inFIG.2, the apparatus300may include an adhesive applicator device302bthat deposits adhesive222onto the first surface210of the carrier substrate202to define the zone240of adhesive222that bonds the elastic part200with the carrier substrate202. It is to be appreciated that the adhesive applicator device302amay be configured to operate in addition to or in place of the adhesive applicators302,302b, and adhesive applicator device302bmay be configured to operate in addition to or in place of the adhesive applicators302,302a. It is also to be appreciated that the adhesive applicator devices302a,302bmay be configured in various ways, such as the adhesive applicator302described above, such as for example, as a spray nozzle and/or a slot coating device. It is also to be appreciated that in some configurations, the discrete elastic parts200may be combined with the carrier substrate202with only mechanical bonds and without the use of adhesive.

In accordance with the above discussion with regard to the various shapes and sizes of the zones240of adhesive222, it is to be appreciated that adhesive222may be applied to the continuous elastic substrate200aand/or the carrier substrate202in various ways to define the zones240of adhesive222. For example, as discussed above with reference toFIGS.2and5, adhesive222may be applied to the continuous elastic substrate200ato define a region224of adhesive222extending continuously in the machine direction MD and/or the cross direction CD. In another example, shown inFIG.5B, the adhesive222may be applied to the second surface220of the continuous elastic substrate200ain discrete patches226separated from each other in on the continuous elastic substrate200ain the machine direction MD. In yet another example, shown inFIG.5C, the adhesive222may be applied to the second surface220of the continuous elastic substrate200ato define a region224of adhesive222that surround discrete areas228on the continuous elastic substrate200awhere no adhesive is applied. In still another example, shown inFIG.14, the adhesive222may be applied to the first surface210of the carrier substrate202in discrete patches226separated from each other on the carrier substrate202in the machine direction MD. It is to be appreciated that adhesive222may be applied to the continuous elastic substrate200a, the elastic part200, and/or the carrier substrate202in shapes and sizes that define the zones240of adhesive222that bond the elastic parts200and the carrier substrate202together. The discrete patches226of adhesive222may be separated from each other on the carrier substrate202in the machine direction MD by the pitch distance PD.

It is to be appreciated that the continuous elastic substrate200aand the discrete elastic parts200herein may be configured in various ways and may include one or more elastic materials, such as for example, elastic film and/or strands. For example, the continuous elastic substrate200aand the discrete elastic parts200may be configured as a single layer of elastic film. In some configurations, the continuous elastic substrate200aand the discrete elastic parts200may be configured as a laminate of two more substrates. For example, the continuous elastic substrate200aand the discrete elastic parts200may be configured as an elastic film bonded in between two or more nonwoven substrates and/or may be bonded with one or more nonwoven substrates. For example, the continuous elastic substrate200aand the discrete elastic parts200may be configured as a bi-laminate with an elastic film bonded with a single nonwoven substrate. In another example, the continuous elastic substrate200aand the discrete elastic parts200may be configured as an elastic film bonded between two or more substrates, wherein the substrates may comprise nonwovens. It is also to be appreciated that nonwoven substrates of the elastic substrate200aand discrete elastic parts200may be of the same or different material and/or basis weights. In some configurations, one more nonwoven substrates of the elastic substrate200aand discrete elastic parts200may be of the same or different material and/or basis weights as one more nonwoven substrates of the carrier substrate202.

It is also to be appreciated that the continuous elastic substrate200aand the discrete elastic parts200may be assembled in various ways, such as for example, as disclosed in U.S. Pat. Nos. 6,572,595; 6,830,800; 7,087,287; and 7,803,244; and U.S. Patent Publication Nos. 2018/0042778 A1; 2018/0042787 A1; 2018/0042779 A1; and 2018/0042780 A1, which are all incorporated by reference herein. For example,FIGS.15A-15Dshow various schematic views of an apparatus500operating to assemble a continuous elastic substrate200afrom which the discrete elastic parts200may be cut from, such as discussed above.

As shown inFIGS.15A-15C, a first substrate402advances in a machine direction MD onto a rotating anvil502. More particularly, the first substrate402includes a first surface404and an opposing second surface406, and the first substrate402advances to wrap the first surface404onto an outer circumferential surface504of the rotating anvil502. During the assembly process, a spreader mechanism512stretches an elastic film408by stretching the elastic film408to a first elongation in the cross direction CD. And the stretched elastic film408is positioned into contact with the second surface406of the first substrate402. In turn, the elastic substrate200amay be formed by ultrasonically bonding the first substrate402and the elastic film408together with a second substrate410on the anvil502. More particularly, the second substrate410includes a first surface412and an opposing second surface414, and the second substrate410advances to position the first surface412in contact with the elastic film408and the second surface406of the first substrate402.

With continued reference toFIGS.15A-15C, as the anvil502rotates, the first substrate402, the elastic film408, and the second substrate410are advanced between the outer circumferential surface504of the anvil502and one or more ultrasonic devices530adjacent the anvil502. It is to be appreciated that the ultrasonic device530may include a horn532and may be configured to impart ultrasonic energy to the combined substrates and elastic films on the anvil502. It is to be appreciated that aspects of the ultrasonic bonding device530may be configured in various ways, such as for example linear or rotary type configurations, and such as disclosed for example in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and 6,645,330. In some configurations, the ultrasonic bonding device530may be configured as a linear oscillating type sonotrode, such as for example, available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode may include a plurality of sonotrodes nested together in the cross direction CD. In turn, the ultrasonic horn532bonds the first substrate404, the elastic film408, and the second substrate410together to form the elastic substrate200a.

As shown inFIGS.15A and16, the elastic substrate200amay then advance from the anvil502and may be accumulated, such as for example, by being wound onto a roll200R or being festooned in a container. It is to be appreciated that the elastic substrate200amay be wound onto a roll200R in a fully stretched, partially stretched, or fully relaxed state. The accumulated elastomeric substrate200amay be stored and/or moved to a location for incorporation into an absorbent article assembly process wherein the elastomeric substrate200amay be converted into an absorbent article component, such as discussed above. It is also to be appreciated that the elastic substrate200amay advance from the anvil502and directly to absorbent article assembly processes.FIG.17also shows the elastic substrate200ain a relaxed state wherein the central region408cof the elastic film408is contracted in the cross direction CD. It is to be appreciated that the apparatus500may be configured to assemble elastic substrates200awith a single lane of elastic film408and may also be configured to assemble elastic substrates200awith multiple lanes of elastic film408separated from each other in the cross direction. In turn, the elastic substrate200amay be cut along the machine direction MD between such lanes of elastic films408to create multiple individual elastic substrates200a.

During the ultrasonic bonding process, it is to be appreciated that bonds imparted into the elastic substrate200afrom the ultrasonic horn532may correspond with patterns and/or shapes defined by a plurality of pattern elements extending radially outward from the outer circumferential surface504of the anvil502. It is to be appreciated that the elastic substrate200amay include various portions of components bonded together in various ways and with differing or identical bond patterns. For example, the elastic film408may be bonded together with the first and/or second substrates402,410, and the first substrate402may be bonded directly to the second substrate410in areas of the elastic substrate200a. In some configurations, the first and second substrates402,410may be bonded directly to each other through apertures in the elastic film, wherein such apertures may be formed during the bonding process. In some configurations, the elastic film408can be involved, or participate, in the bonding between the first and second substrates402,410, wherein “involved” can mean that the elastic film can, to some extent, be in intimate contact with, and possibly partially merged with, one or both the first and second substrates402,410. The involvement may be due to actual melt bonding about the perimeter of a bond site or may be due to mechanical interaction, such as by entanglement of a fibrous elastic layer between fibrous nonwoven layers also about the perimeter of bond site. It is to be appreciated that the apparatus500may be adapted to create various types of bond configurations, such as disclosed, for example, in U.S. Pat. Nos. 6,572,595; 6,830,800; 7,087,287; and 7,803,244; and U.S. Patent Publication Nos. 2018/0042778 A1; 2018/0042787 A1; 2018/0042779 A1; and 2018/0042780 A1, which are all incorporated by reference herein.

As previously mentioned, the spreader mechanism512stretches the elastic film408to a first elongation E1in the cross direction CD. With particular reference toFIGS.15A and15D, the elastic film408includes a first edge416aand a second edge416bseparated from the first edge416ain the cross direction CD. In addition, the elastic film408includes a first edge region408aadjacent the first edge416aand a second edge region408badjacent the second edge416b. The first edge region408ais separated from the second edge region408bin the cross direction CD by a central region408c. As shown inFIGS.15A and15B, the elastic film408may define an initial width Wi in the cross direction CD between the first edge416aand the second edge416bupstream of the spreader mechanism512. The elastic film512advances in a machine direction MD onto the spreader mechanism512at a first location520. It is to be appreciated that elastic film408may be at the initial width Wi in the cross direction CD while advancing onto the spreader mechanism512. It is also to be appreciated that the elastic film408may be in a relaxed state upstream of the spreader mechanism512.

As shown inFIGS.15B and15D, the first edge region408aof the elastic film408advances onto an outer rim516bof a first disk516of the spreader mechanism512, and the second edge region408badvances onto an outer rim518bof a second disk518. In addition, the outer rim516bof the first disk516may extend axially between an inner edge516cand an outer edge516d, and the outer rim518bof the second disk518may extend axially between an inner edge518cand an outer edge518d. The outer rims516b,518bof the first and second disks516,518of the spreader mechanism512may include channels524fluidly connected to a vacuum pressure source and may include radially protruding nubs528. Thus, as shown inFIG.15D, the first edge region408aof the elastic film408may be held in position on the outer rim516bwith vacuum air pressure in the channels524and with the radially protruding nubs528. Similarly, the second edge region408bof the elastic film408may be held in position on the outer rim518bwith vacuum air pressure in the channels524and with the radially protruding nubs528.

With continued reference toFIGS.15B and15D, the first disk516and the second disk518are canted. Thus, as the first disk516and the second disk518of the spreader mechanism512rotate, the elastic film408is stretched in the cross direction CD while advancing from the first location520or downstream of the first location520toward a second location522. Thus, as shown in theFIGS.15A,15B, and15D, the spreader mechanism512may stretch the elastic film408in the cross direction CD from the initial width Wi (and an initial elongation Ei) to a first width W1(and a first elongation E1) in the cross direction CD, wherein W1is greater than Wi and wherein E1is greater than Ei. In some configurations, the elastic film408may be consolidated to a second width W2(and second elongation E2), wherein W2is less than W1and wherein E2is less than E1. It is to be appreciated that the elastic film408remains stretched at the second width W2(and second elongation E2). It is also to be appreciated that the elastic film408may be in a relaxed state at the initial width Wi (and initial elongation Ei), and as such, the second width W2may be greater than the initial width Wi and the second elongation E2may be greater than the initial elongation Ei. In configurations where the elastic film is not consolidated, W2may be equal to W1and E2may be equal to E1.

It is to be appreciated that the apparatuses500herein may be configurated to operate with various extensions of elastic film. In some configurations, the difference between the first elongation E1and the second elongation E2may be about 25%. In some configurations, E1−E2=25%. In some configurations, when the spreader mechanism includes canted disks, the first and second edge regions408a,408bof the elastic film408may be held in position on the outer rims516b,518bof the disks516,518. And as such, some portions of the first and second edge regions408a,408bmay remain unstretched in the cross direction CD as the first and second disks516,518rotate. Thus, as the first disk516and the second disk518of the first spreader mechanism512rotate, the central region408cof the elastic film408is stretched in the cross direction CD.

As shown inFIG.15A-15D, the elastic film408advances from the spreader mechanism512downstream of the second location522to the anvil502, and onto the second surface406of the first substrate402on the anvil502. And as the anvil502rotates, the second substrate410advances onto anvil502to position the first surface412in contact with elastic film408and the second surface406of the first substrate402to form an elastic substrate200aand the first substrate402, elastic film408, and second substrate410are bonded together.

With continued reference toFIGS.15A and15B, the outer circumferential surface504of the anvil502may be fluidly connected with a vacuum source505, and as such, vacuum air pressure may be applied to the first substrate402on the anvil502. For example, the outer circumferential surface504of the anvil roll502may include a plurality of apertures fluidly connected with the vacuum pressure source. When the first substrate402is configured as a porous substrate, such as a nonwoven, vacuum air pressure may also be applied to the elastic film408on the anvil502, and as such, may help maintain the stretched condition of the of the elastic film408while on the anvil502. In some configurations, adhesive on a nonwoven may also help decrease the porosity of the nonwoven, which in turn, may enhance the ability of the vacuum air pressure to help maintain components in a stretched state.

It is also to be appreciated that aspects of the spreader mechanisms512may be configured in various ways. For example, the cross direction CD positions of the disks516,518of the spreader mechanism512may be adjustable relative to each other. In addition, canting angles of the disks516,518of the spreader mechanism512may be adjustable. The canting angle of the first disk516may be defined as an angular offset between the axis of rotation516aof the first disk516and the axis of rotation506of the anvil502, and the canting angle of the second disk518may be defined as an angular offset between the axis of rotation518aof the second disk518and the axis of rotation506of the anvil502. In some configurations, radial clearances between the outer circumferential surface504of the anvil502and the outer rims516b,518bof the first and second disks516,518of the spreader mechanisms512may be adjustable, wherein the positions of the disks516,518may be configured to be independently or collectively adjustable. In some configurations, the radial clearance between the outer circumferential surface504of the anvil502and the outer rims516b,518bmay be zero or greater than zero.

It is to be appreciated that various drives may be used to control the rotation of the disks516,518of the spreader mechanism512. For example, the disks516,518of the spreader mechanism512may be driven by one or more motors, such as a servo motor. In some configurations, motors may be directly connected with the disks516,518, and in some configurations, motors may be indirectly connected with the disks516,518, such as through belts, pulleys, and/or gears. The disks516,518may be driven as a pair through the use of a common driveshaft with a coupling between the disks. In some configurations, a common jackshaft may be used to drive both disks516,518together with a single motor. In some configurations, drives of the anvil502and spreader mechanism512may be operatively connected, and may be configured with a single motor. In some configurations, the disks516,518of the spreader mechanism512may be driven only by the advancement of the elastic film408. In some configurations, the disks516,518of the spreader mechanism512may be driven by rotation of the anvil502or an infeed idler. Other drives may include surface driving through a jackshaft with a friction material in operative contact with disks516,518.

It is to be appreciated that elastic substrates may be characterized by the force for a given extension when used in a disposable absorbent article. The magnitude of the force required to extend the elastic substrate may vary between the first extension and subsequent extensions. In some configurations, the elastic substrate may include an elastic film that may comprise a base elastic film, such as a styrenic-block copolymer, and surface layers also known as skins. Such skins may help prevent interlayer adhesion when the elastic film is wound into a roll format for shipping and handling. In some configurations, the skins may be a polyolefin, which may be 0.5-5 microns thick. However, the polyolefin skins on the surface of the elastic film may cause the higher initial extension forces for an elastic substrate. As such, some manufacturers of films may apply processes to help reduce the initial extension force for a given displacement relative to subsequent extensions. For example, some manufactures of elastic films may apply a process, sometimes referred to as “activation,” wherein the films are extended or stretched to create a plurality of cracks and tears in the skins at a microscopic scale. In turn, these cracks and tears may help reduce the skin contribution to the extension forces. In some configurations, activation operations are performed separate to the assembly process, such as for example, activating the films offline wherein the films may be stored until needed for production. For example, activation operations may be accomplished during the manufacture of the films, separately from converting lines that are dedicated to manufacturing elastic substrates that may be used in disposable absorbent articles. After manufacturing and activating the films, the films are delivered to the converting lines, such as in a form of continuous films wound onto a roll. As such, it is to be appreciated that the elastic film408may be supplied to a laminating process, such as discussed above with reference toFIGS.15A-15D, having already been activated. In some configurations, the elastic film408may be activated during the laminating process that forms the elastic substrate200a, such as disclosed for example, in U.S. Patent Publication No. 2018/0042780 A1, which is incorporated herein by reference. It is also to be appreciated that the elastic substrate200amay be subjected to activation processes. In some configurations, the elastic film408and/or the elastic substrate200amay be subjected to various types of activation processes, such as disclosed for example, in U.S. Pat. Nos. 4,116,892; 4,834,741; 5,143,679; 5,156,793; 5,167,897; 5,422,172; 5,518,801; 7,824,594; 7,896,641; 8,062,572; 8,118,801; and 9,687,580, and U.S. Patent Publication No. 20120143165 A1, which are all incorporated by reference herein.

As mentioned above, some portions of the first and second edge regions408a,408bof the elastic film408may remain unstretched in the cross direction CD when assembling the elastic substrate200a. Thus, as shown inFIG.16, the elastic substrate200amay include a first film dead zone FDZ1and a second film dead zone FDZ2that may correspond with the unstretched regions of the elastic film408. In addition, elastic substrate200amay also include a first nonwoven dead zone NWDZ1and a second nonwoven dead zone NWDZ2that correspond with regions where the elastic film408is not positioned between the first substrate402and the second substrate410. The first nonwoven dead zone NWDZ1may extend from the first longitudinal edge214of the elastic substrate200ato the first film dead zone FDZ1, and the second nonwoven dead zone NWDZ2may extend from the second longitudinal edge216of the elastic substrate200ato the second film dead zone FDZ2. With continued reference toFIG.16, the elastic substrate200amay include a stretch zone SZlocated between the nonwoven dead zones NWDZ1, NWDZ2and the film dead zones FDZ1, FDZ2. The elastic substrate200amay be elastomeric in the cross direction CD in the stretch zone SZ. As shown inFIGS.16and17, the elastic substrate200amay define a width WFSwhen fully stretched in the cross direction CD, and the elastic substrate200amay define a width WFRwhen fully relaxed in the cross direction CD, wherein WFRis less than WFS. Similarly, the stretch zone SZmay define a width WSZSwhen fully stretched in the cross direction CD, and the stretch zone SZmay define a width WSZRwhen fully relaxed in the cross direction CD, wherein WSZRis less than WSZS.

As shown inFIG.16, the first nonwoven dead zone NWDZ1may define a width WNWDZ1in the cross direction CD, and the second nonwoven dead zone NWDZ2may define a width WNWDZ2in the cross direction CD, wherein WNWDZ1may be equal to or different than WNWDZ2. The first film dead zone FDZ1may define a width WFDZ1in the cross direction CD, and second film dead zone FDZ2may define a width WFDZ2in the cross direction CD, wherein WFDZ1may be equal to or different than WFDZ2. In addition, the widths of the nonwoven dead zones WNWDZ1, WNWDZ2may be equal to or different from the widths of the film dead zones WFDZ1, WFDZ2. In some configurations, the combination of the first nonwoven dead zone NWDZ1and the first film dead zone FDZ1may define a first dead zone DZ1of the elastic substrate200a, and the combination of the second nonwoven dead zone NWDZ2and the second film dead zone FDZ2may define a second dead zone DZ2of the elastic substrate200a. Thus, the first dead zone DZ1may define a width WDZ1in the cross direction CD that is equal to the sum of the width WNWDZ1and the width WFDZ1, and/or the second dead zone DZ2may define a width WDZ2in the cross direction CD that is equal to the sum of the width WNWDZ2and the width WFDZ2. In some configurations, the elastic substrate200amay not include the first nonwoven dead zone NWDZ1and/or the second nonwoven dead zone NWDZ2. As such, the first film dead zone FDZ1may define the first dead zone DZ1of the elastic substrate200a, and the second film dead zone FDZ2may define a second dead zone DZ2of the elastic substrate200a. Thus, the width WDZ1may be equal to the width WFDZ1, and/or the width WDZ2may be equal to the width WFDZ2.

It is to be appreciated the elastic substrate200a, and elastic parts200cut therefrom, may be configured such that the width WDZ1of the first dead zone DZ1may be equal to or different from the width WDZ2of the second zone DZ2. In some configurations, the width WDZ1of the first dead zone DZ1may be equal to, less than, or greater than width WBZ1of the first bond zone BZ1discussed above with reference toFIG.12. In addition, the width WDZ2of the second dead zone DZ2may be equal to, less than, or greater than width WBZ2of the second bond zone BZ2discussed above with reference toFIG.12.

As mentioned above, the elastic substrate200aand elastic parts200may include nonwoven substrates that may be of the same or different material and/or basis weights. For example, the first substrate402and the second substrate410referred to above with reference toFIGS.15A-17may be configured as nonwoven substrates. As such, the first substrate402and the second substrate410of the elastic substrate200aand elastic parts200may be the same or different types of nonwovens and/or may have the same or different basis weights. In addition, the carrier substrate202may include one or more nonwoven substrates. As such, the first substrate402and/or the second substrate410of the elastic substrate200aand elastic parts200may be the same or different types of nonwovens and/or may have the same or different basis weights as a nonwoven substrate of the carrier substrate202. In addition, the nonwoven substrates of elastic substrate200aand elastic parts200, such as the first substrate402and/or the second substrate410for example, may include nonwoven substrates having the same or different fiber orientations as a nonwoven substrate of the carrier substrate202. In turn, the elastic part200configured as a waistband158and a carrier substrate202configured as a topsheet or backsheet in an absorbent article may each include nonwoven substrates that are the same or different types of nonwovens and/or may have the same or different basis weights and/or may have the same or different fiber orientations. Fiber orientations of a nonwoven substrate may affect stretch properties of the nonwoven substrate in different directions. For example, a nonwoven substrate may have a fiber orientation that causes the nonwoven to be relatively more extensible in the cross direction CD than in the machine direction MD. In some configurations, a nonwoven having a relatively low extensibility in the machine direction MD may be relatively easier to manipulate and/or guide when advancing in a machine direction MD though converting operations and/or assembly transformations.

It is also to be appreciated that the processes and/or apparatuses herein may be configured with additional features, such as splicing operations, to help avoid having to stop assembly process operations in order to replenish material supplies. In some configurations, the apparatuses300discussed herein may be configured to operate with apparatuses that are configured to provide an uninterrupted supply of continuous elastic substrate200a. For example, during operation, a replacement supply of a continuous elastic substrate200amay be spliced to a current supply of continuous elastic substrate200abeing used in assembly operations before the current supply is completely depleted.

It is to be appreciated that various types of splicing operations may be used to replenish the supply of a continuous elastic substrate200a. For example, some splicing operations may be configured to apply a strip of splicing tape to connect a replacement continuous elastic substrate200ato a nearly depleted elastic substrate200ato help avoid supply interruptions. As discussed above, the continuous elastic substrate200amay advance through a cutting device304that separates the continuous elastic substrate200ainto discrete elastic parts200. In addition, a transfer device322and/or bonding device324may further subject the discrete elastic parts200to cross directional stretching and/or bonding operations. However, some splicing tape material may not be stretchable and/or may not be conducive to bonding operations. In turn, discrete elastic parts200connected with splicing tape may undesirably disrupt operations of stretching and/or bonding processes. As such, some apparatuses300may be configured to remove discrete elastic parts200with splicing tape attached thereto from assembly operations before such undesired process disruptions may occur. In some examples, splicing operations may be configured to utilize stretchable splicing tape and/or other materials more conducive to various assembly operations to help prevent unintended assembly process disruptions and/or eliminate the need to remove elastic parts200with splicing tape attached thereto.

Some splicing operations may be configured to weld or otherwise bond a replacement supply of a continuous elastic substrate200ato a current supply of continuous elastic substrate200abeing used in assembly operations without the need to use splicing tape. Such welding operations may utilize hot-wire or ultrasonic apparatuses to create a thermal splice. The thermal splice process may both cut and weld the materials together. In some configurations, thermal splices may be applied so as to maintain some stretch properties, which may allow discrete elastic parts200with such thermal splices to advance through cross directional stretching and/or bonding operations without disrupting such operations.

As discussed above, it is to be appreciated that the continuous elastic substrate200aand the discrete elastic parts200herein may be configured in various ways and may include one or more elastic materials, such as for example, elastic film and/or strands. In some configurations, the continuous elastic substrate200aand the discrete elastic parts200may comprise a single layer of elastic film. In some configurations, the continuous elastic substrate200aand the discrete elastic parts200may comprise a laminate of two more substrates, such as an elastic film bonded with one or more nonwoven substrates. When the continuous elastic substrate200ais configured to comprise an elastic film bonded with one or more consolidated nonwovens, a thermal splice may be configured to melt the layers of both film and nonwoven to create a weld that traps consolidations of the nonwoven materials. In turn, the cross directional stretching process may stretch the elastic part200such that the weld may also extend in the cross direction by partially failing a part of the weld that has trapped the consolidated nonwoven, sometimes referred to as “popping the weld.” Depending on various splicing process parameters, such as for example weld time, dwell time, and quench time and various material properties, such as for example basis weight, fiber type, and plastic characteristics, the cross directional forces necessary to pop and stretch the weld may vary. In some examples, an ultrasonic splicing apparatus including a relatively sharp cutting anvil may be configured to produce a weld that has a relatively low cross directional force required to pop and stretch. In particular, a relatively smaller overall weld may be produced when a sharp angle of the anvil may penetrate through and burst fibers in the materials without causing a relatively large melt zone, while at the same time allowing the film to weld together, resulting in a splice that may be relatively easier to stretch in the cross direction CD with reduced and/or no popping required.