Patent Publication Number: US-2020297551-A1

Title: Apparatus and method of manufacturing an elastic composite structure for an absorbent sanitary product

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of, and claims priority to, U.S. non-provisional application Ser. No. 16/260,259, filed Jan. 29, 2019, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/623,381, filed Jan. 29, 2018, and to U.S. Provisional Patent Application Ser. No. 62/666,508, filed May 3, 2018, the disclosures of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Embodiments of the invention relate generally to absorbent sanitary products and, more particularly, to an improved apparatus and method for manufacturing an elastic composite structure for use in an absorbent sanitary product that includes elasticized regions and regions of relative inelasticity while minimizing or eliminating the use of consumable adhesives such as glue. 
     Absorbent sanitary products, such as disposable diapers, are typically equipped with elastic composite structures that include one or more elastic threads. These elastic composite structures are positioned at various locations throughout the product, including in the waistbands, leg cuff regions, and throughout all or portions of the front or back panels of the product. During the typical manufacturing process of an elastic composite structure, the elastic threads are held in a tensioned state and an adhesive is used to secure the elastic threads between the two facing layers of non-woven materials or webs. The tension in the elastic threads is subsequently released, causing the web material to pucker or fold in the areas that contain the adhered elastic threads. In some applications, it is desired to provide areas of relative inelasticity in the elastic composite structure. To create these distinct regions, adhesive is applied to some areas of the web material and omitted from others. The elastic threads are cut in the adhesive-free areas by a cutting unit such as a rotary knife unit, and the cut ends of the elastic thread snap back to the adjoining adhesive areas. 
     The use of adhesives to bond the elastic threads within an elastic composite structure presents a number of disadvantages in both the end product and manufacturing method, including costs associated with the consumable material and undesirable tactile properties of the end product (e.g., stiffness). While thermal or ultrasonic welding techniques have been proposed as alternatives for bonding and/or cutting elastic threads within an elastic composite structure, known ultrasonic techniques for severing elastic threads tend to create cuts or slits in the web material, which reduce web tension in the severed part of the web and create an undesirable hole in the end product. Another problem associated with cutting the elastic threads is that the cut ends of elastic have a tendency to retract beyond the desired boundary of the elasticized area and land at a position somewhere within the elasticized area. This results in an incomplete elastic pattern and poor aesthetic and functional characteristics in the end product. 
     Accordingly, there is a need for an improved apparatus and method for fabricating an elastic composite structure of an absorbent sanitary product that maintains tension in the elastic strands within the elasticized areas of the product and does not cut the web materials in areas of relative inelasticity. It would further be desirable for such an apparatus and method to eliminate or minimize the use of consumable adhesives to secure the elastic threads to the facing web layers. 
     BRIEF STATEMENT OF THE INVENTION 
     In accordance with one aspect of the invention, an elastic composite structure includes a plurality of tensioned elastic threads, a first web layer positioned on a first side of the plurality of tensioned elastic threads, and a second web layer positioned on a second side of the plurality tensioned elastic threads. The elastic composite structure also includes a pattern of laminating bonds that fuse the first web layer to the second web layer within a deactivated zone of the elastic composite structure. The deactivated zone includes a cut end of a first portion of a tensioned elastic thread of the plurality of tensioned elastic threads and a cut end of a second portion of the tensioned elastic thread of the plurality of tensioned elastic threads. Neither the cut end of the first portion of the tensioned elastic thread nor the cut end of the second portion of the tensioned elastic thread is bounded by a pair of adjacent laminating bonds of the pattern of laminating bonds spaced at a distance less than a distance between adjacent threads of the plurality of tensioned elastic threads. The elastic composite structure further includes a pattern of anchoring bonds that fuse the first web layer to the second web layer within an anchored zone bounding opposing ends of the deactivated zone. The anchored zone includes a first plurality of bonds of the pattern of anchoring bonds arranged to anchor the first portion of the tensioned elastic thread to the first and second web layers and a second plurality of bonds of the pattern of anchoring bonds arranged to define pairs of bonds that anchor the second portion of the tensioned elastic thread to the first and second web layers. 
     In accordance with another aspect of the invention, a method of manufacturing an elastic composite structure includes positioning a tensioned elastic thread between a first web layer and a second web layer, fusing the first web layer to the second web layer to form an anchored zone comprising a plurality of discrete anchoring bonds that fuse the first web layer to the second web layer and anchor the tensioned elastic thread therebetween, and cutting the tensioned elastic thread to form a deactivated zone of the elastic composite structure that is free of the tensioned elastic thread, the deactivated zone positioned between adjacent portions of the anchored zone. The method also includes fusing the first web layer to the second web layer within the deactivated zone with a pattern of laminating bond and defining the position of the pattern of laminating bonds relative to a cut end of the tensioned elastic thread such that the cut end of the tensioned elastic thread does not extend into the pattern of laminating bonds in a machine direction. 
     In accordance with another aspect of the invention, a bonding apparatus for manufacturing an elastic composite structure comprising at least one elastic thread secured between a pair of facing web layers, the bonding apparatus includes a rotary anvil having a face with weld pattern comprising at least one anchoring region and at least one deactivating region. The at least one anchoring region includes a plurality of anchoring welds constructed to form anchoring bonds that fuse the pair of facing web layers together and anchor the at least one elastic thread in position relative to the pair of facing web layers. The at least one deactivating region includes a plurality of laminating welds constructed to form laminating bonds that fuse the pair of facing web layers together without anchoring the at least one elastic thread in position relative to the pair of facing web layers. The plurality of laminating welds are arranged in a zig-zag pattern within the at least one deactivating region. 
     These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate embodiments presently contemplated for carrying out the invention. 
       In the drawings: 
         FIG. 1  is a schematic perspective view of a portion of a manufacturing line for fabricating an elastic composite structure. 
         FIG. 2  is a schematic perspective view of a rotary anvil usable with the manufacturing line of  FIG. 1 , according to one embodiment of the invention. 
         FIG. 3  is a schematic cross-sectional view of a bonding apparatus that includes the rotary anvil of  FIG. 2  and is usable with the manufacturing line of  FIG. 1 , according to one embodiment of the invention. 
         FIG. 4  is a detailed view of a portion of the bonding apparatus of  FIG. 3  illustrating the horn aligned with an anchoring weld on the rotary anvil, according to one embodiment of the invention. 
         FIG. 5  is a detailed view of a portion of the bonding apparatus of  FIG. 3  illustrating the horn aligned with a break bar on the rotary anvil, according to one embodiment of the invention. 
         FIG. 6  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 2 , according to one embodiment of the invention. 
         FIG. 7  is a schematic top view illustrating the spaced relationship between a non-tensioned elastic thread, a pair of anchoring bonds, a pair of pinching bonds, and laminating bonds, according to various embodiments of the invention. 
         FIG. 8  is a schematic perspective view of a rotary anvil usable with the manufacturing line of  FIG. 1 , according to another embodiment of the invention. 
         FIG. 9  is a top view of a plurality of non-segmented absorbent sanitary products that includes a continuous elastic composite structure manufactured using the manufacturing line of  FIG. 1 , according to one embodiment of the invention. 
         FIG. 10  is a flattened representation of an exemplary anvil pattern usable to manufacture the continuous elastic composite structure of  FIG. 9 , according to one embodiment of the invention. 
         FIG. 10A  is a detailed view of a portion of the rotary anvil of  FIG. 10 . 
         FIG. 11  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 10 , according to an embodiment of the invention. 
         FIG. 11A  is a detailed view of a portion of the elastic composite structure of  FIG. 11 . 
         FIG. 12  is a flattened representation of an exemplary anvil pattern usable to manufacture one of the elastic composite structures of  FIG. 9 , according to another embodiment of the invention. 
         FIG. 13  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 12 , according to an embodiment of the invention. 
         FIG. 14  is a flattened representation of an exemplary anvil pattern usable to manufacture the continuous elastic composite structure of  FIG. 9 , according to another embodiment of the invention. 
         FIG. 15  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 14 , according to an embodiment of the invention. 
         FIG. 16  is a flattened representation of an exemplary anvil pattern usable to manufacture the continuous elastic composite structure of  FIG. 9 , according to yet another embodiment of the invention. 
         FIG. 17  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 16 , according to an embodiment of the invention. 
         FIG. 18  depicts a technique for manufacturing an elastic composite structure, according to another embodiment of the invention. 
         FIG. 19  is a flattened representation of an exemplary anvil pattern usable to manufacture an elastic composite structure in accordance with the technique of  FIG. 18 , according to one embodiment of the invention. 
         FIG. 20  is a flattened representation of an exemplary anvil pattern usable to manufacture an elastic composite structure in accordance with the technique of  FIG. 18 , according to one embodiment of the invention. 
         FIG. 21  is a top view of a portion of an elastic composite structure manufactured using the rotary anvils of  FIGS. 19 and 20 , according to an embodiment of the invention. 
         FIG. 22  depicts a technique for manufacturing an elastic composite structure, according to yet another embodiment of the invention. 
         FIG. 23  depicts a technique for manufacturing an elastic composite structure, according to yet another embodiment of the invention. 
         FIG. 24  is a cross-sectional view of a portion of a cutting unit usable to manufacture an elastic composite structure in accordance with the technique of  FIG. 23 , according to one embodiment of the invention. 
         FIG. 25  depicts a technique for manufacturing an elastic composite structure, according to yet another embodiment of the invention. 
         FIG. 26  is a flattened representation of an exemplary anvil pattern on a first rotary anvil that may be used to manufacture an elastic composite structure in accordance with the technique of  FIG. 25 , according to one embodiment of the invention. 
         FIG. 27  is a flattened representation of the circumferential face of a cutting unit usable to manufacture an elastic composite structure in accordance with the technique of  FIG. 25 , according to one embodiment of the invention. 
         FIG. 28  is a flattened representation of an exemplary anvil pattern on a second rotary anvil that may be used to manufacture an elastic composite structure in accordance with the technique of  FIG. 25 , according to one embodiment of the invention. 
         FIG. 29  is a top view of a portion of an elastic composite structure manufactured using the rotary anvils of  FIGS. 26 and 28  and the cutting unit of  FIG. 27 , according to an embodiment of the invention. 
         FIG. 30  is a schematic cross-sectional view of a bonding apparatus usable with the manufacturing line of  FIG. 1 , according to embodiments of the invention. 
         FIG. 31  is a top view of a continuous elastic composite structure manufactured using the bonding apparatus of  FIG. 30 , according to one embodiment of the invention. 
         FIG. 32  is an orthogonal, flattened representation of an exemplary anvil pattern usable on a rotary anvil that may be used to manufacture an elastic composite structures herein according to one embodiment of the invention. 
         FIG. 33  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 32  according to an embodiment of the invention. 
         FIG. 34  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 32  according to an embodiment of the invention. 
         FIG. 35  is an orthogonal, flattened representation of an exemplary anvil pattern usable on a rotary anvil that may be used to manufacture an elastic composite structures herein according to one embodiment of the invention. 
         FIG. 36  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 35  according to an embodiment of the invention. 
         FIG. 37  is an orthogonal, flattened representation of an exemplary anvil pattern usable on a rotary anvil that may be used to manufacture an elastic composite structures herein according to one embodiment of the invention. 
         FIG. 38  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 37  according to an embodiment of the invention. 
         FIG. 39  is an orthogonal, flattened representation of an exemplary anvil pattern usable on a rotary anvil that may be used to manufacture an elastic composite structures herein according to one embodiment of the invention. 
         FIG. 40  is a top view of a portion of a continuous elastic composite structure manufactured using the rotary anvil of  FIG. 39  according to an embodiment of the invention. 
         FIG. 41  is an orthogonal, flattened representation of an exemplary anvil pattern usable on a rotary anvil that may be used to manufacture an elastic composite structures herein according to one embodiment of the invention. 
         FIGS. 42-48  illustrate respective top views of a portion of respective continuous elastic composite structures manufactured using corresponding modified projection patterns of the rotary anvil of  FIG. 41  according to embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention provide for a method and apparatus for manufacturing an elastic composite structure that includes one or more activated or elasticized zones, where one or more tensioned elastic threads are anchored or secured in place relative to facing web layers, and one or more deactivated zone that are inelastic relative to the elasticized zone(s). The resulting elastic composite structure may be used in an absorbent sanitary product such as, for example, a diaper, disposable adult pant, or feminine care product. As one non-limiting example, the elastic composite structure described herein may be a waistband for a diaper that includes a deactivated zone in an area where the absorbent core is coupled to the waistband. 
     Referring now to  FIG. 1 , a portion of an exemplary manufacturing line  10  is illustrated according to one embodiment of the invention. As shown, a first web layer  12  is fed in the machine direction  14 . A second web layer  16  is similarly fed in the machine direction  14 . First web layer  12  and second web layer  16  are materials capable of fusing to one another upon application of an applied energy that causes one or both of the webs  12 ,  16  to soften or melt and join together without the use of an intermediate layer of adhesive material such as glue. The facing pair of web layers  12 ,  16  may be the same type of material or different materials according to alternative embodiments. As non-limiting examples, first and second web layers  12 ,  16  may include nonwoven materials, woven materials, films, foams, and/or composites or laminates of any of these material types. 
     One or more elastic threads  18  are positioned between the first and second web layers  12 ,  16 . While the below description refers to elastic threads in the plural form, it is to be understood that the methods described herein may be used to manufacture an elastic composite structure that includes a single elastic thread or any number of multiple elastic threads. The elastic threads  18  travel in the machine direction  14  under tension from a creel assembly (not shown) or similar device. The elastic threads  18  may be composed of any suitable elastic material including, for example, sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or LYCRA, as non-limiting examples. Each elastic thread  18  may be provided in the form of an individual elastomeric strand or be a manufactured multifilament product that includes many individual elastomeric filaments joined together, such as by a dry-spinning manufacturing process, to form a single, coalesced elastic thread  18 . 
     Elastic threads  18  may have any suitable cross-sectional shape that facilitates formation of an elastic composite structure having desired elasticity, visual aesthetic, and manufacturability. As non-limiting examples, elastic threads  18  may have a cross-sectional shape that is round, rectangular, square, or irregular as may be the case where each elastic thread  18  is a multifilament product. 
     While first web layer  12  and second web layer  16  are depicted in  FIG. 1  and described herein as physically separate components, it is contemplated that alternative embodiments may utilize a unitary web structure that is folded to capture the elastic threads  18  between upper and lower layers of the unitary web structure. In such an embodiment, the portion of the unitary structure positioned below the elastic threads  18  would be referred to as the first web layer  12  and the portion of the unitary structure positioned above the elastic threads  18  would be referred to as the second web layer  16 . 
     Manufacturing line  10  includes one or more feeding assemblies  20  such as guide rollers that are employed to accurately position and (optionally) tension the elastic threads  18  as they travel in the machine direction  14  toward a bonding apparatus  22 . Immediately upstream of the bonding apparatus  22  are one or more assemblies that feed and guide the first and second web layers  12 ,  16  and the elastic threads  18  into the bonding apparatus  22 . In the illustrated embodiment, these feeding assemblies include an upper roller  24 , a lower roller  26 , and a strand guide roller  28  that guide a combined assembly  30  that includes the first web layer  12 , the second web layer  16 , and the elastic threads  18  into the bonding apparatus  22 . It is contemplated that rollers  24 ,  26 ,  28  may be replaced with other known types of feeding assemblies and/or replaced by a single roller unit or other known type of feeding assembly in an alternative embodiment. 
     Bonding apparatus  22  may be any known ultrasonic welding system in alternative embodiments, including, as non-limiting examples, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, bonding apparatus  22  includes a rotary anvil  32  and an ultrasonic fixed blade horn  34 , also known as a sonotrode, which cooperate with each other to bond (i.e., fuse) the first web layer  12  to the second web layer  16 . Alternative embodiments may include multiple fixed blade horns or one or more rotary horns. During the bonding process the elastic threads  18  are secured or anchored in position relative to the first and second web layers  12 ,  16  as described in detail below. 
     Bonding apparatus  22  also includes one or more frames  36  that support and/or house a motor (not shown) that drives the ultrasonic horn  34 , a vibration control unit (not shown) that ultrasonically energizes the horn  34  and causes the horn  34  to vibrate, and a second motor (not shown) that drives the anvil  32 . The horn  34  and anvil  32  are positioned in a spaced relationship relative to one another to facilitate ultrasonically bonding the first and second web layers  12 ,  16  to one another while the elastic threads  18  are held in tension in the space between the horn  34  and anvil  32 . During the bonding process, the first and second web layers  12 ,  16  are exposed to an ultrasonic emission from the horn  34  that increases the vibration of the particles in the first and second web layers  12 ,  16 . The ultrasonic emission or energy is concentrated at specific bond points where frictional heat fuses the first and second web layers  12 ,  16  together without the need for consumable adhesives. While bonding apparatus  22  is described herein as an ultrasonic bonding assembly that ultrasonically fuses first web layer  12  to second web layer  16 , it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse together two or more material layers without the use of adhesive, including sonic, thermal, or pressure bonding techniques and various other forms of welding known in the industry. 
     Referring now to  FIG. 2 , anvil is illustrated according to one embodiment of the invention. As shown, the anvil  32  of includes an arrangement of discrete projections or welds  38  that extend outward from the anvil face  40 . These welds  38  are constructed to (A) fuse first and second web layers  12 ,  16  together and (B) restrain or anchor the elastic threads  18  in position relative to the first and second web layers  12 ,  16  in the manufactured elastic composite structure. As described in more detail below, anchoring welds  38  are designed so that an elastic thread  18  that passes between two adjacent anchoring welds  38  on the face  40  of anvil  32  is anchored in position relative to the first and second web layers  12 ,  16  by frictional resistance that prevents the elastic thread  18  from sliding through the pair of resulting bonds. The location of anchoring welds  38  define anchoring regions  42  of the anvil  32 . 
     Anvil  32  also includes one or more additional projections that are referred to herein as laminating welds  44 . Similar to the restraining or anchoring welds  38 , laminating welds  44  fuse first and second web layers  12 ,  16  to one another. Laminating welds  44  differ from anchoring welds  38  because they do not anchor the elastic threads  18  in position relative to the first and second web layers  12 ,  16 . 
     Anvil  32  also includes one or more edges or break bars  46  that extends outward from the anvil face  40 . Each break bar  46  is configured to break the elastic threads  18  when the tensioned elastic threads  18  pass between the horn  34  and anvil  32  without cutting or perforating the first web layer  12  or the second web layer  16 . The pressure or pinching force exerted on a given elastic thread  18  as it passes between the horn  34  and the break bar  46  imparts a stress on the elastic thread  18  that breaks the elastic thread  18 . In a preferred embodiment, break bar(s)  46  are constructed so that they do not bond the first and second web layers  12 ,  16  to one another. In an alternative embodiment, break bar(s)  46  form a bond between the first and second web layers  12 ,  16  that has a geometry that mirrors that of the working surface of the respective break bar  46 . Together the anchoring welds  38 , laminating weld(s)  44 , and break bar(s)  46  define a pattern of projections  48  or weld pattern that extends outward from the face  40  of the anvil  32 . 
     In the illustrated embodiment, break bar  46  has a length equal or substantially equal to the overall length  50  of the pattern of projections  48 . In alternative embodiments, each break bar  46  may be sized to span only a subportion of the overall anvil length  50 , as described in further detail below. Optionally, break bar(s)  46  may include one or more grooves  56  (shown in phantom) that are recessed within the working surface  58  of the break bar(s)  46 . In yet other embodiments, the break bar  46  is constructed of a series of discrete but closely spaced projections or pinching welds, so called because the close spacing of two adjacent pinching welds functions as a pinch point that severs an elastic thread  18  that passes through the adjacent pinching welds during the bonding process. Break bar(s)  46  may be linear and oriented parallel to the rotational axis  60  of the anvil  32 , as shown, oriented at an angle relative to the rotational axis  60 , or have any alternative geometrical configuration determined based on design specifications to achieve the desired result of cutting an elastic thread  18 . 
     The location of break bar  46  defines a deactivating region  62  of the anvil  32 , which corresponds to a region of deactivated or broken elastic threads in the manufactured elastic composite structure and is referred to hereafter as a deactivated zone. One or more laminating weld(s)  44  are also located within the deactivating region  62  of the anvil  32 . In the illustrated embodiment, deactivating region  62  includes one break bar  46  with laminating welds  44  positioned on both sides of the break bar  46 . Alternative embodiments may include multiple break bars  46  within a given deactivating region  62  with laminating welds  44  positioned on one or both sides of each break bar  46 . Laminating welds  44  may be omitted entirely from the deactivating region  62  in yet other embodiments. 
     The particular size, shape, and general arrangement of anchoring welds  38 , laminating welds  44 , and break bar  46 , as well as the total number of welds  38 ,  44  and break bar(s)  46  illustrated in  FIG. 2 , are intended to depict a representative and non-limiting example of an overall pattern of projections  48  on anvil  32 . Alternative embodiments may include any number of welds  38 ,  44  and break bar(s)  46  arranged in any number of alternative configurations to achieve a desired pattern of bonds on the end product. The respective working surfaces of anchoring welds  38  and laminating welds  44  may be configured to form bonds of similar size and shape, or bonds of different size and/or shape in alternative embodiments. As non-limiting examples, respective land surfaces of anchoring welds  38  and laminating welds  44  may be circular, rectangular, crescent shaped, or have irregular shapes that may be selected to form a desired overall pattern on the end product. As explained above, the resulting pattern of bonds will include one or more anchored zones, which fix one or more elastic threads  18  under tension in position relative to the first and second web layers  12 ,  16 , and one or more deactivated regions or zones, which are free of tensioned elastic threads  18 . Being free of tensioned elastic threads  18 , these deactivated zones define areas of relative inelasticity in the resulting elastic composite structure. 
     In a preferred embodiment the anchoring welds  38 , laminating welds  44 , and break bar(s)  46  are formed on anvil  32  using a machining process that removes bulk material from the anvil  32  to create the desired raised pattern of projections  48  relative to the face  40  of the anvil  32 . Alternatively, anchoring welds  38 , laminating welds  44 , and/or break bar(s)  46  may be provided on one or more inserts that are mechanically coupled to the face  40  of the anvil  32 . 
     Referring now to  FIG. 3 , the working surface  64  of the horn  34  has a smooth or substantially smooth surface contour in one non-limiting embodiment. Alternatively, working surface  64  may include an arrangement of projections that mate or align with the pattern of projections  48  on the anvil  32  to further facilitate fusing the first web layer  12  to the second web layer  16  and securing the elastic threads  18  in position relative to the first and second web layers  12 ,  16 . 
     During the manufacturing process, the first and second web layers  12 ,  16  are positioned between the face  40  of the anvil  32  and the working surface  64  of the horn  34  as shown in  FIG. 3 . Elastic threads  18  are positioned between the first and second web layers  12 ,  16  in a tensioned state. As generally shown in  FIG. 3  and in further detail in  FIG. 4 , the position of horn  34  is controlled to maintain a nip gap  66  between the working surface  64  of horn  34  and the land surfaces  68 ,  70  of the anchoring welds  38  and laminating welds  44 , respectively. The size of the nip gap  66  is determined based on parameters of the manufacturing process to facilitate bonding between the first and second web layers  12 ,  16 . Bonding apparatus  22  may include any known positioning means  67  that exerts a force on at least one of the horn  34  and anvil  32  to maintain a desired nip gap  66  between the horn  34  and anvil  32 . Positioning means  67  may be an air pressure assembly (not shown) or a mechanical camshaft (not shown) as non-limiting examples. 
     Anchoring welds  38  may have a planar working surface, planar side surfaces, or some mixture of curved and straight working and side surfaces in alternative embodiments. In the embodiment illustrated in  FIG. 4 , the land surface  68  of anchoring weld  38  has an arced or curved surface profile. This curved profile permits the first and second weld layers  12 ,  16  to slip relative to the face  40  of the anvil  32  during the bonding process and thus allows the velocity at which the combined assembly  30  including tensioned elastic strands  18  and first and second web layers  12 ,  16  is advanced toward the bonding apparatus  22  to be increased or decreased relative to the rotational velocity of the anvil  32 . When the combined web/thread assembly  30  is advanced at a velocity greater than the velocity of the anvil  32 , the resulting bonds are spaced apart by a distance greater than the radial spacing between of adjacent welds  38 ,  44  on the anvil face  40 . Similarly, slowing the feed rate of the combined web/thread assembly  30  relative to the velocity of the anvil  32  will result in bonds that are spaced apart by a distance less than the radial spacing between of adjacent welds  38 ,  44  on the anvil face  40 . The velocity mismatch or differential between web speed and anvil velocity can be controlled to accommodate size changes in the end product. As a result, the bonding of an elastic composite for one size diaper may be carried out with little or no slip, while the bonding of an elastic composite for a larger or smaller diaper may be carried out with a larger amount of slip. A manufacturing line  10  outfitted with anvil  32  thus provides for dynamic size changing without having to change the tooling set-up of the manufacturing line  10 , as the same anvil  32  can be used to manufacture multiple sizes of elastic composite structures for use in different sized products. 
       FIG. 5  is a detailed view of the relationship between the horn  34  and a break bar  46  on the anvil  32 . In the embodiment shown, break bar  46  has straight side surfaces  72  and a curved working surface  58 , to permit slip to occur between the anvil  32  and first and second web layers  12 ,  16  in a manner similar to that described above with respect to anchoring weld  38 . Alternatively, the entire working surface  58  of break bar  46  may have a continuous arced profile similar to that of anchoring weld  38  of  FIG. 4 . In yet other embodiments, working surface  58  may be flat or planar, side surfaces  72  may be curved, or break bar  46  may be configured with any other geometric profile that accomplishes the intended function of cutting the elastic threads  18  and, optionally, fusing the first and second web layers  12 ,  16 . 
     As shown in  FIG. 5 , the working surface  64  of horn  34  is spaced apart from the working surface  58  of break bar(s)  46  by a nip gap  76 . In one embodiment, nip gap  76  is equal or substantially equal to the nip gap  66  between working surface  64  of horn  34  and the land surfaces  68 ,  70  of the anchoring and laminating welds  38 ,  44 . In alternative embodiments where it is desired that break bar(s)  46  form a bond between the first and second web layers  12 ,  16  by virtue of the geometry of the break bar(s)  46 , size of the nip gap  76 , or a combination thereof. 
       FIG. 6  illustrates a portion of an elastic composite structure  78  formed using the anvil  32  with pattern of projections  48  shown in  FIG. 2 . The elastic composite structure  78  is illustrated in an elongated state with elastic threads  18  stretched to a point where the first web layer  12  and second web layer  16  are flat or substantially flat. Elastic threads  18  are located between the first and second web layers  12 ,  16  are oriented along a longitudinal axis  80  of the elastic composite structure  78 . While the illustrated embodiment includes three (3) elastic threads  18  it is contemplated that alternative embodiments may include a single elastic thread  18  or any number of multiple elastic threads  18  based on design specifications of the end product. 
     The first and second web layers  12 ,  16  are fused together by anchoring bonds  82  at locations where the anchoring welds  38  on anvil  32  ( FIG. 2 ) communicate with web layers  12 ,  16  and by laminating bonds  84  at locations where the laminating welds  44  on anvil  32  ( FIG. 2 ) communicate with web layers  12 ,  16 . The break bar(s)  46  of anvil  32  break the elastic threads  18 , causing them to snap back toward the nearest anchoring bonds  82 . When the elastic composite structure  78  is permitted to relax, the elastic threads  18  will attempt to swell or expand to return to their non-tensioned or relaxed state. As the elastic threads  18  expand, frictional forces restrain or anchor the threads  18  between adjacent anchoring bonds  82  and the first and second web layers  12 ,  16 . The result is an elastic composite structure  78  that includes one or more elasticized or anchored regions or zones  86  corresponding to the anchoring region  86  of anvil  32  and one or more non-elasticized or deactivated zone  88  corresponding to the deactivating region  62  of anvil  32 . The length  90  of the anchored zone(s)  86  and the length  92  of the deactivated zone(s)  88  is defined by control of the rotational speed of the anvil  32  relative to the feed rate of the combined web/thread assembly  30  during the bonding process and anvil geometry. 
     Referring now to  FIG. 7  together with  FIG. 2  as appropriate, in one embodiment the proximal edges of adjacent anchoring welds  38  are spaced apart from one another by a distance  94  that is less than the strand diameter  96  of a given elastic thread  18  in its non-tensioned state. As used herein the phrase “strand diameter” refers to the smallest measurable cross-sectional width of the elastic thread  18  in its non-tensioned state. In embodiments where a given elastic thread  18  is a monofilament structure, the strand diameter is the minor diameter or smallest measurable width of the monofilament structure in its non-tensioned state. In embodiments where a given elastic thread  18  is a multi-filament structure, the phrase “strand diameter” refers to the smallest distance between opposite edges of an outline that generally defines the irregular cross-sectional area. The adjacent anchoring welds  38  on anvil  32  form a pair of adjacent anchoring bonds  82  that will act to secure or anchor the elastic thread  18  because the distance  98  between the proximal edges of the adjacent anchoring bonds  82  is smaller than the strand diameter  96  of the non-tensioned elastic thread  18 , as shown in  FIG. 7 . 
     In embodiments where break bar  46  is configured with discrete pinching welds, adjacent pinching welds will form a pair of adjacent pinching bonds  100  having proximal edges spaced apart by a distance  102  that is smaller than the strand diameter  96  and the distance  98  between adjacent anchoring bonds  82 . 
     In embodiments where the anvil  32  of  FIG. 2  includes multiple adjacent laminating welds  44 , the adjacent welds  44  are spaced apart at a distance  104  that forms a pair of adjacent laminating bonds  84  having proximal edges spaced apart either by (A) a distance  106  that is greater than the strand diameter  96  of a single non-tensioned elastic thread  18 , as illustrated by laminating bonds  84 A in  FIG. 7 , or (B) a distance  108  that is greater than the summed total of the strand diameters  96  of two or more non-tensioned elastic threads  18 , as illustrated by laminating bonds  84 B. 
       FIG. 8  illustrates anvil  32  according to an alternative embodiment of the invention. Anvil  32  includes a pattern of projections  110  that differs from the pattern of projections  48  described with respect to  FIG. 2  in that it includes a narrower break bar  46  and does not include laminating welds  44 . In such an embodiment, the resulting elastic composite structure would include anchored zones similar to the anchored zone  86  shown in  FIG. 6  and a deactivated zone that includes a bond line formed by break bar  46  but does not include any laminating bonds. In one embodiment an adhesive may be used to couple the first and second web layers  12 ,  16  together within the deactivated zone. Alternatively, laminating bonds similar to the laminating bonds  84  of  FIG. 6  may be formed within the deactivated zone using a second anvil unit positioned downstream from anvil  32 , as described in more detail below. 
     In the embodiment described with respect to  FIGS. 2-8 , the anchored zones  86  and deactivated zones  88  span similar widths of the resulting elastic composite structure  78  in the cross-machine direction  54  as a result of the particular configuration of the break bar(s)  46 , laminating weld(s)  44  (when used), and anchoring welds  38  on the anvil  32 .  FIGS. 10, 12, 14 , and  16  depict alternative anvil projection patterns that may be used with the bonding apparatus  22  of  FIG. 1  to form deactivated zones  88  that span only a portion of the overall width of the resulting elastic composite structure. These alternative projection patterns may be used to manufacture continuous elastic composite structures such as the front waist panel  112  and rear waist panel  114  illustrated in  FIG. 9 . As shown, front and rear waist panels  112 ,  114  include anchored zones  86  that contain multiple anchoring bonds that anchor elastic threads  18  and deactivated zones  88  that define attachment locations for respective absorbent cores  116  of a disposable diaper or pant and may include laminating bonds in some embodiments. Lines  118  represent product cut lines. Each of  FIGS. 10, 12, 14, and 16  is to be understood as illustrating one exemplary and non-limiting pattern of projections for manufacturing waist panels  112 ,  114 . The concepts described herein may be extended to manufacture an end product with one or more anchored zones and one or more deactivated zones using an anvil with an alternative pattern of projections than those described relative to  FIGS. 10, 12, 14, and 16 . Thus, it is contemplated that the pattern of projections on anvil may be modified from those shown herein to create an elastic composite structure that includes one or more anchored zone(s) and one or more deactivated zone(s) that vary in size and/or position relative to the embodiments specifically depicted herein. 
       FIG. 10  is a flattened representation of the circumferential face  40  of anvil  32  according to an embodiment where anvil  32  includes a pattern of projections  120  that form the deactivated zones  88  and anchored zones  86  of  FIG. 9 . The pattern of projections  120  includes multiple anchoring weld lines  122  that are spaced apart from one another along the circumferential axis  124  of the anvil face  40 . The anchoring weld lines  122  define an anchoring region  126  of the projection pattern  120 . The pattern of projections  120  also includes a break bar  128  and plurality of laminating weld lines  130  that collectively define a deactivating region  132 . 
     As shown in the detailed view provided in  FIG. 10A , each of the anchoring weld lines  122  contains a plurality of discrete anchoring welds  38 . Likewise, each of the laminating weld lines  130  includes a plurality of discrete laminating welds  44 , which are spaced apart from one another at a distance greater than that of the anchoring welds  38 . In alternative embodiments, each laminating weld line  130  may consist of a single laminating weld  44  or the laminating weld lines  130  may be omitted altogether. Break bar  128  may be formed having a continuous working surface as shown, or include one or more grooves similar to grooves  56  of  FIG. 2 . 
     In the embodiment shown, break bar  128 , laminating weld lines  130 , and anchoring weld lines  122  have a similar sinusoidal geometry that results in an overall sinusoidal pattern across the anvil face  40 . In this embodiment, break bar  128  is constructed to fuse the first and second web layers  12 ,  16  and sever the elastic thread(s)  18  that pass between the break bar  128  and horn  34  ( FIG. 1 ) during the bonding process. In an alternative embodiment, one or more of the laminating weld lines  130  immediately adjacent the leading and trailing edges of the deactivating region  62  may be omitted. Break bar  128 , laminating weld lines  130 , and anchoring weld lines  122  may be straight lines, curved lines, or otherwise arranged to create a continuous and repeating overall pattern on the end product in alternative embodiments. 
     As shown in  FIG. 11 , the bonding process creates an overall pattern of anchoring bond lines  134  and laminating bond lines  136  on the resulting elastic composite structure  138  that mirrors the geometry of anchoring weld lines  122  and laminating weld lines  130  within the pattern of projections  120  of  FIG. 10 . Thus, in an embodiment where the weld lines  122 ,  130  are sinusoidal, the resulting bond lines  134 ,  136  have a similar sinusoidal pattern. Alternative bond patterns on elastic composite structure  138  may be achieved by varying the geometry of the corresponding weld lines  122 ,  130  on the anvil  32 . In the illustrated embodiment a continuous bond line  140  is formed by break bar  128 , which severs the elastic threads  18 . The severed or cut ends  142  of the elastic threads  18  snap back toward the nearest anchoring bond lines  134 , which secures the two segmented portions  18 A,  18 B of a given cut elastic thread  18  under tension and in position relative to the first and second web layers  12 ,  16 . In an alternative embodiment, break bar  128  may be configured to sever the elastic threads  18  without fusing first and second web layers  12 ,  16 . The anchoring bond lines  134  also bond the first and second web layers  12 ,  16  together and define the anchored zones  86 . The first and second web layers  12 ,  16  are bonded together within the deactivated zones  88  by the continuous bond line  140  formed by break bar  128  and by laminating bond lines  136  formed by the laminating weld lines  130  on anvil  32 . Similar to the embodiments described above, the anchoring bond lines  134  collectively define anchored zone  86  on the elastic composite structure  138 . A deactivated zone  88  is defined the laminating bond lines  136  and continuous bond line  140  (when formed). 
       FIG. 12  illustrates a pattern of projections  144  formed on anvil  32  according to an alternative embodiment of the invention. Pattern of projections  144  includes anchoring weld lines  122 , which that are arranged in a similar manner as those included in the pattern of projections  120  of  FIG. 10  and include discrete anchoring welds similar to anchoring welds  38  in  FIG. 10A . Pattern of projections  144  also includes a pair of break bars  128 , one positioned at the leading edge of the deactivating region  132  and the other positioned at the trailing edge of the deactivating region  132 . A series of laminating weld lines  130  are positioned between break bars  128 , each of which include discrete laminating welds similar to laminating welds  44  of  FIG. 10A . 
     The pattern of projections  144  creates an elastic composite structure  138  that includes the pattern of bonds depicted in  FIG. 13 . Since each break bar  128  severs the elastic threads  18  as the elastic threads  18  pass over it, the use of two break bars  128  produces two cut points in a given elastic thread  18  that passes through the deactivating region  132  of the anvil  32 , resulting in a severed elastic thread portion  146  for each of those elastic threads  18 . These severed elastic portions  146  are retained within the deactivated zone  88  of the resulting elastic composite structure  138  as shown in  FIG. 13 . 
       FIG. 14  depicts an alternative pattern of projections  148  on anvil  32  according to another embodiment of the invention. The anchoring region  126  includes anchoring weld lines  122  similar to those of  FIGS. 10 and 10 . Deactivating region  132  includes an alternating pattern of anchoring weld lines  122  and break bars  128 . In one embodiment, the break bars  128  are constructed so that they do not fuse first and second web layers  12 ,  16 . During the bonding process each elastic thread  18  that passes through the deactivating region  132  of the anvil  32  is cut by each of the break bars  128 . The result is the elastic composite structure  138  shown in  FIG. 15 , which includes a series of severed elastic thread portions  146  corresponding to each elastic thread  18  that passes through the deactivating region  132 . These severed elastic thread portions  146  are anchored in place by anchoring bond lines  134  within the anchored zone  86 . 
     Yet another alternative pattern of projections  150  is shown in  FIG. 16 . In this embodiment, the deactivating region  132  of the pattern  150  includes a continuous weld pattern  152  that simultaneously cuts the elastic threads  18  and forms a corresponding unbroken bond pattern  154  or geometric design on the resulting elastic composite structure  138 , as shown in  FIG. 17 . Each elastic thread  18  that passes between the weld pattern  152  and horn  34  ( FIG. 1 ) during the bonding process may be cut one or multiple times based on geometry of the weld pattern  152 . In the embodiment shown, the weld pattern  152  cuts each of the affected elastic threads  18  two or more times, resulting in numerous severed elastic thread portions  146  that are contained within the bond pattern  154  in the elastic composite structure  138 . The continuous weld pattern  152  shown in  FIG. 16  is to be understood as only one example of a weld pattern geometry that may be implemented within the pattern of projections  150 . In alternative embodiments, pattern of projections  150  may include a continuous weld pattern  152  that forms any desired pattern, shape, design, logo, or the like on the resulting elastic composite structure  138 . 
     The bond patterns depicted on the elastic composite structures  138  in  FIGS. 11, 13, 15, and 17  are described above as being formed using a single anvil  32  with a pattern of projections that defines the location and boundaries of the anchored and deactivated zones on the end product. Alternatively, a similar end product may be manufactured using two or more anvils that each include a portion of the overall pattern of projections. In such an embodiment, the multiple anvils would be positioned adjacent one another in the cross-machine direction  54  (i.e., the direction perpendicular to the machine direction  14 ) and configured to rotate simultaneously about a common axis of rotation. 
     In an alternative embodiment, the first and second web layers  12 ,  16  are fused together using multiple bonding apparatuses positioned in series in the machine direction  14 . With reference to  FIG. 1 , a first bonding apparatus  22  is outfitted with a first anvil  32  that includes a pattern of projections that forms a first portion of the overall bond pattern and one or more horns  34 . A second bonding apparatus  156  is positioned downstream from the first bonding apparatus  22  in the machine direction  14 . Second bonding apparatus  156  includes a second horn  158  and a second anvil  160 , which includes a second pattern of projections that completes the overall bond pattern. Second bonding apparatus  156  may include multiple horns and/or multiple anvils in alternative embodiments. 
       FIG. 18  depicts an exemplary manufacturing method  162  that utilizes this two-stage anvil arrangement. Method  162  begins at step  164  by operating the first anvil  32  in combination with the horn  34  to bond the first and second web layers  12 ,  16  together. Anvil  32  includes one or more break bar(s)  46  that cut or sever the elastic threads  18 . The resulting intermediate product  166  is shown in  FIG. 18  with the position of the horn  34  and break bar(s)  46  overlaid atop the intermediate product  166  for reference. The intermediate product  166  includes an anchored zone  86  and a deactivated zone  88 , which at this point in the manufacturing process do not include any laminating bonds  84 . The anchored zone  86  include anchoring bond lines  134 , similar to those described relative to  FIGS. 11, 13, 15, and 17 , which are formed by anchoring weld lines  122  and corresponding anchoring welds  38  similar to any of those described with respect to  FIGS. 2, 10, 12, 14, and 16 . 
     Method  162  continues at step  168  by fusing the first and second web layers  12 ,  16  within the resulting deactivated zone(s)  88  via a pattern of laminating welds or laminating weld lines similar to any of those described with respect to  FIGS. 2, 10, 12, 14, and 16 . The result is an elastic composite structure  138  that includes one or more anchored zones  86  and one or more deactivated zones  88 . 
       FIGS. 19 and 20  show flattened representations of the respective circumferential faces of the first anvil  32  and the second anvil  160 , according to one embodiment of the invention. First anvil  32  includes a first pattern of projections  170  with anchoring weld lines  122  and break bars  128 . Second anvil  160  includes a second pattern of projections  172  that includes a series of laminating weld lines  130 . When anvils  32 ,  160  are operated in the manner described with respect to method  162  of  FIG. 18 , the first and second projection patterns  170 ,  172  form the elastic composite structure  138  shown in  FIG. 21 . In the illustrated embodiment, the break bars  128  shown in  FIG. 19  are not configured to form bonds between first and second web layers  12 ,  16  of the elastic composite structure  138  ( FIG. 21 ). In an alternative embodiment, the geometry of break bars  128  may be designed to form bond lines within the deactivated zone  88 . 
     An alternative two-stage bonding method  174  is illustrated in  FIG. 22 . Similar to method  162  of  FIG. 18 , technique  174  utilizes a pair of anvils  32 ,  160  arranged in series in the machine direction  14  to form the overall bond pattern. Methods  162 ,  174  differ from one another through the use of different patterns of projections on anvils  32 ,  160 . During a first step  176  of method  174 , a first portion of the overall bond pattern is formed using a first anvil  32  that includes a pattern of projections that forms intermediate product  178 . As shown in  FIG. 22 , the intermediate product  178  includes discrete anchored zones  86  that span the width of the product  178 . First anvil  32  also includes one or more break bar(s)  46  that sever the elastic and create one or more deactivated zones  88 . 
     During the second step  180  of method  174 , the overall bond pattern is completed using second anvil  160 , which includes anchoring weld lines  122  in addition to one or more laminating weld lines  130 . Second anvil  160  forms one or more laminating bonds  84  within the deactivated zones  88  and one or more additional anchored zones  86 , resulting in the elastic composite structure  138 . 
     Yet another alternative method  182  for forming elastic composite structure  138  is illustrated in  FIG. 23 . Method  182  utilizes a manufacturing line  10  that includes first anvil  32 , a cutting unit  184  positioned downstream from the anvil  32  as shown in  FIG. 1 , and a second anvil  160  positioned downstream from cutting unit  184 . A detailed view of a portion of cutting unit  184  is provided in  FIG. 24 , according to one embodiment of the invention. Cutting unit  184  includes a rotary knife roll  186  aligned with a rotary anvil  188 . A knife  190  is positioned within an insert  192  on the rotary knife roll  186 . An anvil insert  194  is inset within the rotary anvil  188 . Cutting unit  184  may include a single knife  190  and corresponding anvil insert  194  or multiple knife  190 /anvil insert  194  pairs spaced apart from one another around the respective faces of the knife unit  186  and rotary anvil  188 . Each rotary knife roll  186  and its corresponding rotary anvil  188  are spaced apart at a distance that defines a nip gap  196  between the knife  190  and the working surface  198  of the anvil insert  194 . In a preferred embodiment, the nip gap  196  is defined such that the force of the knife  190  on the anvil insert  194  is large enough to sever the elastic threads  18  without severing or creating slits in the first and second web layers  12 ,  16 . 
     In the illustrated embodiment, the working surface  198  of the anvil insert  194  is sloped between its leading edge  200  and trailing edge  202 . The sloped configuration of working surface  198  permits the size of the nip gap  196  to be adjusted by adjusting the phase or relative rotational position between the knife  190  and anvil insert  194 . In alternative embodiments, working surface  198  may be flat, curved, or any other geometry to facilitate the desired cutting functionality. Anvil insert  194  may be omitted entirely in another embodiment. Cutting unit  184  is described herein as a crush cut unit. In other embodiments, cutting unit  184  may be replaced with alternative types of cutting units known in the art, including units having rotary or non-rotary configurations and laser systems. 
     Referring again to  FIG. 23  in combination with  FIGS. 1-3  as appropriate, method  182  begins at step  204  using first anvil  32  to form discrete anchored bond zones  86  on intermediate product  206 . In one embodiment, anvil  32  includes a uniform pattern of anchoring welds  38  that extend around the circumferential face  40  of the anvil  32 . Horn  34  oscillates up and down in the direction of arrows  208 ,  210  ( FIG. 3 ) between a raised position and a lowered position during the bonding process. This oscillation may be carried out using a mechanical camshaft assembly coupled to the horn  34  or other known position control mechanism  67 . When horn  34  is in its lowered position, anchoring bonds  82  are formed within the desired anchored bond zones  86 . When horn  34  is in its raised position, horn  34  is moved out of communication with anvil  32  and a region  212  free of bonds is formed within the intermediate product  206 . At step  214  the partially bonded intermediate product  206  passes through cutting unit  184 , which severs one or more of the elastic threads  18  and forms one or more deactivated zones  88  in the resulting intermediate product  216 . Intermediate product  216  passes through second anvil  160  at step  218 , which includes a pattern of projections that includes anchoring weld lines and laminating weld lines that completes the bond pattern on the elastic composite structure  138 . 
       FIG. 25  depicts an alternative method  220  for forming elastic composite structure  138  using the optional cutting unit  184  and dual bonding apparatus  22 ,  156  arrangement of  FIG. 1 . For this method  220 , bonding apparatus  22  is outfitted with at least two horns  34 A,  34 B and an anvil  32  with a uniform pattern of anchoring welds  38  that spans the circumferential face  40  of the anvil  32 . During the first step  222  of the method  220 , an intermediate product  224  is formed by oscillating horn  34 B between raised and lowered positions in a similar manner as described with respect to step  204  of method  182  ( FIG. 22 ) to produce a region  226  free of bonds. At step  228 , the knife  190  (or knives) severs one or more of the elastic threads  18  and forms one or more deactivated zones  88  in the resulting intermediate product  230 . At step  232 , the second anvil  160  forms one or more laminating bonds within the deactivated zone  88  to complete the elastic composite structure  138 . 
     Beneficially, method  220  can be carried out to produce different sized end products without tooling changes by controlling time intervals in which the oscillating horn  34 B is held in the raised and lowered positions during step  222  and controlling the web speed relative to the rotational speed of the second anvil  160  in step  232 . More specifically, oscillating horn  34 B would be retained in the raised position for a longer time interval for a larger sized product vs. a smaller sized product to produce a longer region  226  free of bonds. During step  232 , the relative web-to-anvil speed would be controlled to form a pattern of laminating bonds that spans the resulting bond free region  226  by a desired amount. 
       FIGS. 26, 27, and 28  are exemplary flattened representations of the respective faces of first anvil  32 , knife unit  186  (of cutting unit  184  — FIG. 1 ), and second anvil  160  according to another alternative embodiment where the first anvil  32 , knife unit  186 , and second anvil  160  are positioned in the series arrangement shown in  FIG. 1  and operated according to a method that produces the elastic composite structure  138  shown in  FIG. 29 . First anvil  32  includes a first pattern of projections  234  that includes anchoring weld lines  122  that create the anchoring bond lines  134  in  FIG. 29 . In the illustrated embodiment, knife unit  186  includes two knives  190  that are oriented at an angle relative to the rotational axis of the knife unit  186 . In such case, the corresponding anvil inserts  194  ( FIG. 24 ) may be arranged at a similar angle relative to the rotational axis of the rotary anvil  188  ( FIG. 24 ). Knives  190  of knife unit  186  cut the elastic threads  18  and form the deactivated zone  88  of elastic composite structure  138 . The second anvil  160  ( FIG. 28 ) includes a second pattern of projections  236  with a series of laminating weld lines  130  that forms a series of laminating bond lines  136  ( FIG. 29 ) within the deactivated zone  88 . 
       FIG. 30  depicts a bonding apparatus  238  that can be used in manufacturing line  10  in place of bonding apparatus  22  to create an elastic composite structure  240  such as that shown in  FIG. 31 . In one embodiment, bonding apparatus  238  includes horn  34 , as described above, and an anvil  32  that includes at least one break bar  242  that spans the length of the pattern of anchoring welds  38  on the anvil  32 , similar to break bar  46  ( FIG. 2 ), or only a portion of the overall length, similar to break bar  128  ( FIG. 10 ). The first and second web layers  12 ,  16  and one or more tensioned elastic threads  18  are directed onto the face  40  of anvil  32  and into the gap  66  between anvil  32  and horn  34  either by a common guiding roller  244  or multiple rollers similar to those shown in  FIG. 3 . As one or more elastic threads  18  pass between a break bar  242  and horn  34 , the thread(s)  18  are cut. Immediately following the cut, a tensioning device  246  increases the tension of the cut thread(s)  18  so that they are pulled backward (upstream) across the face  40  of the anvil  32  toward the common guiding roller  244 . Frictional forces between the cut elastic thread(s)  18  and the first and second web layers  12 ,  16  prevent the cut elastic thread(s)  18  from retracting to a position upstream of the guiding roller(s)  244 . As the cut thread(s)  18  are retracted to a distance equal to the desired length  248  of the deactivated zone  88  via tensioning device  246 , anvil  32  continues to rotate in direction  250  and anchoring bonds  82  are formed that fuse the first and second web layers  12 ,  16  as the horn  34  engages anchoring welds  38  on the face  40  of anvil  32 . The deactivated zone  88  shown in  FIG. 31  is formed during the time period in which tensioning device  246  maintains the cut thread(s)  18  in a retracted position. 
     After a predetermined period of time has elapsed during which the cut thread(s)  18  retract to the trailing edge of the deactivated zone  88 , the tensioning device  246  adjusts the tension in the cut elastic thread(s)  18  to the original tensioned state, causing the cut elastic thread(s)  18  to resume downstream travel toward the horn  34 . After the severed end(s) of the cut elastic thread(s)  18  reach the horn  34 , they effectively rethread and are anchored in place relative to the first and second web layers  12 ,  16  by subsequently formed anchoring bonds. 
     In an alternative embodiment, horn  34  is replaced by a cutting knife (for example cutting unit  184  of  FIG. 24 ) and a horn  252  is positioned downstream of the cutting knife. One or more elastic threads  18  is severed using the cutting knife and subsequently slipped backward toward guiding roller(s)  244  by tensioning device  246  in a similar manner as described above. Once the cut elastic thread(s)  18  slips a distance equal to the length of the desired deactivated zone, tensioning device  246  adjusts the tension in the cut elastic thread(s)  18  so that the cut elastic thread(s)  18  resume travel between the first and second web layers  12 ,  16  across the anvil face  40 . Interaction between the horn  252  and anchoring welds  38  creates anchoring bonds  82  on the resulting elastic composite structure  240 . 
     In yet another alternative embodiment, tensioning device  246  is omitted and guiding roller  244  is replaced with an eccentric roller tensioner (not shown) that rotates to increase and decrease tension in the combined web/thread assembly  30  according to a timing pattern that is synchronized with when the elastic thread(s)  18  break. More specifically, eccentric roller tensioner is controlled to a decrease tension in the combined web/thread assembly  30  at or shortly after the time that the elastic thread(s)  18  are cut. Decreasing the tension in the combined web/thread assembly  30  reduces friction between the cut elastic thread(s)  18  and the first and second web layers  12 ,  16 , which allows the cut elastic thread(s)  18  to snap back toward the eccentric roller tensioner. Once the cut elastic thread(s)  18  slips a distance equal to the length of the desired deactivated zone, the eccentric roller tensioner is controlled to rotate to increase tension in the combined web/thread assembly  30 , thereby increasing friction between the cut elastic thread(s)  18  and the first and second web layers  12 ,  16 . The increased friction causes the cut elastic thread(s)  18  to resume travel along with the first and second web layers  12 ,  16  across the anvil face  40 . A deactivated zone  88  ( FIG. 31 ) that is free of elastic thread(s)  18  but includes bonds spaced at a similar spacing as anchoring bonds  82  is formed on the resulting elastic composite structure  240  in time interval during between when the cut elastic thread(s)  18  are cut and subsequently rethread. 
       FIG. 32  is a flattened representation of a portion of the circumferential face  40  of anvil  32  according to an embodiment where anvil  32  includes a pattern of projections  120  that form deactivated zones and anchored zones. The pattern of projections  120  includes multiple anchoring weld lines  122  that are spaced apart from one another along the circumferential axis  124  of the anvil face  40  that include anchoring welds  38 . The anchoring weld lines  122  define an anchoring region  126  of the projection pattern  120 . The pattern of projections  120  also includes a plurality of laminating weld lines  130  including laminating welds  44  that collectively define a deactivating region  132 . 
     As shown in  FIGS. 33 and 34 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  that mirrors the geometry of anchoring weld lines  122  and laminating weld lines  130  within the pattern of projections  120  of  FIG. 32 . In the embodiment shown in  FIG. 33 , when broken to create a non-elasticized or deactivation region, the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is unbounded by any laminating bond  84 . In the embodiment shown in  FIG. 34 , when broken to create a non-elasticized or deactivation region, the length of the elastic thread  84  provides that the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all but one space of the spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is positioned between only a single laminating bond  84  pair. 
       FIG. 35  is a flattened representation of a portion of the circumferential face  40  of anvil  32  according to an embodiment similar to that of  FIG. 32  except for the removal of on laminating weld line  130  within the deactivating region  132 . The missing laminating weld line  130  illustrated in  FIG. 35  corresponds with the second laminating weld line  130  adjacent to the anchoring region  126 . Thus, a larger gap between the first two laminating weld lines  130  is larger than the gaps between the remaining laminating weld lines  130 . In this manner, as illustrated in  FIG. 36 , when broken to create a non-elasticized or deactivation region, the length of the elastic thread  84  provides that the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all but one space of the spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is positioned between only a single laminating bond  84  pair even though the length of the relaxed portion illustrated in  FIG. 36  is longer than that illustrated in  FIG. 34 . Embodiments of the invention also contemplate the removal of additional neighboring laminating weld lines  130  such that the gap between the first two laminating weld lines  130  may be yet wider than that illustrated in  FIG. 36 . 
       FIG. 37  is a flattened representation of a portion of the circumferential face  40  of anvil  32  according to another embodiment of the invention. Similar to the anvil  32  illustrated in  FIG. 32 , the anchoring weld lines  122  include pairs of anchoring welds  38  in each weld line  122 . Laminating weld lines  130 , however, have a single laminating weld  44  in each weld line  130 . As illustrated in  FIG. 38 , neighboring pairs of laminating bonds  84  alternate accordingly on one side of the elastic thread  18  or the other. In this manner, no matter the length of the portion of the end of the relaxed portion of the elastic thread, the relaxed portion of the elastic thread is bounded at most by a single laminating bond  84 , and no facing pair of laminating bonds  84  limits movement of the elastic thread  18 . 
       FIG. 39  is a flattened representation of a portion of the circumferential face  40  of anvil  32  according to an embodiment similar to that of  FIG. 37  except for a different pattern or layout of the single laminating welds  44  of the laminating weld lines  130 . As illustrated in  FIGS. 39 and 40 , the single laminating welds  44  create a linear arrangement of the laminating bonds  84 . The laminating bonds  84  of  FIG. 40  bound the elastic thread  18  only on one side of the elastic thread  18 . In this manner, similar to the laminating bonds  84  of  FIG. 38 , and no facing pair of laminating bonds  84  limits movement of the elastic thread  18 . 
       FIG. 41  is a flattened representation of a portion of the circumferential face  40  of anvil  32  according to an embodiment where anvil  32  includes a pattern of projections  120  that form deactivated zones and anchored zones. The pattern of projections  120  includes multiple anchoring weld lines  122  that are spaced apart from one another along the circumferential axis  124  of the anvil face  40  that include anchoring welds  38 . The anchoring weld lines  122  define an anchoring region  126  of the projection pattern  120 . The pattern of projections  120  also includes a plurality of laminating weld lines  130  including laminating welds  44  that collectively define deactivating regions  132 . The embodiment illustrated in  FIG. 41  extends the embodiment illustrated in  FIG. 32  to more than two anchoring welds  38  in anchoring weld lines  122  and more than two laminating welds  44  in laminating weld lines  130 . While  FIG. 41  illustrates one possible projection pattern  120  defined by linear weld lines  130 , embodiments of the invention contemplate that other projection patterns  120  are within the scope of the present disclosure. These alternative patterns  120  may define linear or non-linear bond patterns on the elastic composite structure, including patterns that define a repeating sinusoidal or chevron pattern of bonds. As illustrated in  FIGS. 42-48 , respective top views are shown of a portion of respective continuous elastic composite structures manufactured using corresponding modified projection patterns of the rotary anvil of  FIG. 41 . 
     As shown in  FIG. 42 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  duplicating the pattern illustrated in  FIG. 33  across the cross-direction according to an embodiment of the invention. Accordingly, when broken to create a non-elasticized or deactivation region, the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is unbounded by any laminating bond  84 . 
     As shown in  FIG. 43 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  duplicating the pattern illustrated in  FIG. 34  across the cross-direction according to an embodiment of the invention. Accordingly, when broken to create a non-elasticized or deactivation region, the length of the elastic thread  84  provides that the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all but one space of the spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is positioned between only a single laminating bond  84  pair. 
     As shown in  FIG. 44 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  duplicating the pattern illustrated in  FIG. 36  across the cross-direction according to an embodiment of the invention. Accordingly, when broken to create a non-elasticized or deactivation region, the length of the elastic thread  84  provides that the portion of the elastic thread  18  not anchored by any anchoring bonds  82  relaxes or contracts such that the end of the relaxed portion retracts from all but one space of the spaces separating pairs of laminating bonds  84 . In this manner, the end of the relaxed portion of the elastic thread is positioned between only a single laminating bond  84  pair even though the length of the relaxed portion illustrated in  FIG. 44  is longer than that illustrated in  FIG. 43 . 
     As shown in  FIG. 45 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  similar to the pattern illustrated in  FIG. 38  across the cross-direction according to an embodiment of the invention. In this embodiment, no matter the length of the portion of the end of the relaxed portion of the elastic thread, the relaxed portion of the elastic thread is bounded at most by a single laminating bond  84 , and no facing pair of laminating bonds  84  limits movement of the elastic thread  18 . 
     As shown in  FIG. 46 , the bonding process creates an overall pattern of anchoring bonds  82  across the cross-direction and separated by deactivating regions  132 , which are defined between opposing single rows of laminating bonds  84 . In this manner, none of the elastic threads  18  is limited in its movement by both bonds  84  of any facing pair of laminating bonds  84 . 
     As shown in  FIG. 47 , the bonding process creates an overall pattern of anchoring bonds  82  across the cross-direction and separated by deactivating regions  132 , which include alternating rows of alternating laminating bonds  84 . In this manner, the end of any one of the relaxed portions of the elastic threads  18  is positioned at most between only a single laminating bond  84  pair. 
     As shown in  FIG. 48 , the bonding process creates an overall pattern of anchoring bonds  82  and laminating bonds  84  similar to the pattern illustrated in  FIG. 42  where every other row of laminating bonds  84  in each deactivating region  132  is removed as compared with that illustrated in  FIG. 42 . In this manner, the end of any one of the relaxed portions of the elastic threads  18  is positioned at most between only a single laminating bond  84  pair. 
     It is to be understood that the concepts described above with respect to the bond patterns of  FIGS. 32-48  may be extended to manufacture an end product with one or more anchored zones and one or more deactivated zones using an anvil with an alternative pattern of projections than those described above. Thus, it is contemplated that the pattern of projections on anvil may be modified from those shown herein to create an elastic composite structure that includes one or more anchored zone(s) and one or more deactivated zone(s) that vary in size and/or position relative to the embodiments specifically depicted herein to create alternative bond patterns within the anchored and/or deactivated zones. 
     The apparatus and methods described herein can be used to make elastic composite structures for waist regions, below-waist regions, and/or leg cuff regions of a single-piece or three-piece diaper, as non-limiting examples, without the use of glue. By eliminating the use of glue, the resulting elastic composite is softer to the touch and has a more uniform ruffling pattern in the cross-machine direction. The apparatus and methods described herein also provide various means for forming distinct elasticized (i.e., anchored) zones and non-elasticized (i.e., deactivated) zones in the resulting elastic composite without creating cuts or slits in the web layers. Accordingly, embodiments of the invention disclosed herein enable a manufacturing process that creates an end product that is structurally more robust and visually and tactilely more pleasing to the end customer than prior art approaches. 
     Therefore, according to one embodiment of the invention, an elastic composite structure includes a plurality of tensioned elastic threads, a first web layer positioned on a first side of the plurality of tensioned elastic threads, and a second web layer positioned on a second side of the plurality tensioned elastic threads. The elastic composite structure also includes a pattern of laminating bonds that fuse the first web layer to the second web layer within a deactivated zone of the elastic composite structure. The deactivated zone includes a cut end of a first portion of a tensioned elastic thread of the plurality of tensioned elastic threads and a cut end of a second portion of the tensioned elastic thread of the plurality of tensioned elastic threads. Neither the cut end of the first portion of the tensioned elastic thread nor the cut end of the second portion of the tensioned elastic thread is bounded by a pair of adjacent laminating bonds of the pattern of laminating bonds spaced at a distance less than a distance between adjacent threads of the plurality of tensioned elastic threads. The elastic composite structure further includes a pattern of anchoring bonds that fuse the first web layer to the second web layer within an anchored zone bounding opposing ends of the deactivated zone. The anchored zone includes a first plurality of bonds of the pattern of anchoring bonds arranged to anchor the first portion of the tensioned elastic thread to the first and second web layers and a second plurality of bonds of the pattern of anchoring bonds arranged to define pairs of bonds that anchor the second portion of the tensioned elastic thread to the first and second web layers. 
     According to another embodiment of the invention, a method of manufacturing an elastic composite structure includes positioning a tensioned elastic thread between a first web layer and a second web layer, fusing the first web layer to the second web layer to form an anchored zone comprising a plurality of discrete anchoring bonds that fuse the first web layer to the second web layer and anchor the tensioned elastic thread therebetween, and cutting the tensioned elastic thread to form a deactivated zone of the elastic composite structure that is free of the tensioned elastic thread, the deactivated zone positioned between adjacent portions of the anchored zone. The method also includes fusing the first web layer to the second web layer within the deactivated zone with a pattern of laminating bond and defining the position of the pattern of laminating bonds relative to a cut end of the tensioned elastic thread such that the cut end of the tensioned elastic thread does not extend into the pattern of laminating bonds in a machine direction. 
     According to yet another embodiment of the invention, a bonding apparatus for manufacturing an elastic composite structure comprising at least one elastic thread secured between a pair of facing web layers, the bonding apparatus includes a rotary anvil having a face with weld pattern comprising at least one anchoring region and at least one deactivating region. The at least one anchoring region includes a plurality of anchoring welds constructed to form anchoring bonds that fuse the pair of facing web layers together and anchor the at least one elastic thread in position relative to the pair of facing web layers. The at least one deactivating region includes a plurality of laminating welds constructed to form laminating bonds that fuse the pair of facing web layers together without anchoring the at least one elastic thread in position relative to the pair of facing web layers. The plurality of laminating welds are arranged in a zig-zag pattern within the at least one deactivating region. 
     While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.