Apparatus and method for applying a first web to a base web in a nonlinear pattern

An applicator for and method of guiding a first web to a base web in a nonlinear pattern as the base web is advanced in a machine direction are disclosed. The applicator can include a support structure, a cantilever arm, a guide roller, and a connecting link. The cantilever arm can be supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction. The guide roller can guide the first web onto the base web and can be pivotally mounted on the cantilever arm for pivotal movement of the guide roller with respect to the cantilever arm. The connecting link can be operatively coupled to the guide roller. Pivotal movement of the guide roller can be dependent on movement of the connecting link. Positioning of the guide roller in the cross machine direction can be dependent on movement of the cantilever arm.

BACKGROUND

The present invention relates generally to an apparatus for and methods of applying a first web to a base web, and more particularly, to an apparatus for and a method of adhesively bonding a first web in a nonlinear pattern to a moving base web.

Absorbent articles, such as disposable diapers, training pants, adult incontinence articles and the like, generally include several different components that are bonded together. Typical absorbent articles include a bodyside liner, an outer cover, and an absorbent core disposed between the liner and outer cover. Besides the liner, the outer cover, and the absorbent core, typical absorbent articles also include a number of discrete components, e.g., fasteners, waist elastics, leg elastics. These discrete components of the article are often bonded to the bodyside liner and/or the outer cover. For example, it is known to adhesively bond leg elastics in a curved pattern to a continuous web of outer cover material or bodyside liner material.

Some known techniques for bonding leg elastics to a web moving at high line speeds are limited in the amount of displacement (e.g., the amount of amplitude in a curved pattern) that can be achieved. Thus, leg elastics in known absorbent articles produced at high line speeds are often straight or relatively straight. The leakage protection and the aesthetic appearance of known absorbent articles can be improved, however, by incorporating leg elastics with significant curvature along their lengths.

While some efforts to place leg elastics with significant amounts of displacement (i.e., curvature) onto a web at high line speeds have enjoyed some success, these known techniques still present challenges in terms of manufacturing reliability efficiency as machine line speeds continue to increase. These efforts have resulted in leg elastics being placed off target. Moreover, the deviation of the applied leg elastics from the target was not always the same. Some manufacturing issues, such as an elastic web breaking, cause the machine to be shut down, and thus, negatively impact machine line efficiency.

As an example, U.S. Pat. No. 8,720,518 issued to Rajala (the '518 patent) discloses an apparatus for bonding a ribbon in a nonlinear pattern to a web.FIG. 1of the present application provides a representative figure from the '518 patent. The '518 patent discloses an apparatus2and applicator4for applying a first web12(such as an elastic ribbon) to a base web14. The applicator4includes a guide roller6pivotally mounted to a lower cantilever arm8. The guide roller6of the applicator4of the '518 patent pivots with respect to the lower cantilever arm8to provide the proper cross direction position of the first web12for the nip5based on the force provided by the first web12itself. This process works adequately where the angular accelerations of the pivotal movement of the guide roller6are relatively low (e.g., when running at lower machine line speeds or when the amplitude of the pattern of applying the first web12to the base web14is reduced). However, when angular accelerations of this pivotal movement of the guide roller6are increased (e.g., when running at increased machine line speeds and/or increased amplitudes of the pattern for applying the first web12to the base web14), the forces in the first web12may surpass the tensile strength of the first web12and cause the first web12to break. Alternatively, the actual pivotal movement of the guide roller6may lag behind the desired pivotal movement of the guide roller6when faced with increased demands for angular accelerations of the guide roller6in the situations of high line speeds and/or larger amplitudes of the pattern of applying the first web12to the base web14. Such a lag can result in inaccurate placement of the first web12with respect to the desired pattern on the base web14.

As a result, it is desirable to provide an apparatus for and method of applying a first web in a nonlinear manner to a base web that can provide greater capabilities in providing a wider amplitude in a pattern of the first web to a base web and/or at greater machine line speeds. It is also desirable to provide an apparatus for and method of applying a first web in a nonlinear manner to a base web that provides the desired pattern with more reliability and operates under more favorable conditions for the first web.

SUMMARY

In one aspect, an applicator for guiding a first web to a base web as the base web is advanced in a machine direction is provided. The applicator can include a support structure and a cantilever arm. The cantilever arm can be supported by the support structure and can be moveable through a range of motion relative to the support structure in a cross machine direction. The applicator can include a guide roller for guiding the first web onto the base web. The guide roller can be pivotally mounted on the cantilever arm for pivotal movement of the guide roller with respect to the cantilever arm. The applicator can further include a connecting link operatively coupled to the guide roller. Pivotal movement of the guide roller can be dependent on movement of the connecting link. Positioning of the guide roller in the cross machine direction can be dependent on movement of the cantilever arm.

In another aspect, a method for guiding a first web to a base web in a nonlinear pattern is provided. The method can include providing the first web and providing the base web. The method can also include advancing the base web in a machine direction. The method can include providing an applicator. The applicator can include a cantilever arm supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction. The guide roller can also include a guide roller configured for engaging the first web and a connecting link operatively coupled to the guide roller. Pivotal movement of the guide roller can be dependent on movement of the connecting link. The method can additionally include guiding the first web to the base web in a nonlinear pattern by moving the guide roller through a range of motion relative to the support structure in a cross machine direction by moving the cantilever arm and moving the connecting link in a machine direction to pivot the guide roller with respect to the cantilever arm to guide the first web to the base web.

DETAILED DESCRIPTION

Referring toFIG. 2, an apparatus10for applying a first web12to a base web14is shown. The apparatus10can include an applicator16for guiding the first web12to the base web14as the base web14is advanced in a machine direction18. The applicator16can include a support structure20. Support structure20can include framework that can provide stability and mounting for the applicator16. The applicator16can also include a cantilever arm22that is supported by the support structure and moveable through a range of motion relative to the support structure20in a cross machine direction19. In some embodiments, cantilever arm22can be referred to as a lower cantilever arm22, as the applicator16can also include an upper cantilever arm24. The lower cantilever arm22and the upper cantilever arm24can be connected to a pivot motor26, and specifically, a pivot shaft28forming part of the pivot motor26. In a preferred embodiment, the pivot motor26can be a servo motor.

As depicted inFIG. 2, the lower cantilever arm22can be disposed below the pivot motor26and the upper cantilever arm24can be disposed above the pivot motor26. Each of the cantilever arms22,24can include an attachment end22a,24a, a free end22b,24b, and an intermediate portion22c,24c, respectively. The intermediate portion22c,24cof the cantilever arms22,24, respectively, extends between the attachment end22a,24aand the free end22b,24b, respectively. The attachment end22a,24aof each of the lower and upper cantilever arms22,24, respectively, is coupled to the pivot shaft28of the pivot motor26such that rotation of the pivot shaft28results in conjoint rotation of the lower and upper cantilever arms22,24. The cantilever arms22,24can extend outward from the pivot shaft28. In some embodiments, the lower cantilever arm22can be the same length as the upper cantilever arm24. However, in other embodiments, the lower cantilever arm22can be of a different length than the upper cantilever arm24. For example, in one embodiment, the lower cantilever arm22can be longer than the upper cantilever arm24. In one such embodiment, the lower cantilever arm22can be about 10 inches in length and the upper cantilever arm can be about 8.5 inches in length.

The applicator16can include one or more guide rollers. In the embodiment depicted inFIGS. 2-3A, the applicator16can include three guide rollers30,32,34. A first guide roller30can be mounted on the upper cantilever arm24adjacent the attachment end24aof the upper cantilever arm24. A second guide roller32can be mounted on the upper cantilever arm24adjacent the free end24bof the upper cantilever arm24. A third guide roller34can be mounted on the lower cantilever arm22adjacent the free end22bof the lower cantilever arm22.

As best depicted inFIGS. 3 and 3A, the third guide roller34is pivotally mounted on the lower cantilever arm22adjacent the free end22bof the lower cantilever arm22such that the guide roller34can pivot with respect to the lower cantilever arm22. The third guide roller34can include a bracket36including a base plate38and a pair of sidewalls40(only one sidewall40labeled inFIG. 3Afor clarity). Each of the sidewalls40can include an aperture42(only one aperture42being labeled inFIG. 3Afor clarity) for receiving and thereby mounting a shaft44to the bracket36. A roller46can be rotatably mounted to the shaft44. The base plate38can also include an opening48. A pivot pin50can be received through the opening48in the base plate38to pivotally mount the third guide roller34to the lower cantilever arm22, as discussed above. That is, the third guide roller34can pivot with respect to the lower cantilever arm22about the pivot pin50. In the illustrated embodiment, the roller46is a cylindrical roller, but it is contemplated that the roller46can have any other suitable shapes (e.g., spool-like, hourglass, prolate spheroid, truncated prolate spheroid) without departing from the scope of this disclosure.

As illustrated inFIG. 3A, the bracket36for third guide roller34can also include a flange52. Flange52can be in the same plane as the base plate38and can extend beyond one wall40of the pair of side walls40of the bracket36. Flange52can include an opening54. A pivot pin56can be received through the opening54in the flange52to pivotally mount the flange52to a connecting link58, as will be discussed in further detail below.

As illustrated inFIG. 3, the applicator16can also include a connecting link58. The connecting link58can be operatively coupled to the third guide roller34. The connecting link58can include a proximal end58a, a distal end58b, and an intermediate portion58cextending between the proximal end58aand the distal end58b. As noted above, the pivot pin56can be received in the opening54of the flange52of bracket36and can pivotally mount the connecting link58to the flange52of bracket36. As illustrated inFIG. 3A, the pivot pin56can be received by an opening (not pictured) near the distal end58bof the connecting link58. In this embodiment, the connecting link58can be coupled to the bracket36for the third guide roller34, such that the pivotal movement of the third guide roller34is dependent upon movement of the connecting link58.

Referring toFIGS. 2 and 3, the applicator16can additionally include a guide motor60including a guide shaft62. In a preferred embodiment, the guide motor60can be a servo motor. The guide shaft62can be operatively connected to the connecting link58such that rotation of the guide shaft62can move the connecting link58in the machine direction18. For example, in one embodiment, the guide shaft62can be coupled to a guide arm64. The guide arm64can include an attachment end64a, a free end64b, and an intermediate portion64cextending between the attachment end64aand the free end64b. The guide arm64can be coupled to the guide shaft62adjacent the attachment end64aof the guide arm64. The proximal end58aof the connecting link58can be coupled to the guide arm64adjacent the free end64bof the guide arm64. As illustrated inFIG. 3A, the proximal end58aof the connecting link58can include an opening66for receiving a pivot pin68to couple the connecting link58to the guide arm64. From this coupling, the guide arm64can be operably connected to the guide shaft62and the connecting link58. Thus, the guide shaft62can be coupled to the connecting link58. As will be discussed in further detail below, in this embodiment, rotation of the guide shaft62can thus move the connecting link58in a machine direction18, which in turn, controls the pivotal movement of the third guide roller34guiding the first web12.

With reference again toFIGS. 2 and 3, the apparatus10also includes a pair of anvil rolls70,72that together define a nip74(labeled inFIG. 3). The anvil rolls70,72are configured to apply a predetermined pressure to the first web12and base web14as they pass through the nip74. The pressure applied to the first web12and base web14at nip74can be varied by changing the relative positions of the rolls70,72.

The rolls70,72rotate in opposite directions, as indicated by the arrows inFIG. 1, to draw the first web12and the base web14into the nip74. Each of the rolls70,72is operable independently from the other and are driven (i.e., rotated) by suitable drive means, such as, for example, electric motors (not shown). As a result, the rotational speed of the rolls70,72(as measured at the rolls' outer surface) can be the same or can differ. That is, the rolls70,72can operate at the same or different rotational speeds.

Each of the rolls70,72in the illustrated embodiment is cylindrical with a smooth outer surface. It is contemplated, however, that one or both of the rolls70,72can have shapes other than cylindrical and that the outer surface may be other than smooth (i.e., patterned). In addition, the rolls70,72can be formed from any suitable, durable material, such as, for example, hardened metal or steel, hardened rubber, resin-treated cotton, or polyurethane. The rolls70,72can be formed from the same material or different materials. In the illustrated embodiment, for example, the roll70is a steel roll covered with silicone rubber having a 55A to 70A Shore Durometer to facilitate release of any adhesive that may contact the roll70, and the roll72is a hardened steel roll.

The temperature of the outer surface of at least one of the rolls70,72can be controlled to heat or cool the respective roll. In one suitable embodiment, the outer surface of at least one of the rolls70,72is cooled to inhibit adhesive from bonding to or otherwise adhering to the outer surface of the roll. In another suitable embodiment, the outer surface of at least one of the rolls70,72is heated to enhance bonding between first web12and the base web14.

As illustrated inFIG. 2, the apparatus10can also comprise an adhesive applicator76for applying adhesive in a nonlinear pattern to the base web14. It is understood that any suitable adhesive applicator can be used to apply the adhesive to the base web14. It is contemplated, however, that adhesive can be applied to the first web12instead of or in addition to the base web14.

The first web12can be formed from any suitable material including, but not limited to, wovens, nonwovens, films, foams, or combinations thereof. The material can be stretchable, non-stretchable, elastic or inelastic. In one suitable embodiment, the first web12is an elastomeric material suitable for use as leg elastics in absorbent articles.

As seen inFIG. 2, the illustrated first web12can be an elastomeric laminate comprising one or more elastic materials78(such as LYCRA strands). The apparatus10can include an adhesive applicator80that applies an adhesive to the first web12and/or the elastic material78. The first web12can then be folded and pass through a nip82to further couple the elastic material78to the first web12. Instead of folding the first web12over the elastic material78as depicted inFIG. 2, it is contemplated that the first web12could include two separate webs with the elastic material78sandwiched between the two sheets. It is also contemplated that one of the first and second sheets or the folding of the first web to sandwich the elastic material78can be omitted. In other suitable embodiments, the first web12can be formed from spunbond laminates (SBL), necked bonded laminates (NBL), and spunbond-meltblown-spunbond (SMS) nonwovens, which are also suitable materials for use as leg elastics in absorbent articles.

In one suitable embodiment, the base web14comprises a material suitable for use as an outer cover of absorbent articles. As one example, the outer cover material may be a multi-layered laminate structure to provide desired levels of extensibility as well as liquid impermeability and vapor permeability. For example, the outer cover may be a two-layer construction, including an outer layer constructed of a vapor permeable material and an inner layer constructed of a liquid impermeable material, with the two layers being secured together by a suitable adhesive. It is understood, however, that the outer cover material can have more or fewer layers (e.g., a single layer plastic film).

In another embodiment, the base web14can comprise a material suitable for use as a bodyside liner of absorbent articles. The bodyside liner material can be a material that is suitably pliable, soft feeling, and nonirritating to the wearer's skin. The bodyside liner material should be sufficiently porous to be liquid permeable to thereby permit liquid (e.g., urine) to readily penetrate through its thickness. Suitable bodyside liner materials can be manufactured from a wide selection of web materials.

In use, the base web14can be provided from a roll (or other suitable web source) to the adhesive applicator76where adhesive77is applied in a nonlinear pattern to the base web14(FIGS. 2 and 3). In one embodiment, the adhesive77can be applied to the base web14in a nonlinear pattern using an adhesive applicator76that includes a rotary valve, as taught by International Patent Application PCT/US15/52919 of Kimberly Clark Worldwide, Inc., which is incorporated by reference in its entirety. In one suitable embodiment, the base web14is traveling at a high line speed. As used herein, high line speed refers to a line speed greater than about 600 feet per minute. In some embodiments, the line speed can be greater than about 800 feet per minute, or greater than about 1000 feet per minute. The adhesive77is heated to a suitable temperature and driven to the adhesive applicator76at a suitable pressure by an adhesive source. In an “on position” of the adhesive applicator76, adhesive77is driven through a housing of the adhesive applicator76and onto the base web14in the desired nonlinear pattern of adhesive77(e.g., a curved pattern).

After the adhesive77is applied to the base web14by the adhesive applicator76, the base web14is fed to the nip74defined by the pair of opposed rolls70,72. As described in more detail below, the first web12is laid over the adhesive77applied to the base web14prior to the web14entering the nip74.

As illustrated inFIG. 2, the first web12is fed to the applicator16by a source of the first web12(such as a roll). The applicator16guides and applies the first web12to the base web14in a nonlinear pattern that substantially matches the nonlinear pattern along which the adhesive77was applied to the base web14such that the first web12overlies and covers the adhesive77. More specifically, the first web12is fed past the first guide roller30and generally parallel to the upper cantilever arm24to the second guide roller32. From the second guide roller32, the first web12is fed downward (as viewed inFIG. 2) to the pivotable third guide roller34.

Preferably, the first web12can be fed through the guide rollers30,32,34under tension which causes the first web12to stretch. In one suitable embodiment, the first web12is under tension of about 0.1 pound to about 1 pound per linear inch of width of the first web12. It is understood, however, that the tension force applied to first web12can be different than disclosed herein.

The third guide roller34is spaced from the second guide roller32by a vertical distance. The vertical distance can be selected to facilitate proper alignment of the first web12as it is fed to the third guide roller34and to inhibit twisting or bunching of the first web12during movement of the third guide roller34relative to the second guide roller32, which is mounted to the upper cantilever arm24in a non-pivoting manner. In one suitable configuration, the vertical distance between the third guide roller34and the second guide roller32is approximately 10 times the width of the first web12.

In the illustrated embodiment, the first web12is wrapped around approximately 90 degrees of the circumference of each of the guide rollers30,32,34. In other words, the first web12extends around about a quarter of the circumference of the guide rollers30,32,34as it passes over the respective guide roller. It is understood that the first web12can be wrapped around more or less of the circumference of one or more of the guide rollers30,32,34by changing the angle at which the first web12is fed to the respective guide roller (i.e., the approach angle of the first web12).

The placement of the first web12onto the base web14can be accurately controlled by the applicator16. Specifically, the position of the third guide roller34is controlled to accurately guide and apply the first web12to the base web14by controlling the cross direction position of the third guide roller34with respect to the nip74by movement of the lower cantilever arm22and by controlling the angle θ of the third guide roller34with respect to the nip74by movement of the connecting link58(as angle θ being labeled inFIG. 4).

As illustrated in the schematic ofFIG. 4, movement of the lower cantilever arm22to direct the third guide roller34to move in a cross direction19can be controlled by rotating the pivot shaft28of the pivot motor26, either clockwise or counter-clockwise. The movement of the connecting link58can be controlled by the rotational movement of the guide shaft62of the guide motor60, either clockwise or counter-clockwise, which rotates the guide arm64to which the connecting link58is coupled, as discussed above. The machine direction movement18of the connecting link58controls the angle θ of the third guide roller34with respect to the nip74. Although a servo motor is preferred for pivot motor26and guide motor60, servo motors may be substituted with cam boxes driven from any suitable drive source including, for example, lineshafts, AC or DC variable speed drives and motors. It is contemplated that programmable controllers connected to pivot motor26and guide motor60cause the pivot shaft28and guide shaft62to perform suitable respective back and forth motions in synchronism with the advancement of base web14.

FIGS. 5A-5Billustrate how the third guide roller34can move in a cross direction19position with respect to the nip74as well as pivotally move with respect to the lower cantilever arm22such that the angle θ of the first web12entering the nip74can change. Starting first withFIG. 5A, the angle θ is 0° with respect to a line perpendicular to the nip74. In other words, an axis47of the roller46of the third guide roller34is parallel to an axis75defined by the nip74. The cross direction position of the third guide roller34is, as viewed inFIG. 5A, is in a position on the left side of the nip74.

Moving toFIG. 5B, as time passes the applicator16controls the third guide roller34to accurately guide and position the first web (not shown for clarity) to the nip74to form the desired nonlinear pattern of the first web12on the base web14(not shown for clarity). This is accomplished by the pivot motor26rotating the pivot shaft28in a clockwise direction, which in turn rotates lower cantilever arm22in a clockwise direction. Rotating lower cantilever arm22in a clockwise direction moves the third guide roller34in a cross direction19to the right when viewingFIG. 5B. To maintain the angle θ to match the instantaneous angle of the first web12, the guide motor60rotates the guide shaft62in a clockwise direction, which in turn rotates guide arm64in a clockwise direction, and which in turn rotates connecting link in a clockwise direction and moves the connecting link58in a machine direction18downward as viewed inFIG. 5B. The axis47of the roller46of the third guide roller34forms an angle ß with a line49parallel to the nip axis75. Angle ß can equal angle θ, which defines the angle of the first web12entering the nip74. By purposefully pivoting the guide roller34to manage the angle θ of the guide roller34with respect to the nip74as the guide roller34moves in a cross direction19, the tension on the first web12is beneficially reduced helping to reduce the risk that the first web12breaks or is under unnecessary stress.

InFIG. 5C, more time passes and the first web12migrates to the new cross directional position of the third guide roller34as noted above inFIG. 5B. The guide motor60then rotates guide shaft62counter-clockwise, which in turn rotates the guide arm64counter-clockwise, which moves the connecting link58in a machine direction18upwards when viewingFIG. 5C. With such movement of the connecting link58, the angle θ is reduced to coincide with the instantaneous angle of the first web12(not shown). Again, by purposefully pivoting the guide roller34to manage the angle θ of the guide roller34with respect to the nip74as the guide roller34moves in a cross direction19, the tension on the first web12is beneficially reduced helping to reduce the risk that the first web12breaks or is under unnecessary stress.

InFIG. 5D, sufficient time has passed for the first web12to migrate to a final cross directional position in line with the third guide roller34. As such, the guide motor60rotates guide shaft62counter-clockwise, which in turn rotates the guide arm64counter-clockwise, which moves the connecting link58in a machine direction18upwards when viewingFIG. 5C. With such movement of the connecting link58, the angle θ is reduced to 0° with respect to a line perpendicular to the nip74and coincides with the instantaneous angle of the first web12(not shown).

The applicator16, and specifically, the third guide roller34can return to the position as shown inFIG. 5A. To do so, the lower cantilever arm22can rotate in a counter-clockwise direction through the rotation of the pivot shaft28in a counter-clockwise direction. As such, the lower cantilever arm22can rotate in a reciprocating arc motion in the process of guiding the first web12to the base web14. The third guide roller34can also be pivoted with respect to the lower cantilever arm22in returning to the position as shown inFIG. 5Aby first rotating the guide shaft62in a counter-clockwise direction as the third guide roller34moves cross directionally to the left and then by rotating the guide shaft62in a clockwise direction as the first web12aligns with the third guide roller to maintain the angle θ to match the instantaneous angle of the first web12as described above.

The apparatus10for and method of guiding and applying the first web12to the base web14in a nonlinear pattern as described above can be in various configurations. In one suitable embodiment, as illustrated inFIGS. 2 and 6, the applicator16can provide a generally sinusoidal pattern of the first web12on the base web14. For example, as the base web14is running, the applicator16can pause the cross directional and pivotal movement of the third guide roller34to provide a generally linear segment86of the first web12on the base web14. Such a generally linear segment86of the nonlinear pattern of the first web12on the base web14can be provided when the third guide roller34is in the position as described above with respect toFIG. 5C. When the third guide roller34begins to move cross directionally with respect to the nip74and pivotally with respect to the lower cantilever arm22as described above with respect toFIGS. 5B and 5Cabove, the applicator16can provide a generally curved segment88of the nonlinear pattern of the first web12on the base web14. As the third guide roller34reaches its position as described above with respect toFIG. 5D, the applicator16can briefly pause and guide and apply the first web12to the base14to form an apex90of the nonlinear pattern of the first web12on the base web14. As the applicator16moves the third guide roller34cross directionally to the left (which occurs by rotating the pivot shaft28in a counter-clockwise direction) and pivots the third guide roller34with respect to the lower cantilever arm22to maintain the angle θ to match the instantaneous angle of the first web12as described above, the applicator16can provide a generally curved segment92of the nonlinear pattern of the first web12on the base web14. When the third guide roller34reaches the position described above with respect toFIG. 5A, the applicator16can provide another generally linear segment86of the nonlinear pattern of the first web12on the base web14.

The applicator16is adapted to apply the first web12to the base web14with significant curvature while the base web14is traveling at high line speeds. As used herein, “significant curvature” refers to the acute angle α defined by a line tangent to the elastic curve and the longitudinal centerline of the web that is greater than about 45 degrees (seeFIG. 6). It is conceived that the nonlinear pattern of the first web12on the base web14can have curved segment88be a mirror image of curved segment92. It is also conceived that the nonlinear pattern of the first web12on the base web14can be configured such that the generally curved segment88can have a different curvature or acute angle α than the generally curved segment92.

After the first web12is overlaid on the adhesive77and applied to the base web14, the first web12and the base web14are pulled into the nip74by the rotation of the anvil rolls70,72. The anvil rolls70,72can apply a predetermined pressure to the first web12, the adhesive77, and the base web14as they pass through the nip14to facilitate adhesive bonding of the first web12to the base web14.

In one suitable embodiment, a distance D (seeFIG. 3A) between the third guide roller34and the nip74is minimized to inhibit misalignment of the first web12relative to the base web14before the first web12is adhesively bonded to the base web12(seeFIG. 2). Suitably, the distance D between the third guide roller34and the nip74is less than about 60 millimeters and suitable between about 20 millimeters and about 50 millimeters.

One suitable embodiment of the resulting composite (i.e., the base web14having the first web12adhered thereto by adhesive77) is illustrated inFIG. 6. As seen therein, the first web12has a width that is greater than a width of the adhesive77. It is contemplated that the widths of the first web12and adhesive77can be substantially equal.

The composite can be used in the manufacture of absorbent articles (e.g., diapers, training pants, inconstancy articles). In one particularly suitable configuration, the base web14can be used to form outer covers of absorbent articles and the first web12can be used to form leg elastics of the absorbent articles. One such absorbent article is illustrated inFIG. 7in the form of an incontinence garment100.

As seen inFIG. 7, the incontinence garment100comprises an outer cover101, an absorbent core103, and leg elastics105. The outer cover101can be made from the base web14and the leg elastics can be defined by the first web12. It is understood that the garment100can include numerous other components (e.g., a bodyside liner, fasteners) other than those illustrated and described herein.

EMBODIMENTS

An applicator for guiding a first web to a base web as the base web is advanced in a machine direction, the applicator comprising: a support structure; a cantilever arm supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction; a guide roller for guiding the first web onto the base web, the guide roller being pivotally mounted on the cantilever arm for pivotal movement of the guide roller with respect to the cantilever arm; and a connecting link operatively coupled to the guide roller; wherein pivotal movement of the guide roller is dependent on movement of the connecting link, and positioning of the guide roller in the cross machine direction is dependent on movement of the cantilever arm.

The applicator of embodiment 1, further comprising a guide shaft operatively connected to the connecting link to move the connecting link in a machine direction.

The applicator of embodiment 2, further comprising a guide motor, the guide motor including the guide shaft, the guide motor being a servo motor.

The applicator of embodiment 2 or embodiment 3, further comprising a guide arm, the guide arm being operably connected to the guide shaft and the connecting link.

The applicator of embodiment 4, wherein the guide arm comprises an attachment end affixed to the guide shaft, a free end, and an intermediate portion extending between the attachment end and the free end, a proximal end of the connecting link being coupled to the guide arm adjacent the free end of the guide arm.

The applicator of any one of the preceding embodiments, further comprising a pivot shaft, the cantilever arm being mounted to and extending outward from the pivot shaft.

The applicator of embodiment 6, further comprising a pivot motor, the pivot motor including the pivot shaft, the pivot motor being a servo motor.

The applicator of embodiment 6 or embodiment 7, wherein the cantilever arm comprises an attachment end affixed to the pivot shaft, a free end, and an intermediate portion extending between the attachment end and the free end, the guide roller being mounted to the cantilever arm adjacent the free end of the cantilever arm.

The applicator of any one of the preceding embodiments, wherein the guide roller comprises a bracket, a shaft supported by the bracket, and a roller rotatably mounted on the shaft, the bracket being pivotally mounted to the cantilever arm via a pivot pin and being pivotally mounted to the connecting link.

An apparatus for bonding a first web in a nonlinear pattern to a base web, the apparatus comprising: a base web source for feeding the base web to the apparatus; an adhesive applicator for applying adhesive in a pattern to the base web; and the applicator according to embodiment 1, the applicator being configured to deliver and place the first web in the nonlinear pattern on the base web such that the first web overlies the adhesive applied to the base web.

The apparatus of embodiment 10, wherein the applicator further comprises a guide arm and a guide motor, the guide motor being operably connected to the guide arm adjacent an attachment end of the guide arm and the connecting link being operably connected to the guide arm adjacent a free end of the guide arm.

The apparatus of embodiment 10 or 11, wherein the applicator further comprises a pivot motor, the pivot motor being operably connected to the cantilever arm adjacent an attachment end of the cantilever arm and the guide roller being operably connected to the cantilever arm adjacent a free end of the cantilever arm.

The apparatus of any one of embodiments 10-12, wherein the guide roller comprises a bracket, a shaft supported by the bracket, and a roller rotatably mounted on the shaft, the bracket being pivotally mounted to the cantilever arm via a pivot pin and being fixedly mounted to the connecting link.

A method for guiding a first web to a base web in a nonlinear pattern, the method comprising: providing the first web; providing the base web; advancing the base web in a machine direction; providing an applicator comprising: a cantilever arm supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction; a guide roller configured for engaging the first web; and a connecting link operatively coupled to the guide roller; wherein pivotal movement of the guide roller is dependent on movement of the connecting link; guiding the first web to the base web in a nonlinear pattern by moving the guide roller through a range of motion relative to the support structure in a cross machine direction by moving the cantilever arm and moving the connecting link in a machine direction to pivot the guide roller with respect to the cantilever arm to guide the first web to the base web.

The method of embodiment 14, wherein moving the cantilever arm includes rotating the cantilever arm in a reciprocating arc motion.

The method of embodiment 14 or 15, wherein the movement of the cantilever arm is controlled by a pivot motor, the pivot motor comprising a pivot shaft coupled to the cantilever arm, the pivot motor being a servo motor.

The method of any one of embodiments 14-16, wherein moving the connecting link in a machine direction is controlled by a guide motor, the guide motor comprising a guide shaft coupled to the connecting link, the guide motor being a servo motor.

The method of any one of embodiments 14-17, wherein the guide roller comprises a bracket, a shaft supported by the bracket, and a roller rotatably mounted on the shaft, the bracket being pivotally mounted to the cantilever arm via a pivot pin and being pivotally mounted to the connecting link.

The method of any one of embodiments 14-18, further comprising: providing an adhesive applicator; applying adhesive to the adhesive in a pattern to the base web; and placing the first web in the nonlinear pattern on the base web such that the first web overlies the adhesive applied to the base web.

The method of any one of embodiments 14-19, further comprising: providing a nip; and bonding the first web to the base web by passing the first web and the base web through the nip.

While the invention has been described in detail with respect to the specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present disclosure should be assessed as that of the appended claims and any equivalents thereto.