Patent Description:
Various manufacturing equipment and processes employ a variety of techniques to transfer energy to an item, which can be for accomplishing different tasks. Energy transfer mechanisms can include apparatuses configured for cutting, sealing, embossing, pressure bonding, and ultrasonic bonding, to name a few. In the manufacturing of some absorbent articles, ultrasonic bonding equipment is one energy transfer apparatus that can be utilized for providing an ultrasonic bond on one or more components of an absorbent article. As one example, some absorbent articles include side panels having a side seam bond that can be formed by transferring ultrasonic energy from respective components of an ultrasonic bonding apparatus commonly referred to as an anvil and an ultrasonic horn across the web of material forming the side panels.

While current ultrasonic bonding equipment can provide sufficient bonds in some absorbent article configurations and manufacturing process conditions, increases in manufacturing speeds and/or absorbent article configuration can produce less than desirable bond strength in the material being bonded together. For example, some ultrasonic bonding equipment does not provide sufficient dwell time for the ultrasonic horn and anvil to provide energy to the material in which an ultrasonic bond is desired. Additionally, past ultrasonic bonding apparatuses that sought to increase the dwell time between the ultrasonic horn and anvil involve complicated systems with multiple components to move and/or manipulate the material that is to be bonded. <CIT> discloses an energy apparatus according to the preamble of claim <NUM> and a method of use thereof.

Thus, there is a desire for an improved energy apparatus and methods of providing energy to an item. More particularly, there is a desire for an improved ultrasonic bonding apparatus and methods of providing ultrasonic energy to an item.

According to a first aspect of the invention, there is provided an energy apparatus according to claim <NUM>.

According to a second aspect of the invention, there is provided a method for providing energy to an item according to claim <NUM>.

A full and enabling disclosure thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the disclosure.

In an embodiment, the present disclosure is generally directed towards an energy apparatus <NUM> for providing energy to an item <NUM>. In one preferred embodiment, the energy apparatus <NUM> can provide ultrasonic energy for ultrasonically bonding an item <NUM>. It is contemplated, however, that the energy apparatus <NUM> can provide different forms of energy to an item <NUM> to provide other mechanisms other than ultrasonic bonding including, but not limited to, thermal energy transfer for heat sealing, embossing, and cutting. The energy apparatus <NUM> can be utilized in various manufacturing environments and on various items. In one preferred embodiment, the energy apparatus <NUM> herein is discussed with respect to providing an ultrasonic bond on a component of an absorbent article <NUM>, such as a cross-directional pant ("CD pant") when the absorbent article <NUM> is still in the form of a web <NUM> of interconnected absorbent articles <NUM>. It is to be appreciated that the energy apparatus <NUM> can be utilized on other manufactured consumer goods, including, but not limited to, other personal care articles, consumer goods, and packaging.

Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present disclosure include such modifications and variations. When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles "a", "an", "the" and "said" are intended to mean that there are one or more of the elements. As used herein, the terminology of "first," "second," "third", etc. does not designate a specified order or that items referred to using such terms must be present sequentially, but is used as a means to differentiate between different features being described in the present disclosure. Many modifications and variations of the present disclosure can be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

The term "absorbent article" refers herein to an article which may be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles, as described herein, are intended to be discarded after a limited period of use instead of being laundered or otherwise restored for reuse. It is to be understood that the present disclosure is applicable to various disposable absorbent articles, including, but not limited to, diapers, diaper pants, training pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads or pants, incontinence products, including, but not limited to, adult fecal incontinence garments, medical garments, surgical pads and bandages, other personal care or health care garments, and the like without departing from the scope of the present disclosure.

The term "bonded" or "coupled" refers herein to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered bonded or coupled together when they are joined, adhered, connected, attached, or the like, directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. The bonding or coupling of one element to another can occur via continuous or intermittent bonds.

The term "film" refers herein to a thermoplastic film made using an extrusion and/or forming process, such as a cast film or blown film extrusion process. The term includes apertured films, slit films, and other porous films which constitute liquid transfer films, as well as films which do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

The term "meltblown" refers herein to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g., air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which can be a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in <CIT>. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than about <NUM> denier, and may be tacky and self-bonding when deposited onto a collecting surface.

The term "nonwoven" refers herein to materials and webs of material which are formed without the aid of a textile weaving or knitting process. The materials and webs of materials can have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") which can be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs can be formed from many processes such as, but not limited to, meltblowing processes, spunbonding processes, carded web processes, etc..

The term "spunbond" refers herein to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced by a conventional process such as, for example, eductive drawing, and processes that are described in <CIT>, <CIT>, <CIT>, <CIT> and <CIT>, <CIT>, <CIT>, and <CIT> Spunbond fibers are generally continuous and often have average deniers larger than about <NUM>, and in an embodiment, between about <NUM>, <NUM> and <NUM> and about <NUM>, <NUM> and <NUM>. Spunbond fibers are generally not tacky when they are deposited on a collecting surface.

Referring to <FIG>, an energy apparatus <NUM> configured for providing energy to an item being transferred over a rotatable drum <NUM> is shown. In the embodiment described herein, the energy apparatus <NUM> is configured to provide ultrasonic energy to a web <NUM> being transferred in a machine direction <NUM> that is a layered assembly of various non-woven materials, film, cellulosic and superabsorbent materials, which after being cut, will form discrete absorbent articles <NUM> after transferring beyond the rotatable drum <NUM>. In some embodiments, the web <NUM> can include a laminate of spunbond-meltblown-spunbond ("SMS") material and elastics (e.g., strands or sheets). The web <NUM> can be transferred to the rotatable drum <NUM> and removed from the rotatable drum <NUM> with known web handling equipment and processes, including, but not limited to conveyors <NUM> and rollers 22a, 22b. In one embodiment, the energy apparatus <NUM> can be configured to provide an ultrasonic bond to form a side seam <NUM> on each side of an absorbent article <NUM>, such as shown in <FIG>. For clarity of other components of the energy apparatus <NUM> as described herein, the web <NUM> is removed from its position over the rotatable drum <NUM> in <FIG> and is only shown in an upstream position prior to engaging the rotatable drum <NUM> and a downstream position after disengaging from the rotatable drum <NUM> in <FIG>. In the embodiment described herein, the energy apparatus <NUM> can form the side seam <NUM> on the web <NUM> before the web <NUM> is cut into discrete absorbent articles <NUM>, however, it is contemplated that the energy apparatus <NUM> can be configured to provide energy to discrete items, such as absorbent articles <NUM>, as well.

The energy apparatus <NUM> includes a first energy mechanism <NUM> and a second energy mechanism <NUM>. The first energy mechanism <NUM> can be configured to be mounted inside of the rotatable drum <NUM>, and as such, is not visible in <FIG>. However, <FIG> depict several first energy mechanisms <NUM>. As shown in the embodiment depicted in <FIG>, the energy apparatus <NUM> can include more than one first energy mechanism <NUM> and more than one second energy mechanism <NUM>. In some embodiments, the energy apparatus <NUM> can include two, three, four, five, six, or more pairs of first and second energy mechanisms <NUM>, <NUM>. For example, as shown in <FIG> and <FIG>, the energy apparatus <NUM> can include six pairs of first and second energy mechanisms <NUM>, <NUM> (it is to be noted that only one second energy mechanism <NUM> is depicted in <FIG>, for purposes of clarity). In such an embodiment, the rotatable drum <NUM> can be configured to include a shell <NUM> for each pair of first and second energy mechanisms <NUM>, <NUM>. As will be described in further detail below, each shell <NUM> can include a slot <NUM> (labeled in <FIG> and <FIG>) allowing for the respective first and second energy mechanism <NUM> to provide energy to the web <NUM>. For discussion throughout, any reference to a single first energy mechanism <NUM> or a single second energy mechanism <NUM> is to be intended to refer to all of such energy mechanisms <NUM>, <NUM> present in an embodiment, unless otherwise noted.

The first energy mechanism <NUM> is configured to be fixedly coupled to the rotatable drum <NUM> and rotate with the rotatable drum <NUM>. In other words, the first energy mechanism <NUM> is configured to rotate with the rotatable drum <NUM>, but remain stationary in the axial direction <NUM> and the radial direction <NUM>. As depicted in <FIG>, the first energy mechanism <NUM> can be disposed within at least a portion of a shell <NUM> of the rotatable drum <NUM>. The second energy mechanism <NUM> is configured to rotate around a circumference <NUM>, or outer surface, of the rotatable drum <NUM> as will be described in more detail below. In the embodiment described herein where the energy apparatus <NUM> is configured to provide ultrasonic energy to the web <NUM>, the first energy mechanism(s) <NUM> can be an ultrasonic horn and the second energy mechanism(s) <NUM> can be configured to be an anvil. Of course, it is contemplated that in an alternative embodiment the energy apparatus <NUM> could be configured such that the first energy mechanism <NUM> that is fixedly coupled to the rotatable drum <NUM> inside of the circumference (outer surface) <NUM> of the drum <NUM> could be an anvil and the second energy mechanism <NUM> that is configured to rotate around a circumference <NUM> of the drum <NUM> could be an ultrasonic horn.

As best illustrated in <FIG>, the energy apparatus <NUM> also includes a translation system <NUM>. As will be described in further detail below with respect to <FIG>, the translation system <NUM> can be configured to move the second energy mechanism <NUM> to a run condition setting end position that allows the second energy mechanism <NUM> and the first energy mechanism <NUM> to provide energy to the item <NUM> while there is no relative motion between the first energy mechanism <NUM> and the second energy mechanism <NUM>. The translation system <NUM> is configured to move the second energy mechanism <NUM> in an axial direction <NUM> and can be configured to move it in a radial direction <NUM>. The axial direction <NUM> is parallel to a longitudinal axis <NUM> of the rotatable drum <NUM>. The radial direction <NUM> is in a direction that is radial with respect to a center point CP (labeled in <FIG>) of the rotatable drum <NUM>. It is contemplated that the translation system <NUM> can be configured in various ways to move the second energy mechanism <NUM> in an axial direction <NUM> and the radial direction <NUM>, however, one preferred embodiment is depicted in the figures herein and is described below.

The translation system <NUM> includes a first drive-side cam <NUM> (depicted in <FIG>, <FIG>, and <FIG>) and at least one cam follower <NUM>, which is depicted in <FIG> and schematically in <FIG>. The cam follower <NUM> is configured to travel a path <NUM> provided by the first drive-side cam <NUM>. As illustrated in <FIG> and <FIG>, in a preferred embodiment the first drive-side cam <NUM> can be a rib cam, and thus, the path <NUM> can be provided by a rib <NUM> that encircles the first drive-side cam <NUM>. It is contemplated that the first drive-side cam <NUM> can be in the form of other types of cams, such as, but not limited to, a barrel cam.

The translation system <NUM> also includes a sled <NUM>. As illustrated in <FIG> and shown schematically in <FIG>, the sled <NUM> is coupled to the cam follower <NUM>, in this embodiment through connecting frame <NUM>, and is coupled to the second energy mechanism <NUM>. The rib <NUM> provides a path <NUM> that varies in axial position depending on its circumferential position, and thus, can help provide the axial movement of the second energy mechanism <NUM>. As shown in <FIG> and <FIG>, the sled <NUM> can be configured to move axially along rails <NUM> mounted on a housing <NUM>.

Further components of the translation system <NUM> are depicted in <FIG>. The translation system <NUM> can additionally include a second drive-side cam <NUM> (shown schematically in <FIG>). The translation system <NUM> can also include a first connecting link <NUM> that can be coupled to a second cam follower <NUM> and to the sled <NUM>. The second cam follower <NUM> can follow along a path provided by the second drive-side cam <NUM>. The translation system <NUM> can also include a second connecting link <NUM> that can be coupled to the first connecting link <NUM>. The translation system <NUM> can further include a third connecting link <NUM> that can be coupled to the second connecting link <NUM> and to the second energy mechanism <NUM> by being coupled to a frame <NUM>. As will be described further below, the second connecting link <NUM> can be configured to pivot about a first pivot point P1 and the third connecting link <NUM> can be configured to pivot about a second pivot point P2. The frame <NUM> can be configured to slide on rails <NUM> mounted to the sled <NUM> to provide for radial movement of the second energy mechanism <NUM>.

The translation system <NUM> can also include an actuator <NUM>. As depicted in <FIG>, the actuator <NUM> can be coupled to the first connecting link <NUM> and to the second connecting link <NUM>. The actuator <NUM> can maintain a desired angle α between the first connecting link <NUM> and the second connecting link <NUM> during the run condition setting of the energy apparatus <NUM>. As will be described in further detail below, the actuator <NUM> can be selectively retractable to pivot the second connecting link <NUM> about the first pivot point P1 and to pivot the third connecting link <NUM> about the second pivot point P2 between the second connecting link <NUM> and the third connecting link <NUM> to assist in raising the second energy mechanism <NUM> in the radial direction <NUM> when the energy apparatus <NUM> is desired to run in the thread-up condition setting.

The functioning of the energy apparatus <NUM> in a run condition setting will now be described with respect to <FIG>. For purposes of clarity, <FIG> only depict one second energy mechanism <NUM> of the embodiment of the energy apparatus <NUM> of <FIG> that includes six pairs of first and second energy mechanisms <NUM>, <NUM>. The associated first energy mechanism <NUM> is disposed within the rotatable drum <NUM>, as shown in <FIG> and rotates with the rotatable drum <NUM>. Although not depicted, the other additional pairs of first and second energy mechanisms <NUM>, <NUM> of the energy apparatus <NUM> can be configured to function in the same manner and positioning with respect to the discussion below. Of course, and as previously stated, the energy apparatus <NUM> of the present disclosure can be configured to include one or more pairs of first and second energy mechanisms <NUM>, <NUM>, depending on various factors, including, but not limited to, manufacturing space, running speed of the item <NUM>, diameter of the rotatable drum <NUM>, dimensions of the item <NUM> (e.g., the pitch of the absorbent articles <NUM> forming web <NUM>), and the desired amount of energy to be provided by the energy apparatus <NUM>.

As illustrated in <FIG>, the energy apparatus <NUM> can be described as passing through four phases (Phases <NUM>-<NUM>) during the run condition setting. <FIG> depicts the four phases as creating one full revolution that a first energy mechanism <NUM> (not visible in <FIG>) and a second energy mechanism <NUM> make around a center point CP of the rotatable drum <NUM>. Although each phase is shown as occupying approximately <NUM>/<NUM>th of a revolution (or about <NUM>°), the angular amount of each phase may vary depending on a variety of factors, including but not limited to, the speed of the item or web <NUM>, the desired energy transfer being applied to the item or web <NUM>, the diameter of the rotatable drum <NUM>, the dimensions of the item or web <NUM> (e.g., the pitch of the absorbent articles <NUM> forming web <NUM>), the location of the web as it engages with and disengages from the drum <NUM>, and the location of surrounding equipment (such as rollers 22a, 22b) near the rotatable drum <NUM>. In some embodiments, one or more phases of the four phases of the run condition setting may range from about <NUM>° to about <NUM>°, or more preferably from about <NUM>° to about <NUM>°. Thus, it is contemplated that one or more of the phases may utilize a greater or smaller amount of angular rotation around the rotatable drum <NUM> than other phase(s).

The first phase can occupy a portion of the rotation around the center point CP of the rotatable drum <NUM> that allows the web <NUM> to engage with and disengage from the rotatable drum <NUM> without interference from the second energy mechanism <NUM>. As shown in <FIG>, the web <NUM> depicted in the embodiment illustrated travels from the left-side of the figure over conveyor <NUM> and roller 22a, engages with the rotatable drum <NUM>, rotates with the rotatable drum <NUM> in a clock-wise fashion, and disengages from the rotatable drum <NUM> around the roller 22b.

The axial and radial positioning of the second energy mechanism <NUM> in phase <NUM> can be referred to as the run condition setting start position. As illustrated in <FIG>, which provides a side view showing the energy apparatus <NUM> of <FIG> as viewed from a downstream side of the rotatable drum <NUM>, the second energy mechanism <NUM> is positioned by the translation system <NUM> such that the second energy mechanism <NUM> is axially displaced from the web <NUM>, as well as roller 22b to allow clearance with the web <NUM> and roller 22b in the axial direction <NUM> as the second energy mechanism <NUM> rotates through phase <NUM>. The translation system <NUM>, as described above, allows for such movement in the axial direction <NUM> by the rib <NUM> on the first drive-side cam <NUM>. As the cam follower <NUM> rotates around the rib <NUM> on the first drive-side cam <NUM>, the path <NUM> of the rib <NUM> moves the cam follower <NUM> axially away from the web <NUM> on the rotatable drum <NUM>. Because the second energy mechanism <NUM> is coupled to the sled <NUM>, which in turn is coupled to the cam follower <NUM>, the second energy mechanism <NUM> moves in a similar axial fashion away from the web <NUM>. As also depicted in <FIG>, the second energy mechanism <NUM> can have a radial gap with the web <NUM> when positioned in the run condition setting start position. The axial and radial clearance of the second energy mechanism <NUM> from the web <NUM> allows the second energy mechanism <NUM> to rotate in a clock-wise fashion through phase <NUM> without interfering with the web <NUM>, roller 22b, or roller 22a as the second energy mechanism <NUM> moves towards the position illustrated in <FIG>.

<FIG> illustrates the second energy mechanism <NUM> as it moves towards the end of phase <NUM> of the run condition setting. <FIG> provides a side view showing the energy apparatus <NUM> of <FIG>, as viewed from an upstream side of the rotatable drum <NUM>. As illustrated in <FIG>, the second energy mechanism <NUM>, which is out of view but is coupled to the frame <NUM>, is still axially displaced from the web <NUM>. The path <NUM> (or profile) of the first drive-side cam <NUM> provides for this continued axial clearance of the second energy mechanism <NUM> as the second energy mechanism <NUM> moves through the first phase of the run condition setting. <FIG> provides a detailed view of the second energy mechanism <NUM> in its position from <FIG> and depicts that the second energy mechanism <NUM> includes a radial gap from the web <NUM>, similar to its radial position in <FIG>.

<FIG> depicts the second energy mechanism <NUM> in phase <NUM> of the run condition setting. The second energy transfer mechanism <NUM> moves in an axial direction <NUM> such that it extends over the rotatable drum <NUM> and over the web <NUM> in the second phase of the run condition setting. <FIG> provides a side view showing the energy apparatus <NUM> of <FIG>, as viewed from an upstream side of the rotatable drum <NUM> and depicts the second energy mechanism <NUM> extending over the drum <NUM> and web <NUM>. The cam follower <NUM> following the path <NUM> of the first drive-side cam <NUM> defined by the rib <NUM> provides for the axial movement of the sled <NUM> along rails <NUM>, and in turn, the axial movement of the second energy mechanism <NUM> which is coupled to the sled <NUM>. As depicted in <FIG>, in some embodiments the second energy mechanism <NUM> still can have a radial gap with the web <NUM> in the second phase of the run condition setting. In alternative embodiments, the energy apparatus <NUM> could be configured to move the second energy mechanism <NUM> in a radial direction <NUM> to reduce the radial gap between the second energy mechanism <NUM> and the web <NUM> in the second phase.

As illustrated in <FIG>, as the second energy mechanism <NUM> continues to rotate around the center point CP of the rotatable drum <NUM>, the second energy mechanism <NUM> enters phase <NUM> of the run condition setting. The third phase of the run condition setting can be the phase in which the first energy mechanism <NUM> and the second energy mechanism <NUM> provide energy to the item <NUM>, such as the web <NUM>. In the preferred embodiment being discussed herein, the first energy mechanism <NUM> and the second energy mechanism <NUM> provide ultrasonic energy to the web <NUM> to provide an ultrasonic bond to the web <NUM>. As discussed in the second phase shown in <FIG> and <FIG>, the second energy mechanism <NUM> can already be in position in the axial direction <NUM> for bonding in the third phase, as illustrated in <FIG>. However, as depicted in <FIG> and <FIG>, in the third phase of the run condition setting the second energy mechanism <NUM> can reduce the radial gap between the second energy mechanism <NUM> and the web <NUM> by moving the second energy mechanism <NUM> closer to the web <NUM> on the rotatable drum <NUM>, and in turn, closer to the first energy mechanism <NUM>. The energy can be provided to the web <NUM> from the first and second energy mechanisms <NUM>, <NUM> through a slot <NUM> in the shell <NUM> of the rotatable drum <NUM> depicted in <FIG> and <FIG>.

With reference to <FIG> and prior discussion of the translation system <NUM>, the preferred embodiment as illustrated herein is configured to move the second energy mechanism <NUM> in a radial direction <NUM> through the second drive-side cam <NUM>, the second cam follower <NUM>, and the series of connecting links <NUM>, <NUM>, <NUM> coupling the second cam follower <NUM> to the second energy mechanism <NUM>. As the second cam follower <NUM> follows the second drive-side cam <NUM>, the first connecting link <NUM> and the second connecting link <NUM> can each pivot about the first pivot point P1, with the angle α between the first connecting link <NUM> and the second connecting link <NUM> being maintained by the actuator <NUM>. As the second connecting link <NUM> pivots about the first pivot point P1, the third connecting link <NUM> can pivot about the second pivot point P2 to either raise or lower the frame <NUM> on the rails <NUM> mounted on the sled <NUM>. The second energy mechanism <NUM> can be coupled to the frame <NUM>, and thus, can be raised or lowered in the radial direction <NUM> with the frame <NUM>.

In some embodiments, the second energy mechanism <NUM> can be configured to move in the radial direction <NUM> such that in the end position of the run condition setting the second energy mechanism <NUM> can have an interference fit with the first energy mechanism <NUM> to assist with the energy transfer between the first and second energy mechanisms <NUM>, <NUM> and the web <NUM>. In some embodiments, the second energy mechanism <NUM> can be configured to apply pressure against the first energy mechanism <NUM> in the end position of the run condition setting. In such an embodiment, the actuator <NUM> can provide a dampening effect for the energy apparatus <NUM>. Of course, in some other embodiments, the second energy mechanism <NUM> can be configured to move in the radial direction <NUM> to an end position of the run condition setting and have some amount of radial clearance with the first energy mechanism <NUM> and still transfer energy to the web <NUM>.

Once the second energy mechanism <NUM> is moved into the end position in phase three for the run condition setting, the second energy mechanism <NUM> continues to rotate at the same speed as the first energy mechanism <NUM>, which itself is rotating with the rotatable drum <NUM>, such that there is no relative movement between the first energy mechanism <NUM> and the second energy mechanism <NUM> when the two energy mechanisms <NUM>, <NUM> are providing energy to the web <NUM>. This matching of speeds and paired rotation can increase the amount of time that the energy can be provided to the web <NUM> (e.g., "dwell time"). In the embodiment described herein wherein the energy apparatus <NUM> is providing ultrasonic energy to the web <NUM>, the increase in the amount of dwell time can lead to improved bond strength in the bond created in the web <NUM>, and in turn, an improved product such as an absorbent article <NUM> with a side seam bond <NUM>.

An additional benefit to the energy apparatus <NUM> as described herein is that the full length and width of the ultrasonic bond in the web <NUM> that is formed by a pair of the first energy mechanism <NUM> and the second energy mechanism <NUM> is formed for the entire dwell time. This can provide a more consistent bond with improved bond strength due to the increased dwell time.

Importantly, the energy apparatus <NUM> can be configured such that the second energy mechanism <NUM> is the component of the energy apparatus <NUM> that moves into radial position with respect to the first energy mechanism <NUM> for providing energy to the item <NUM>, rather than moving the first energy mechanism <NUM> from within the rotatable drum <NUM> to the second energy mechanism <NUM>. By configuring the second energy mechanism <NUM> to move radially and have the first energy mechanism <NUM> fixedly coupled to the rotatable drum <NUM> rather than radially moving the first energy mechanism <NUM>, the item <NUM> (such as web <NUM>) can remain in a fixed position relative to the circumference <NUM> of the rotatable drum <NUM>. This provides improved handling characteristics of the item <NUM> that can reduce the chance that the manufacturing process may need to be shut down due to a jam or improper phasing of the item or web <NUM>.

<FIG> and <FIG> illustrate phase four of the run condition setting of the energy apparatus <NUM>. With the bonding of the web <NUM> being completed in phase three, the second energy mechanism <NUM> can move in both a radial direction <NUM> and an axial direction <NUM> to provide clearance for the web <NUM> as it prepares to disengage from the rotatable drum <NUM>. As depicted in <FIG> and <FIG>, the second energy mechanism <NUM> can move both axially and radially via the translation system <NUM> as described above to provide this clearance in phase four. As can be seen in <FIG>, the rib <NUM> on the first drive-side cam <NUM> guides the cam follower <NUM> (labeled in <FIG>) away from the rotatable drum <NUM> in the axial direction <NUM>. As a result, the sled <NUM> can slide on the rails <NUM> to move the frame <NUM> and the second energy mechanism <NUM> in the axial direction <NUM>. Additionally, the frame <NUM> can move in a radial direction <NUM> away from the circumference <NUM> of the rotatable drum <NUM> by sliding on the rails <NUM>, increasing the radial clearance of the second energy mechanism <NUM> from the web <NUM> and the rotatable drum <NUM>. This radial movement can be accomplished similar to that as described above in <FIG>, but in a way to move the second energy transfer mechanism <NUM> away from the rotatable drum <NUM>. As discussed above and as labeled in <FIG>, the second cam follower <NUM> can follow the second drive-side cam <NUM> and the first connecting link <NUM> and the second connecting link <NUM> can each pivot about the first pivot point P1, with the angle α between the first connecting link <NUM> and the second connecting link <NUM> being maintained by the actuator <NUM>. As the second connecting link <NUM> pivots about the first pivot point P1, the third connecting link <NUM> can pivot about the second pivot point P2 to raise the frame <NUM> on the rails <NUM> mounted on the sled <NUM>. The second energy mechanism <NUM> can be coupled to the frame <NUM>, and thus, can be raised in the radial direction <NUM> with the frame <NUM>. In moving both axially and radially, the second energy mechanism <NUM> can return to the run condition starting position at the end of phase four so that the four phase run condition can begin again, starting with phase <NUM> as described above with respect to <FIG> and <FIG>.

The energy apparatus <NUM> can also be configured to include an additional benefit by having the second energy mechanism <NUM> be selectively rotated around the center point CP of the circumference <NUM> of the rotatable drum <NUM> in either the run condition setting (as described above) or a thread-up condition setting. The thread-up condition setting of the energy apparatus <NUM> can provide additional radial clearance for the web <NUM> as the second energy mechanism <NUM> rotates around the center point CP of the rotatable drum <NUM>. The thread-up condition setting of the energy apparatus can be beneficial to be selected when starting up a machine line including the energy apparatus <NUM> until proper phasing and speed is achieved to place the energy apparatus in a run condition setting.

<FIG> and <FIG> illustrate the movement of the second energy mechanism <NUM> between a run condition setting start position (<FIG>) and a run condition setting end position (<FIG>). As described above with respect to <FIG>, the second energy mechanism <NUM> can rotate around a center point CP of the circumference <NUM> of the rotatable drum <NUM> through four phases of the run condition setting and can move in both the axial direction <NUM> and the radial direction <NUM>. The run condition setting end position, as illustrated in <FIG>, can occur when the first and second energy mechanisms <NUM>, <NUM> are providing energy to the web <NUM> in phase <NUM> of the run condition setting. Depending on the desired settings for the energy transfer, the radial gap <NUM> between the second energy mechanism <NUM> and the circumference <NUM> of the rotatable drum <NUM> (and the first energy mechanism <NUM>) can vary, however, the radial gap <NUM> must be close enough to effect the desired energy transfer between the second energy mechanism <NUM> and the first energy mechanism <NUM>.

<FIG> and <FIG> illustrate the movement of the second energy mechanism <NUM> between a thread-up condition setting start position (<FIG>) and a thread-up condition setting end position (<FIG>). In the thread-up condition setting, the second energy mechanism <NUM> can rotate around a center point CP of the circumference <NUM> of the rotatable drum <NUM> through four phases similar to that as described above for the run condition setting, however, the thread-up condition setting is configured to not complete any bonding during phase three. Instead, the thread-up condition setting of the energy apparatus <NUM> is configured to have an increased radial gap between the second energy mechanism <NUM> and the rotatable drum <NUM> (or the first energy mechanism <NUM>) in the third phase of rotation around the center point CP of the circumference <NUM> of the rotatable drum <NUM> to provide clearance for the web <NUM> to rotate around the rotatable drum <NUM>. Comparing the thread-up condition setting end position of <FIG> to the run condition setting end position of <FIG>, it can be seen that a radial gap <NUM> between the second energy mechanism <NUM> and the rotatable drum <NUM> at the thread-up condition setting end position is greater than a radial gap <NUM> between the second energy mechanism <NUM> and the rotatable drum <NUM> at the run condition setting end position.

The energy apparatus <NUM> can be configured to transition between the run condition setting and the thread-up condition setting based on the configuration of the translation system <NUM>. In the run condition setting as illustrated in <FIG> and <FIG>, the actuator <NUM> can be extended and can maintain an angle α between the first connecting link <NUM> and the second connecting link <NUM>. In the thread-up condition setting, the actuator <NUM> can be actuated such that its length is shortened and an angle β is maintained between the first connecting link <NUM> and the second connecting link <NUM>, with angle β being less than angle α. By actuating the actuator <NUM> in this manner, the energy apparatus <NUM> can be selectively run between the run condition setting and the thread-up condition setting. As illustrated in <FIG>, the second energy mechanism <NUM> can be configured such that a radial distance of movement of the second energy mechanism <NUM> in the run condition setting is substantially the same as a radial distance of movement of the second energy mechanism <NUM> in the thread-up condition setting. Additionally, the second energy mechanism <NUM> can be configured such that an axial distance of movement of the second energy mechanism <NUM> in the run condition setting is substantially the same as an axial distance of movement of the second energy mechanism <NUM> in the thread-up condition setting.

Claim 1:
An energy apparatus (<NUM>) configured for providing energy to an item (<NUM>) being transferred over a rotatable drum (<NUM>), the energy apparatus comprising:
a first energy mechanism (<NUM>) configured to be fixedly coupled to the rotatable drum and rotate with the rotatable drum;
a second energy mechanism (<NUM>) configured to rotate around a circumference (<NUM>) of the rotatable drum; and
a translation system (<NUM>) coupled to the second energy mechanism and configured to move the second energy mechanism to an end position that allows the second energy mechanism and the first energy mechanism to provide energy to the item while there is no relative motion between the first energy mechanism and the second energy mechanism, and characterised in that the translation system comprises:
a first drive-side cam (<NUM>);
at least one cam follower (<NUM>) configured to travel along a path (<NUM>) of the first drive-side cam; and
a sled (<NUM>) coupled to the cam follower and to the second energy mechanism (<NUM>);
wherein the translation system is configured to move the second energy mechanism (<NUM>) in an axial direction (<NUM>), the axial direction being parallel to a longitudinal axis (<NUM>) of the rotatable drum, using the at least one cam follower.