Patent Publication Number: US-2023157899-A1

Title: Apparatuses and Methods for Making Absorbent Articles

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of, and claims priority under 35 U.S.C. § 120 to, U.S. patent application Ser. No. 17/019,412, filed on Sep. 14, 2020, which claims the benefit, under 35 USC § 119(e), of U.S. Provisional Patent application Ser. No. 62/901,361, filed on Sep. 17, 2019, the entire disclosures of which are fully incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates to methods for manufacturing absorbent articles, and more particularly, to apparatuses and methods of forming discrete zones of hooks on a substrate while imparting localized speed variances to the substrate while advancing in a machine direction. 
     BACKGROUND OF THE INVENTION 
     Fastening systems for connecting or holding together portions of garment materials are available in various different forms, including buttons, snap fasteners, tape tab fasteners, hook-and-loop fasteners, and the like. Such fastening systems may be utilized on garments and disposable garments, such as absorbent articles, body wraps, bibs, bedsheets, tablecloths and the like. In the field of absorbent articles, such as disposable diapers and feminine protection devices, various types of fasteners may be provided to hold cooperating portions of a structure in a desired spatial relationship. Disposable diapers, for example, may include a fastener system in the form of a hook-and-loop fastening system. 
     In some configurations, a disposable diaper and fastening system may include an absorbent chassis having a front waist region, crotch region and rear waist region, with a pair of fastening members each extending respectively laterally from left and right longitudinal edges of the chassis in the rear waist region. Each fastening member may include a patch of material bearing hooks, affixed to a wearer-facing side of the fastening member. A patch or section of cooperating loops material may be disposed on an outward-facing side of the front waist region. In such a configuration, the chassis may be wrapped through the wearer&#39;s crotch area with the back waist region placed across the wearer&#39;s lower back and buttocks and the front waist region placed across the wearer&#39;s lower belly area. The left and right fastening members may then be wrapped about the wearers left and right hips, respectively, and fastened to the front waist region via engagement of the hooks patches with the loops material on the front waist region, thereby securing the diaper on the wearer. 
     Hooks of various designs for use with various types of loops material have been developed in the past along with techniques for manufacturing hooks. One manufacturing technique has included heating thermoplastic resin in an extruder. A base sheet is extruded, and hooks are then molded and/or otherwise formed into one face of the base sheet from the material thereof, while the material is still soft or partially molten. Another technique has included extruding a continuous structure having a base sheet portion and a series of extruded formations extending from the base sheet portion having desired hook profiles. Following extrusion, a series of cuts through the formations are made along a direction transverse to the extrusion direction to create rows of hooks structures, without cutting through the base portion. The base sheet with rows of hooks structures is then plastically stretched along the extrusion direction, to create or enlarge separation between the rows of hooks structures. In some applications, a layer of suitable adhesive may be applied to the underside of the base material. The combination of hooks, base sheet material, and adhesive may then be cut to any commercially desired size or shape, such as strips. In turn, the strips may be gathered, for example on a roll, to be delivered to a purchaser and/or user. The purchaser and/or user may further cut the product to a desired size, such as a hooks patch that may be affixed to an article and thereby provide the hooks component of a hook-and-loop fastening system for the article. 
     In an attempt to eliminate various processing and handling steps involved with such hooks materials and manufacture of articles with hook-and-loop fastening systems, other techniques have been developed that enable formation of patterns of hooks directly on a preexisting substrate, such as a film or nonwoven. For example, a substrate may be positioned between a mold and a source of vibration, such as an ultrasonic horn. In turn, the ultrasonic horn may impart vibration energy to soften the substrate. The mold may include a plurality of cavities into which the softened substrate material may be forced to form the hooks. However, the relatively slow speeds associated with such hook forming techniques may create challenges, particularly when such hook forming techniques are incorporated into absorbent article assembly processes operating at relatively high speed production rates. In addition, such methods and apparatuses may not be very flexible in allowing a user to reconfigure so as to accommodate for production of different sized articles and/or different patterns of hooks. 
     Consequently, it would be beneficial to provide flexible methods and apparatuses for forming hooks on substrates in absorbent article manufacturing processes without sacrificing relatively high manufacturing speeds. 
     SUMMARY OF THE INVENTION 
     In one form, a method for assembling absorbent articles comprises steps of: advancing a first substrate in a machine direction at a first speed, the first substrate comprising a first surface and an opposing second surface and defining a width, Ws, in a cross direction; decelerating a portion of the first substrate to a second speed; arranging the second surface of the portion the first substrate and a die surface in a facing relationship, wherein the die surface comprises cavities; applying energy to the portion of the first substrate while advancing at the second speed such that softened material of the first substrate moves into the cavities of the die surface to form a zone of protrusions, wherein the zone of protrusions extends in the machine direction for a length, Lz, and wherein each protrusion protrudes from the second surface of the first substrate to a distal end; accelerating the portion of the first substrate with the zone of protrusions from the second speed to the first speed; and cutting the first substrate into discrete pieces each having a pitch length, PL, extending along the machine direction, wherein the length, Lz, of the zone of protrusions extends in the machine direction for less than the pitch length, PL. 
     In another form, a method for assembling absorbent articles comprises steps of: advancing a first substrate in a machine direction at a first speed, the first substrate comprising a first surface and an opposing second surface and defining a width, Ws, in a cross direction; decelerating a portion of the first substrate to a second speed; arranging the second surface of the portion the first substrate and a die surface in a facing relationship, wherein the die surface comprises cavities; applying energy to the portion of the first substrate while advancing at the second speed such that softened material of the first substrate moves into the cavities of the die surface to form a zone of protrusions, wherein the zone of protrusions extends in the cross direction for a width, Wz, and wherein each protrusion protrudes from the second surface of the first substrate to a distal end; accelerating the portion of the first substrate with the zone of protrusions from the second speed to the first speed; and cutting the first substrate into discrete pieces, wherein the width, Wz, of the zone of protrusions extends in the cross direction for a distance that is equal to or less than the width, Ws. 
     In yet another form, a method for assembling absorbent articles comprises steps of: advancing a first substrate in a machine direction at a first speed, the first substrate comprising a first surface and an opposing second surface and defining a width, W, in a cross direction; decelerating a portion of the first substrate to a second speed; arranging the second surface of the portion the first substrate and a die surface in a facing relationship, wherein the die surface comprises cavities; applying energy to the portion of the first substrate while advancing at the second speed such that softened material of the first substrate moves into the cavities of the die surface to form a zone of protrusions, wherein the zone of protrusions extends in the machine direction for a length, Lz, and wherein each protrusion protrudes from the second surface of the first substrate to a distal end; combining a second substrate with the portion of the first substrate; bonding the second substrate with the portion of the first substrate while at the second speed; accelerating the second substrate and the portion of the first substrate with the zone of protrusions from the second speed to the first speed; and cutting the first substrate into discrete pieces. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1 A  is a partially cut away plan view of an absorbent article in the form of a taped diaper that may include one or more substrates with protrusions formed thereon in accordance with the present disclosure with the portion of the diaper that faces away from a wearer oriented towards the viewer. 
         FIG.  1 B  is a plan view of the absorbent article of  FIG.  1 A  that may include one or more substrates with protrusions formed thereon in accordance with the present disclosure with the portion of the diaper that faces toward a wearer oriented towards the viewer. 
         FIG.  2    is a schematic side view of an apparatus for forming protrusions on an advancing substrate. 
         FIG.  3    is a view of an advancing substrate taken along section  3 - 3  in  FIG.  2   . 
         FIG.  4    is a view of the advancing substrate with discrete zones of protrusions taken along section  4 - 4  in  FIG.  2   . 
         FIG.  4 A  is a cross sectional view of the advancing substrate showing a discrete zone of protrusions taken along section  4 A- 4 A in  FIG.  4   . 
         FIG.  4 B  is a view of an advancing substrate with discrete zones of protrusions being slit along the machine direction into multiple lanes. 
         FIG.  5    is a view of a die surface taken along section  5 - 5  in  FIG.  2   . 
         FIG.  5 A  is a view of a configuration of a die surface including cavities and bonding elements taken along section  5 - 5  in  FIG.  2   . 
         FIG.  6    is a detailed view of an accumulator apparatus. 
         FIG.  6 A  is a detailed view of an accumulator apparatus with a substrate partially wrapped onto a roll. 
         FIG.  7    is a detailed view of a second configuration of an accumulator apparatus. 
     
    
    
     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. 
     As used herein, the term “graphic” refers to images or designs that are constituted by a figure (e.g., a line(s)), a symbol or character, a color difference or transition of at least two colors, or the like. A graphic may include an aesthetic image or design that can provide certain benefit(s) when viewed. A graphic may be in the form of a photographic image. A graphic may also be in the form of a 1-dimensional (1-D) or 2-dimensional (2-D) bar code or a quick response (QR) bar code. A graphic design is determined by, for example, the color(s) used in the graphic (individual pure ink or spot colors as well as built process colors), the sizes of the entire graphic (or components of the graphic), the positions of the graphic (or components of the graphic), the movements of the graphic (or components of the graphic), the geometrical shapes of the graphic (or components of the graphics), the number of colors in the graphic, the variations of the color combinations in the graphic, the number of graphics printed, the disappearance of color(s) in the graphic, and the contents of text messages in the graphic. 
     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, 25 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, 25 gsm, 40 gsm, or 60 gsm. Some films may have basis weight of about 8 gsm to about 60 gsm, specifically reciting all 1 gsm increments within the above-recited ranges and all ranges formed therein or thereby. 
     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 manufacturing absorbent articles, and more particularly, to forming discrete zones of protrusions on a substrate. In some configurations, the protrusions may be formed as hooks. When forming the discrete zones of protrusions, localized speed variances may be imparted to the advancing substrate to ensure the necessary time to form the protrusions is provided. As such, protrusions may be formed on portions of the substrate that have been temporarily stopped or slowed to relatively slow speeds. The substrates with zones of protrusions may then be incorporated into assembled absorbent articles so as to place the protrusions in desired positions on the absorbent articles. As such, the methods and apparatuses herein allow for the use of hook forming techniques on substrates in diaper manufacturing processes that provide flexibility in such configurations without sacrificing relatively high manufacturing speeds. 
     With regard to the assembly processes described herein, a continuous substrate may be advanced in a machine direction at a first speed, the substrate comprising a first surface and an opposing second surface, and defining a width, Ws, in a cross direction. A portion of the substrate is decelerated to a second speed. While at the second speed, the second surface of the portion the first substrate and a die surface are arranged in a facing relationship, wherein the die surface comprises cavities. Energy is applied to the portion of the substrate while advancing at the second speed such that softened material of the substrate moves into the cavities of the die surface to form a zone of protrusions. Each protrusion protrudes from the second surface of the substrate to a distal end. The zone of protrusions extends in the machine direction MD for a length, Lz, and extends in the cross direction CD for a width, Wz. The portion of the substrate with the zone of protrusions is then accelerated from the second speed to the first speed. The substrate having the zone of protrusions may then be cut into discrete pieces each having a pitch length, PL, extending along the machine direction, wherein the length, Lz, of the zone of protrusions extends in the machine direction for less than the pitch length, PL. The width, Wz, of the zone of protrusions may also extend in the cross direction for a distance that is equal to or less than the width, Ws, of the substrate. As discussed in more detail below, the substrate may be subject to additional operations while advancing at the second speed, such as for example, bonding with other substrates and/or printing 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.  1 A and  1 B  show an example of an absorbent article  100  that may be assembled in accordance with the methods and apparatuses disclosed herein. In particular,  FIG.  1 A  shows one example of a plan view of an absorbent article  100  configured as a taped diaper  100 T, with the portion of the diaper that faces away from a wearer oriented towards the viewer. And  FIG.  1 B  shows a plan view of the diaper  100  with the portion of the diaper that faces toward a wearer oriented towards the viewer. The taped diaper  100 T shown in  FIGS.  1 A and  1 B  includes an absorbent chassis  102 , first and second rear side panels  104  and  106 ; and first and second front side panels  108  and  110 . 
     As shown in  FIGS.  1 A and  1 B , the diaper  100  and the chassis  102  each include a first waist region  116 , a second waist region  118 , and a crotch region  119  disposed intermediate the first and second waist regions. The first waist region  116  may be configured as a front waist region, and the second waist region  118  may 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 article  100 . The absorbent article may also include a laterally extending front waist edge  120  in the front waist region  116  and a longitudinally opposing and laterally extending back waist edge  122  in the back waist region  118 . To provide a frame of reference for the present discussion, the diaper  100 T in  FIGS.  1 A and  1 B  is shown with a longitudinal axis  124  and a lateral axis  126 . The longitudinal axis  124  may extend through a midpoint of the front waist edge  120  and through a midpoint of the back waist edge  122 . And the lateral axis  126  may extend through a midpoint of a first longitudinal or right side edge  128  and through a midpoint of a second longitudinal or left side edge  130 . 
     As shown in  FIGS.  1 A and  1 B , the diaper  100  includes an inner, wearer facing surface  132 , and an outer, garment facing surface  134 . As such, it is also to be appreciated that the various components of the diaper described below may each include inner, wearer facing surfaces  132 , and an outer, garment facing surfaces  134 . The chassis  102  may include a backsheet  136  and a topsheet  138 . The chassis  102  may also include an absorbent assembly  140 , including an absorbent core  142 , disposed between a portion of the topsheet  138  and the backsheet  136 . As discussed in more detail below, the diaper  100  may 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 in  FIGS.  1 A and  1 B , the periphery of the chassis  102  may be defined by the first longitudinal side edge  128 , a second longitudinal side edge  130 , a first laterally extending end edge  144  disposed in the first waist region  116 , and a second laterally extending end edge  146  disposed in the second waist region  118 . Both side edges  128  and  130  extend longitudinally between the first end edge  144  and the second end edge  146 . As shown in  FIG.  1 A , the laterally extending end edges  144  and  146  may form a portion of the laterally extending front waist edge  120  in the front waist region  116  and a portion of the longitudinally opposing and laterally extending back waist edge  122  in the back waist region  118 . The distance between the first lateral end edge  144  and the second lateral end edge  146  may define a pitch length, PL, of the chassis  102 . When the diaper  100  is worn on the lower torso of a wearer, the front waist edge  120  and the back waist edge  122  may encircle a portion of the waist of the wearer. At the same time, the side edges  128  and  130  may encircle at least a portion of the legs of the wearer. And the crotch region  119  may be generally positioned between the legs of the wearer with the absorbent core  142  extending from the front waist region  116  through the crotch region  119  to the back waist region  118 . 
     It is to also be appreciated that a portion or the whole of the diaper  100  may also be made laterally extensible. The additional extensibility may help allow the diaper  100  to conform to the body of a wearer during movement by the wearer. The additional extensibility may also help, for example, the user of the diaper  100 , including a chassis  102  having a particular size before extension, to extend the front waist region  116 , the back waist region  118 , or both waist regions of the diaper  100  and/or chassis  102  to 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 diaper  100  may include a backsheet  136 . The backsheet  136  may also define the outer surface  134  of the chassis  102 . The backsheet  136  may 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 backsheet  136  may prevent the exudates absorbed and contained in the absorbent core from wetting articles which contact the diaper  100 , such as bedsheets, pajamas and undergarments. The backsheet  136  may 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 backsheet  136  may 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 backsheet  136  may also be embossed and/or matte-finished to provide a more clothlike appearance. Further, the backsheet  136  may permit vapors to escape from the absorbent core (i.e., the backsheet is breathable) while still preventing exudates from passing through the backsheet  136 . The size of the backsheet  136  may be dictated by the size of the absorbent core  142  and/or particular configuration or size of the diaper  100 . 
     Also described above, the diaper  100  may include a topsheet  138 . The topsheet  138  may also define all or part of the inner surface  132  of the chassis  102 . The topsheet  138  may be compliant, soft feeling, and non-irritating to the wearer&#39;s skin. It may be elastically stretchable in one or two directions. Further, the topsheet  138  may be liquid pervious, permitting liquids (e.g., menses, urine, and/or runny feces) to penetrate through its thickness. A topsheet  138  may 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 topsheet  138  includes fibers, the fibers may be spunbond, carded, wet-laid, meltblown, hydroentangled, or otherwise processed as is known in the art. 
     Topsheets  138  may 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&#39;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 diaper  100  may also include an absorbent assembly  140  that is joined to the chassis  102 . As shown in  FIGS.  1 A and  1 B , the absorbent assembly  140  may have a laterally extending front edge  148  in the front waist region  116  and may have a longitudinally opposing and laterally extending back edge  150  in the back waist region  118 . The absorbent assembly may have a longitudinally extending right side edge  152  and may have a laterally opposing and longitudinally extending left side edge  154 , both absorbent assembly side edges  152  and  154  may extend longitudinally between the front edge  148  and the back edge  150 . The absorbent assembly  140  may additionally include one or more absorbent cores  142  or absorbent core layers. The absorbent core  142  may be at least partially disposed between the topsheet  138  and the backsheet  136  and 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, which are all incorporated by reference herein. 
     As previously mentioned, the diaper  100  may also include elasticized leg cuffs  156  and an elasticized waistband  158 . It is to be appreciated that the leg cuffs  156  can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. The elasticized leg cuffs  156  may be configured in various ways to help reduce the leakage of body exudates in the leg regions. Example leg cuffs  156  may 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 in  FIG.  1 B , the chassis  102  may include longitudinally extending and laterally opposing leg cuffs  156  that are disposed on the interior surface  132  of the chassis  102  that 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 assembly  140 , wherein the proximal edges extend laterally inward of the respective side edges of the absorbent assembly  152  and  154 . 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 chassis  102  laterally inward, i.e., toward the longitudinal axis  124 , to form both the respective leg cuffs and the side edges  128  and  130  of the chassis  102 . 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 surface  132  of the chassis and/or the absorbent assembly in leg cuff attachment zones in the front waist region  116  and in leg cuff attachment zones in the back waist region  118 . 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 waistband  158  may provide improved fit and containment and may be a portion or zone of the diaper  100  that may elastically expand and contract to dynamically fit a wearer&#39;s waist. It is to be appreciated that the elasticized waistband  158  may be located in various positions relative to various diaper components. For example, the elasticized waistband  158  may be positioned longitudinally inwardly from the waist edges  120 ,  122  of the diaper and/or toward the lateral edges  148 ,  150  of the absorbent core  142 . In some configurations, the elasticized waistband  158  may be positioned with a lateral edge that is coterminous with the waist edges  120 ,  122 . In some configurations, the elasticized waistband  158  may be positioned such that laterally opposing end regions of the waistband  158  are located laterally inward from the leg cuffs  156 . In some configurations, the elasticized waistband  158  may be positioned such that laterally opposing end regions of the waistband  158  overlap the leg cuffs  156 . In some configurations, the elasticized waistband  158  may be positioned on wearer facing surface  132  of the topsheet  138 . In some configurations, the waistband  158  may be positioned on the wearer facing surfaces  132  of the topsheet  138  and the leg cuffs  156 . In some configurations, the waistband  158  may be positioned on the wearer facing surfaces  132  of the topsheet  138  and laterally opposing end regions of the waistband  158  may be positioned between the leg cuffs  156  and the topsheet  138 . In some configurations, the elasticized waistband  158  may be positioned between the garment facing surface  132  of the topsheet  138  and the wearer facing surface  132  of the backsheet  136 . And in some configurations, the elasticized waistband  158  may be positioned on the garment facing surface  134  of the backsheet  136 . The diaper  100  may also include more than one elasticized waistband  158 , for example, having one waistband  158  positioned in the back waist region  118  and one waistband  158  positioned in the front wait region  116 , although other embodiments may be constructed with a single elasticized waistband  158 . The elasticized waistband  158  may be constructed in a number of different configurations including those described in U.S. Pat. Nos. 4,515,595 and 5,151,092, which are all incorporated by reference herein. 
     Taped diapers may be manufactured and provided to consumers in a configuration wherein the front waist region  116  and the back waist region  118  are not fastened, pre-fastened, or connected to each other as packaged, prior to being applied to the wearer. For example, the taped diaper  100  may be folded about a lateral centerline with the interior surface  132  of the first waist region  116  in surface to surface contact with the interior surface  132  of the second waist region  118  without fastening or joining the waist regions together. The rear side panels  104  and  106  and/or the front side panels  108  and  110  may also be folded laterally inward toward the inner surfaces  132  of the waist regions  116  and  118 . 
     It is to be appreciated that the side panels  104 ,  106 ,  108 ,  110  may be assembled in various ways, such as disclosed for example, in U.S. Pat. No. 7,371,302, which is incorporated by reference herein. With continued reference to  FIGS.  1 A and  1 B , each side panel  104 ,  106 ,  108 ,  110  may form a portion of or may be permanently bonded, adhered or otherwise joined directly or indirectly to the chassis  102  laterally inward from the side edges  128  and  130 , in one of the front waist region  116  or the back waist region  118 . The side panels  104 ,  106 ,  108 ,  110  may also be permanently bonded or joined at or adjacent the side edges  128  and  130  of the chassis  102  in 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. 
     The diaper  100  may also include various configurations of fastening elements to enable fastening of the front waist region  116  and the back waist region  118  together to form a closed waist circumference and leg openings once the diaper is positioned on a wearer. In some configurations, the rear side panels  104 ,  106  may be adapted to releasably and/or refastenably engage or connect with another portion of the diaper  100 . For example, as shown in  FIG.  1 A , the diaper  100  may include a connection zone  168 , sometimes referred to as a landing zone, in the first waist region  116 . As such, when the taped diaper  100  is placed on a wearer, the rear side panels  104 ,  106  may be pulled around the waist of the wearer such that the fasteners may be connected with the connection zone  168  in the first waist region  116  to form a closed waist circumference and a pair of laterally opposing leg openings. It is to be appreciated that the first and second rear side panels  104 ,  106  and/or other portions of the diaper, such as the connection zone  168 , may include mechanical fasteners 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 fasteners are 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. 
     It is also to be appreciated that the connection zone  168  may be constructed from a separate substrate that is connected with the chassis  102  of the taped diaper. In some configurations, the connection zone  168  may be integrally formed as part of the backsheet  136  of the diaper  100 , such as described in U.S. Pat. Nos. 5,735,840 and 5,928,212, which are both incorporated by reference herein. In some configurations, opposing end portions of the connection zone  168  may be integral with and define the first and second front panels  108 ,  110 . 
     It is to be appreciated that the rear side panels  104 ,  106  and the connection zone  168  may be constructed from various materials, such as nonwovens, films, and the like, and/or may be constructed as a laminate structure. As shown in  FIG.  1 B , the rear side panels  104 ,  106  may include discrete zones  162  of protrusions  164 , that may be in the form of hooks  166 . In turn, the hooks  166  on the rear side panels  104 ,  106  may be adapted to releasably and/or refastenably engage or connect with another portion of the diaper  100 , such as the connection zone  168 . As shown in  FIG.  1 A , the connection zone  168  may also include discrete zones  162  of protrusions  164  that may be in the form of hooks  166 . In turn, the hooks  166  on the connection zone  168  may be adapted to releasably and/or refastenably engage or connect with another portion of the diaper  100 , such as the rear side panels  104 ,  106 . As discussed in more detail below, the hooks  166  on the rear side panels  104 ,  106  and/or the connection zone  168  may be integrally formed from the material of the rear side panels  104 ,  106  and the connection  168 , respectively, such as disclosed in U.S. Pat. Nos. 5,242,436; 5,325,569; 5,507,736; 6,476,289; 6,478,784; 6,746,434; and 8,784,722; U.S. Patent Publication No. 2018/0141266 A1; and U.S. patent application Ser. No. 16/545,425, filed on Aug. 20, 2019, which are all incorporated herein by reference. 
     As previously mentioned, absorbent articles may be assembled with various components that may be constructed with the substrates described herein. Thus, in the context of the previous discussion, the apparatuses and methods herein may be used to form discrete zones of hooks on a substrate while imparting localized speed variances to the substrate while advancing in a machine direction during the assembly of an absorbent article  100 . For example, the apparatuses and methods herein may be utilized to form discrete zones  162  of hooks  166  on substrates  200 , and in turn, such substrates  200  may be configured as side panels  104 ,  106 ,  108 ,  110 , connection zones  168 , topsheets  138 , and/or backsheets  136  during the manufacture of absorbent articles  100 , such as taped diapers and pant diapers for example. 
     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.  2    shows a schematic representation of a converting process including an apparatus or system  300  for forming discrete zones  162  of protrusions  164  on a substrate  200  advancing in a machine direction MD. As shown in  FIGS.  2  and  3   , the substrate  200  may be a continuous substrate and may include a first surface  202  and an opposing second surface  204 . The substrate  200  may also define a width Ws extending in the cross direction CD between a first longitudinal side edge  206  and a second longitudinal side edge  208 . Before, during, or after forming the discrete zones  162  of protrusions  164 , it is to be appreciated that the substrate  200  may be subjected to additional manufacturing operations, such as combining, bonding, printing, cutting and/or folding operations. 
     It is also to be appreciated that the substrate  200  may be configured in various ways. For example, the substrate  200  herein may be configured as a single nonwoven substrate or a single film substrate that defines both the first surface  202  and the second surface  204 . It is also to be appreciated that the substrate  200  herein may be configured as a laminate including various layers of substrates bonded together, wherein a nonwoven substrate layer defines the first surface  202  and another substrate layer defines the second surface  204 . For example, the substrate  200  may include a nonwoven substrate layer or a film substrate layer that defines the first surface  202  and a second substrate layer defining the second surface  204 , wherein the second substrate layer may include a nonwoven or a film. 
     As shown in  FIGS.  2 - 4 A , the continuous substrate  200  may advance in a machine direction MD adjacent a protrusion forming apparatus  500  that is configured to form discrete zones  162  of protrusions  164  on the substrate  200 . In particular, the protrusion forming apparatus or system  500  comprises an energy source  502  and a die surface  504 . As shown in  FIG.  5   , the die surface comprises cavities  506 . As such, the energy source  502  applies energy to the advancing substrate  200  such that softened material of the substrate  200  may be pressed or otherwise move or flow into the cavities  506  of the die surface  504  to form a zone  162  of protrusions  164 . In turn, the protrusions  164  are formed directly from and integrally with the material of the substrate  200 . It is to be appreciated that various configurations of protrusion forming systems  500  may be used to integrally mold protrusions  164  directly on a substrate  200 , wherein the substrate material may serve not only as a structural component material for other purposes, but also as a source of material, such as a polymer for example, for formation of the protrusions  164 . Examples of protrusion forming systems  500  are disclosed in U.S. Pat. Nos. 6,478,784; 6,746,434; and 8,784,722; U.S. Patent Publication No. 2018/0141266 A1; and U.S. patent application Ser. No. 16/545,425, filed on Aug. 20, 2019, which are all incorporated herein by reference. 
     As shown in  FIGS.  2 - 5   , the substrate  200  may advance through a nip  508  between the energy source  502  and the die surface  504 . The energy source  502  may be configured to heat and/or otherwise apply energy to soften material of the substrate  200  such that the softened material may be pressed or moved into the cavities  506  of the die surface  504  to form protrusions  164  on the substrate  200 . In some configurations, the substrate  200  may comprise a nonwoven, and as the nonwoven advances through the nip  508 , heating of the polymeric material of the filaments, by application of heating energy, softens the material so that the material may be deformed and forced in the nip  508  and into the cavities  506  of the die surface  504 . In some configurations, the die surface  504  may be cooled or otherwise temperature-controlled to help assure that the finished substrate  200  will advance from the nip  508  with formations of protrusions  164  that are stably formed and solidified. The formed protrusions  164  and areas thereof on the substrate  200  will be molded from and thereby physically integral with material(s) of which the nonwoven material and/or laminate is formed. The zone  162  of protrusions  164  may approximately correspond with the arrangement and features of the cavities  506  in the die surface  504 . 
     It is to be appreciated that the energy source  502  may be configured in various ways. For example, as shown in  FIG.  2   , the energy source may comprise an ultrasonic horn  510  comprising an energy transfer surface  512 . As such, ultrasonic horn  510  may be configured to impart ultrasonic energy to the substrate  200  advancing through the nip  508 . For example, with reference to  FIGS.  2 - 5   , the substrate  200  may advance through the nip  508  such that the second surface  204  of the substrate  200  is arranged in facing relationship with the die surface  504 . In turn, the ultrasonic horn  510  may apply energy to the first surface  202  of the substrate  200  advancing through the nip  508 . Energy from the ultrasonic horn  510  softens material of the substrate  200  and such softened material moves into the cavities  506  to form protrusions  164  that extend outward from the second surface  204  of the substrate  200 . It is to be appreciated that aspects of the ultrasonic horn  510  may 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, all of which are incorporated by reference herein. In some configurations, the ultrasonic horn  510  may 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 to be appreciated that the die surface  504  and/or the cavities  506  therein may be configured in various ways. For example, the protrusion forming apparatus  500  may include a roll  514  comprising an outer circumferential  516  surface adapted to rotate about an axis  518  of rotation. In turn, the die surface  504  may be formed to define a portion of the outer circumferential surface  516  of the roll  514 . During protrusion forming operations, the substrate  200  may advance through the nip  508  with the second surface  204  in a facing relationship with the outer circumferential surface  516  of the rotating roll  514 . It is to be appreciated that the roll  514  may define various cross sectional shapes, such circular or oblong and/or may be configured to constantly or intermittently contact the substrate  200  advancing through nip  508 . 
     As shown in  FIG.  5   , the cavities  506  may be arranged in regions that correspond with the shapes and/or size of the zones  162  of the protrusions  164  formed on the substrate  200 . In some configurations, the cavities  506  may be arranged circumferentially on the roll  514  in various ways to define different shapes and/or sizes of regions capable of forming different sizes and/or shapes of zones  162  of protrusions  164  on the substrate  200 . In some configurations, the cavities  506  may be integrally formed in the outer circumferential surface  516  of the roll  514 . The roll  514  may also be configured with various features to help provide flexible arrangements to more easily accommodate desired changes in shapes, sizes, and/or locations of the zones  162  of protrusions  164  on the substrates  200  and/or the shapes and/or densities of the protrusions  164 . For example, the roll  514  may be connected with a motor, such as a servo motor, adapted to rotate the roll  514  at constant and/or variable angular velocities. The ability to rotate at variable angular velocities may help provide for adjustment of desired machine direction MD spacing between zones  162  of protrusions  164  on the substrate  200  without the need to replace the roll and/or associated components. In some configurations, the die surface  504  and cavities  506  may be defined by parts  520  that may be releasably and/or otherwise movably connected with the roll  504 , such as shown in  FIG.  5   . For example, such parts  520  may be selectively movable axially and/or circumferentially on the roll  514 . Such movable parts  520  may help provide for adjustment of desired machine direction MD spacing between zones  162  of protrusions  164  on the substrate  200  and/or cross directional CD position of zones  162  of protrusions  164  on the substrate  200  without the need to replace the roll  504  and/or associated components. Such releasably connectable and replaceable parts  520  may also help provide the ability to change the shapes and/or sizes of zones  162  of protrusions  164  and/or densities and/or types of protrusions  164  to be formed on a substrate  200  without the need to replace the entire roll  504 . 
     As previously mentioned, it is to be appreciated the protrusion forming system  500  may be configured to form different types and/or shapes of protrusions  164  on the substrate. As shown in  FIGS.  2  and  4 A , the protrusions  164  may be formed to protrude from the second surface  204  of the substrate  200  to a distal end  165 . In some configurations, such as shown in  FIG.  4 A  for example, the protrusions  164  may be formed as hooks  166 . Various examples of protrusion and hook shapes are disclosed in U.S. Pat. Nos. 6,478,784; 6,746,434; and 8,784,722; U.S. Patent Publication No. 2018/0141266 A1; and U.S. patent application Ser. No. 16/545,425, filed on Aug. 20, 2019, which are all incorporated herein by reference. 
     With continued reference to  FIGS.  2  and  4   , the zones  162  of protrusions  164  may extend a maximum length Lz in the machine direction MD and may extend a maximum width Wz in the cross direction CD. As shown in  FIG.  4   , the discrete zones  162  of protrusions  164  may be separated from each other in the machine direction MD, and one or more discrete zones  162  of protrusions  164  may be formed on the substrate  200  in the cross direction CD. It is also to be appreciated the width Wz of the zones  162  may be equal to or less than the width W s  of the substrate  200 . As previously mentioned, the zones  162  may comprise the same or different sizes and/or shapes and/or protrusion densities. 
     As previously mentioned, the protrusion forming systems  500  referred to herein may necessitate relatively slow substrate  200  advancement speeds in order to provide adequate time to perform the protrusion forming operations. Thus, in some configurations where the substrate  200  may be incorporated to other assembly processes, such as absorbent article manufacturing lines, operating at relatively high speed production rates, it may be necessary to temporarily slow the substrate  200  when advancing through the protrusion forming system  500 . Referring again  FIG.  2   , the substrate  200  may advance through an accumulator apparatus  600  that decelerates a portion  200   a  of the substrate  200  to a second speed S2 less than first speed S1. While at the second speed S2, a protrusion forming system  500  may operate to form discrete zones  162  of protrusions  164  on the second surface  204  of the portion  200   a  of the substrate  200 . Once the zone  162  of protrusions  164  is formed, the portion  200   a  of the substrate  200  is accelerated back to the first speed S1 and exits the accumulator apparatus  600 . In some configurations, the accumulator system  600  may operate to temporarily accelerate the portion  200   a  of the substrate  200  to speeds greater than the first speed S1 before decelerating the portion  200   a  of the substrate  200  back to the first speed S1. 
     As previously mentioned, the processing lines herein  300  may include an accumulator apparatus  600  that decelerates a portion  200   a  of an advancing substrate  200  from a first speed S1 to a second speed S2 while advancing past the protrusion forming system  500 . It is to be appreciated that the accumulator apparatus  600  may be configured in various ways for example such as disclosed in U.S. Pat. Nos. 5,373,761; 5,693,165; 6,596,108; 6,620,276; 6,349,867; and 8,377,249. For example,  FIG.  6    shows an example accumulator apparatus  600  for varying the speed of the advancing substrate  200 . As such, the apparatus  600  may be configured to provide localized speed changes of the substrate  200 . For example, the apparatus  600  may provide localized speed changes of the substrate  200  as the substrate  200  advances past the protrusion forming system  500 . 
     As shown in  FIG.  6   , the apparatus  600  may include a first substrate guide  602  and a second substrate guide  604 . The substrate  200  advances in the machine direction MD around an idler roller  606 , and enters the first substrate guide  602  at a first speed S1. The substrate  200  travels from the first substrate guide  602  at a second speed S2 past the protrusion forming system  500 . From the protrusion forming system  500 , the substrate  200  enters the second substrate guide  604 . The substrate  200  then exits the second substrate guide  604  at the first speed S1. As discussed in more detail below, the first substrate guide  602  and second substrate guide  604  operate to change the lengths of the substrate  200  within the respective guides, and thus, vary the second speed S2 of the substrate  200  traveling from the upstream, first substrate guide  602  to the downstream, second substrate guide  604 . At the same time, the speed of the substrate  200  entering the first substrate guide  602  and exiting the second substrate guide  604  is maintained at a constant first speed S  1 . The idler rollers  606  in  FIG.  6    show only one example of how the substrate  200  may be advanced to and from the apparatus  600 , and as such, it is to be appreciated that various other configurations and arrangements can be utilized. 
     As previously mentioned, the second speed S2 of the substrate  200  can be varied as the substrate  200  travels past the protrusion forming system  500 . As discussed in more detail below, the first and second substrate guides  602 ,  604  may be configured to periodically slow (e.g. second speed, S2, is slower than the first speed, S1) the movement of the portion  200   a  of the substrate  200  in the machine direction MD advancing past the protrusion forming system  500 . In some configurations, the first and second substrate guides  602 ,  604  may be configured to periodically stop (e.g. second speed, S2, is zero) the movement of the portion  200   a  of the substrate  200  in the machine direction MD advancing past the protrusion forming system. 
     As described in more detail below, the substrate guides  602 ,  604  may be configured to touch only one side of the substrate  200 . For example, the first and second substrate guides  602 ,  604  may be configured to touch only the first surface  202  of the substrate  200 , and do not touch the second surface  204  of the substrate  200 . Such a configuration may be beneficial to reduce negative impacts on the protrusion forming operations performed on the substrate  200 . For example,  FIG.  6    shows the protrusion forming system as forming protrusions on the second surface  204  of the substrate  200  before the substrate  200  enters the second substrate guide  604 . Because the first and second substrate guides  602 ,  604  touch only the first surface  202  of the substrate  200 , risks of contaminating or otherwise affecting the newly formed protrusions  164  on the second surface  204  of the substrate  200  may be reduced. 
     With continued reference to  FIG.  6   , the first substrate guide  602  includes a first guide member  608  in the form of a first roller, a second guide member  610  in the form of a second roller, and a third guide member  612  in the form of a third roller. As described below, the substrate  200  travels in the machine direction MD at the first speed S1 to the first roller  608 ; from the first roller  608  to the second roller  610 ; from the second roller  610  to the third roller  612 ; and from the third roller  612  to the protrusion forming system  500  and to the second substrate guide  604  at the second speed S2. As shown in  FIG.  6   , the second roller  610  is rotatably connected with a support member  614  at a second roller axis  616 . The support member  614  is adapted to rotate around a second center axis  618 . As such, the second roller  610  orbits around the second center axis  618  as the support member  614  rotates. As the substrate  200  advances through the first substrate guide  602 , only the first surface  202  of the substrate  200  contacts the outer radial surfaces of the first, second, and third rollers  608 ,  610 ,  612 . 
     Similar to the first substrate guide  602 , the second substrate guide  604  includes a first guide member  620  in the form of a first roller, a second guide member  622  in the form of a second roller, and a third guide member  624  in the form of a third roller. As described below, the substrate  200  travels in the machine direction MD at the second speed S2 (from the first substrate guide  602  and past the protrusion forming station  500  to the first roller  620 ; from the first roller  620  to the second roller  622 ; from the second roller  622  to the third roller  624 ; and from the third roller  624  to continue downstream at the first speed S1. As shown in  FIG.  6   , the second roller  622  is rotatably connected with a support member  626  at a second roller axis  628 . The support member  626  is adapted to rotate around a second center axis  630 . As such, the second roller  622  orbits around the second center axis  630  as the support member  626  rotates. As the substrate  200  advances through the second substrate guide  604 , only the first surface  202  of the substrate  200  contacts the outer radial surfaces of the first, second, and third rollers  620 ,  622 ,  624 . 
     Although the guide members  608 ,  610 ,  612 ,  620 ,  622 ,  624  of the first and second substrate guides  602 ,  604  are shown and described as rollers, it is to be appreciated that the guide members can be configured in other ways. For example, in some embodiments, the guide members may be configured as rollers, stationary pins or rods, endless belts, spheres, and/or combinations thereof. In addition, although the support members  614 ,  626  are shown in the form of wheels, it is to be appreciated that the support members may be configured in other ways, such as for example, an elongate member or rotating arm. Further, some or all of the rollers can be driven rollers, idler rollers, and/or combinations of each. In addition, the support members can be rotated at constant or variable speeds. In some embodiments, the support members  614 ,  626  may have separate and/or variable speed drives, such as for example, servo motors. 
     As mentioned above with reference to  FIG.  6   , the first substrate guide  602  and the second substrate guide  604  utilize orbital motion of guide members to change the length of the substrate  200  within the substrate guides. In particular, rotation of the support members  614 ,  626  causes the second rollers  610 ,  622  to orbit around the second center axes  618 ,  630 . In turn, the orbital motions of the second rollers  610 ,  622  result in changes of the lengths of substrate within the substrate guides  602 ,  604 . As such, the coordinated rotation of the support members  614 ,  626  of the first and second substrate guides  602 ,  604  result in localized speed changes of the substrate  200  advancing past the protrusion forming system  500  (i.e. a variable second speed, S2), while maintaining a constant first speed, S1. 
     It is to be appreciated that the protrusion forming apparatus  500  may be configured in various ways to help assure that the finished substrate  200  includes protrusions  164  that are stably formed and solidified. In some configurations, the forming apparatus  500  may be configured to help maintain contact between the substrate  200  and the die surface  504  for relatively longer periods of time to provide the protrusions  164  additional time to cool before advancing from the die surface  504 . For example, the forming apparatus  500  shown in  FIG.  6 A  may be configured such that during protrusion forming operations, the substrate  200  may be partially wrapped onto the roll  514 . As such, a length of the substrate  200  may remain in contact with the outer circumferential surface  516  of the roll  514  after advancing from the nip  508 . Thus, the protrusions  164  may be provided some additional time to cool before the substrate  200  advances from the outer circumferential surface  516  of the roll  514 . In some configurations, the forming apparatus may include rolls  550  to guide the substrate  200  onto the outer circumferential surface  516  of the roll  514 . 
     As previously mentioned, the die surface  504  may also be cooled or otherwise temperature-controlled. As such, it is to be appreciated that the outer circumferential surface  516  of the roll  514  shown in  FIG.  6 A  may also be adapted to the cool the substrate  200  after advancing from the nip  508  and before advancing from the outer circumferential surface  516 . In some configurations, the outer circumferential surface  516  may also be adapted to pre-heat the substrate  200  before advancing to the nip  508 . 
     As shown in  FIG.  6 A , the extent that the substrate  200  wraps around the roll  514  may be referred to herein as the wrap angle, θ, and may be expressed in units of degrees. In some configurations, the wrap angle, θ, may be greater than zero degrees and less than or equal to 180 degrees, specifically reciting all 1 degree increments within the above-recited range and all ranges formed therein or thereby. In some configurations, the wrap angle, θ, may be greater 180 degrees. 
     With continued reference to  FIG.  6 A , the roll  514  may also be configured to rotate at variable angular velocities such that speed of the outer circumferential surface  516  matches or substantially matches the speed profile of the portion  200   a  of the substrate  200  that is decelerated and accelerated by the accumulator apparatus  600 . For example, the roll  514  may be connected with a servo motor that may rotate the roll  514  at constant and/or variable angular velocities in conjunction with the varying speeds of the portion  200   a  of the substrate  200 . 
       FIG.  7    shows another example of an accumulator apparatus  600  for varying the speed of the advancing substrate  200  similar to the apparatus disclosed in U.S. Pat. No. 6,620,276, which is incorporated by reference herein. As such, the apparatus  600  may be configured to provide localized speed changes of the substrate  200  as the substrate  200  advances past the protrusion forming station  500 . As shown in  FIG.  7   , the accumulator apparatus  600  includes web support plates  720  connected with extendible arms  730 , wherein each web support plate  720  comprises a web support surface  722  facing outwardly. The web support plates  720  may be configured as the die surface  504  wherein the web support surface  722  of each web support plate  720  may include cavities  506 , such as described above. As discussed in more detail below, the extendible arms  730  rotate the support plates  720  such that the web support surfaces  722  trace out an essentially circular path around a principal axis  725 . Each extendible arm  730  has a proximal end  732  and a distal end  734 , the proximal end  732  of each extendible arm  730  rotatably connected with a second axis of rotation  735  and the distal end  734  of each extendible arm  730  being pivotally connected with a web support plate  720 . 
     As shown in  FIG.  7   , the principal axis  725  and the second axis  735  are parallel and off-set in relation to each other, and as such, the extendible arms  730  drive the web support plates  720  around the circular path with a variable circumferential velocity. As a web support plate  720  passes through point A of the circular path (at the bottom of the circular path as illustrated in  FIG.  7   ), the web support plate  720  has a maximum circumferential velocity Vmax. As the web support plate  720  is rotated towards the top of the circular path, the web support plate  720  is decelerated until reaching a minimum circumferential velocity Vmin at point B of the circular path. As the web support plate  720  continues around the circular path, the web support plate  720  is accelerated again to Vmax while returning to point A. Also, as shown in  FIG.  7   , adjacent web support plates  720  are spaced apart by a distance d. The adjacent web support plates either side of point A in  FIG.  7    have a maximum distance d between each other. As the web support plates  720  are rotated, one of the web support plates  720  has a faster circumferential velocity than an adjacent web support plate, and the faster web support plate catches up with the slower web support plate, thereby reducing the distance d between the adjacent web support plates  720 . The adjacent web support plates either side of point B in  FIG.  7    have a minimum distance d between each other. 
     With continued reference to  FIG.  7   , the substrate  200  advances in the machine direction MD at a first speed S1 around two idler rollers  606 , and onto the web support surfaces  722  of the rotating web support plates  720 . As the substrate  200  is advanced around the circular path by the decelerating web support plates  720 , loops  701  are formed between adjacent web support plates  720 . As the web support plates rotate, a portion  200   a  of the substrate  200  advances past the protrusion forming station  500  at the second speed S2, wherein S2 is less than S1. As previously mentioned, the web support plates  720  may be configured as the die surface  504  wherein the web support surface  722  of each web support plate  720  may include cavities  506 . As such, the portion  200   a  of the substrate  200  advances at the second speed S2 through the nip  508  defined between the energy source  502  and the die surface  504 . The energy source  502  applies energy to the substrate  200  as described above to form zones  162  of protrusions  164 . Subsequently, the web support plates  720  and substrate  200  accelerate, thereby removing the loops between adjacent web support plates  720 . The substrate  200  then advances from the support plates  720  at the first speed S1 around two idler rollers  606 , and onto the remainder of the assembly process. 
     As previously mentioned, the zones  162  of protrusions  164  may be formed on a portion  200   a  of the substrate  200  while advancing at a second speed S2, wherein the second speed S2 is less than the first speed S1. It is to be appreciated that system may be configured with various relative differences between the first speed and second speeds. For example, in some configurations, the second speed S2 is from about 25% to about 50% of the first speed S1. In some configurations, the second speed S2 is about 25% of the first speed S1. 
     It is to be appreciated that the protrusion forming operations may be performed separate to product assembly processes, such as for example, forming protrusions  164  on the substrates  200  offline wherein the substrates  200  may be stored until needed for production. For example, protrusion forming operations may be accomplished on discrete forming lines, separately from converting lines that are dedicated to manufacturing products such as absorbent articles. After forming the protrusions  164  on the forming lines, the substrates  200  may be delivered to the converting lines, such as in a form of continuous webs comprising protrusions formed thereon. In addition to or alternatively to offline protrusion forming operations, protrusion forming operations may be done online during article assembly processes. As previously mentioned, the substrate  200  may advance from the protrusion forming apparatus  500  and may be subjected to additional manufacturing operations, such as combining, bonding, printing, cutting and/or folding operations. For example, as shown in  FIGS.  2  and  4   , the substrate  200  with the protrusions formed thereon may advance to a cutter apparatus  522  that separates the continuous substrate  200  into separate the pieces  210 . The cutter apparatus  522  is generically represented by dashed rectangle in  FIGS.  2  and  4   . It is to be appreciated the cutter apparatus  522  may be configured in various ways, such as for example, a knife roll and anvil roll. In another example, the cutter apparatus  522  may include a laser adapted to cut the discrete parts  210  from the continuous substrate  200 . As shown in  FIG.  4   , the substrate  200  may be into discrete pieces  210  each having a pitch length, PL, extending along the machine direction MD wherein the length, Lz, of the zone  162  of protrusions  164  extends in the machine direction MD for less than the pitch length, PL. It is also be appreciated that the cutter apparatus  522  may be configured to slit or cut the substrate  200  along the machine direction MD to create two or more lanes L1, L2 of continuous substrates having protrusions  164  formed thereon, such as shown in  FIG.  4 B . 
     It is also to be appreciated that the protrusion forming operations may be performed in conjunction with bonding operations. For example, the roll  514  and ultrasonic horn  510  described above may be configured to perform the protrusion forming process and bonding processes simultaneously. In some configurations, such as shown in  FIG.  5 A , the roll  514  may include cavities  506  capable of interacting with the energy source  502  to form the protrusions  164  as described above. In addition to the cavities  506 , the outer circumferential surface  516  of the roll  514  may also comprise one or more bonding surfaces  524  defined by bonding elements  526  extending radially outward from the outer circumferential surface  516 . As shown in  FIG.  2   , as the roll  514  rotates, the substrate  200  and a second substrate  201  may be advanced between the bonding surfaces  524  and the energy source  502  to mechanically bond or weld the substrate  200  and the second substrate  201  together to create bond regions between the between the two substrates  200 ,  201 . It is to be appreciated that the second substrate  201  may be positioned in a facing relationship with either the first surface  202  or the second surface  204  of the substrate  200  during bonding. Heat and/or pressure between the energy source  502  and the roll  514  may melt and bond the substrates  200 ,  201  together in areas supported by the bonding surfaces  524  on the roll  514 . As such, the mechanical bonds and/or bond regions may have shapes that correspond with and may mirror shapes of the bonding surfaces  524 . In some configurations, the bonding and protrusion forming operations may be done with the same energy source, such as the same ultrasonic horn. In some configurations, the bonding and protrusion forming operations may be done with different energy sources, such as different ultrasonic horns. It is to be appreciated that the bonding operations may also be configured in various ways, such as with heated or unheated pattern rolls, anvil rolls and/or ultrasonic bonding devices. It is to be appreciated that the roll  514  and/or energy source  502  may 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, all of which are incorporated by reference herein. 
     It is to be appreciated that the second substrate  201  illustrated in  FIG.  2    may be configured to be continuous or discrete lengths. It is also to be appreciated that the second substrate  201  and/or additional substrates may be combined with and/or bonded with the substrate  200  before, during, or subsequent to the protrusion forming operations. In addition, the second substrate  201  may be configured as an absorbent article component such as described above with reference to  FIGS.  1 A and  1 B . For example, in some configurations, the second substrate  201  may be configured as a continuous or discrete chassis  102 , topsheet  138 , and/or backsheet  136  and the substrate  200  may be configured as a connection zone  138  or side panels  104 ,  106 ,  108 ,  110 . 
     In yet other configurations, the apparatus  300  may be configured with one or more adhesive applicator devices adapted to apply adhesive to bond substrates  200 ,  201  together with the applied adhesive. It is to be appreciated that such adhesive applicator devices may be configured in various ways, such as for example, as a spray nozzle and/or a slot coating device. In some configurations, the adhesive applicator device may 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 also to be appreciated that adhesive may be applied to create the bond regions in conjunction with or instead of the mechanical bonding processes discussed above. 
     It is also to be appreciated that the protrusion forming operations herein may also be performed in conjunction with other operations, such as printing operations. For example, print stations may be configured to print either or both the first surface  202  and the second surface  204  of the substrate  200  before or after forming the zones  162  of protrusions  164  thereon. It is to be appreciated that the printing stations may be configured in various ways and may include various types of printing accessories. For example, the printing stations may be capable of printing ink on substrate materials to form graphics by various printing methods, such as flexographic printing, rotogravure printing, screen-printing, inkjet printing, and the like. In some configurations, one or more lasers may be provided to create laser induced graphics on either or both the first surface  202  and the second surface  204  of the substrate  200 . It is to be appreciated that graphics may be positioned inside and/or outside areas of the substrate  200  where zones of protrusions have been or will be formed. 
     Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.