Patent Description:
Garments, such as absorbent articles, often include fastening systems such as hook and loop fastenings systems to secure portions of the garments to one another. Such garments may include disposable diapers. Manufacturing processes may be used to form the fastening systems at a rate of throughput that manufacturers may seek to improve.

Accordingly, a need exists for alternative methods to efficiently form fastening systems, in particular fastening elements such as hooks, on a garment.

The invention comprises the features of the independent claim herein. A method for mechanically forming one or more surface protrusions integrally from a garment material, the one or more surface protrusions extending outwardly from a garment surface of the garment material, comprises placing at least one selected area of the garment surface against a first surface of a forming die. The first surface has a plurality of openings which have a configuration and orientation corresponding with the configuration and orientation of the one or more surface protrusions of the garment material. The method further comprises softening the garment surface by application of a source of ultrasonic energy, positioning at least some of the softened garment surface into at least one opening of the plurality of openings from the first surface of the forming die, and separating the forming die from the garment surface to form the one or more surface protrusions. The source of energy comprises at least two sonotrodes mounted about a rotary drum. Documents <CIT>, <CIT>, <CIT> and <CIT> disclose relevant prior art.

Reference will now be made in detail to embodiments of surface protrusion formation systems and methods of manufacture, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. Various embodiments of surface protrusion formation systems will be described in further detail herein with specific reference to the appended drawings.

"Absorbent article" refers to devices which absorb and contain body exudates and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Exemplary absorbent articles include diapers, training pants, pull-on pant-type diapers (i.e., a diaper having a pre-formed waist opening and leg openings such as illustrated in <CIT>), refastenable diapers or pant-type diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene garments such as panty liners, absorbent inserts, and the like.

<FIG> generally depicts a garment material of a garment such as an absorbent article, shown in the form of a diaper <NUM>. A portion of the garment material may be formed of a substrate, and one or more surface protrusions <NUM> may extend outwardly from a garment surface of the garment material. The surface protrusions <NUM> may provide primary fastening functions on garments, such as, for example, a diaper, a body wrap, and a sanitary napkin. The diaper <NUM> may include a liquid impervious topsheet <NUM>, a liquid impervious backsheet <NUM>, and an absorbent core <NUM>. The diaper <NUM> includes a primary fastening system <NUM> that may include the surface protrusions <NUM>.

In embodiments in which primary fastening systems function to maintain the absorbent article secured about the waist of the wearer, the surface protrusions <NUM> may be disposed on the body facing surface of the garment. The surface protrusions <NUM> may be disposed on the fastening tape attached to the garment.

The diaper <NUM> may also comprise a secondary fastening system <NUM> which may include surface protrusions <NUM> to provide a secondary anchoring about the waist and to prevent shifting of overlapped portions of the diaper <NUM> during use. The fastening systems described herein may include hook and loop fasteners for securing one portion of a body wrap of the diaper <NUM> to itself to provide primary securement of the body wrap to the wearer.

One or both of the primary and the secondary fastening systems may include other elements, such as, for example, pressure sensitive adhesives, other mechanical fasteners, or the like.

The surface protrusions <NUM> may also or alternatively be disposed on the outer surface of the garment in a position to maintain the garment in a disposal configuration. The surface protrusions <NUM> may be used with many other tape designs to secure the garment for disposal, including disposal tape systems disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> and publications <CIT> and <CIT>.

The surface protrusions <NUM> may be engaged with protrusion receiving zones to connect one portion of the garment to another portion of the garment. The garment may include at least one protrusion receiving zone <NUM>, as shown in one example in <FIG>. The protrusion receiving zone <NUM> provides a location at which surface protrusions <NUM> connect at least one portion of the garment to at least one another portion of the garment. The relative positions of surface protrusions <NUM> and protrusion receiving zone <NUM> can vary on the garment. In an embodiment, the surface protrusions <NUM> may be disposed on the body facing surface of the garment, and the protrusion receiving zone <NUM> may be disposed on the outer surface of the garment. Alternatively, the protrusion receiving zone <NUM> may be disposed on the body facing surface of the garment and/or the surface protrusions <NUM> may be disposed on the outer surface of the garment. The protrusion receiving zone <NUM> may be a separate piece of material added to the diaper <NUM> or may be an integral or monolithical part of the diaper <NUM>, including but not limited to the topsheet <NUM>, the backsheet <NUM>, the leg cuff, or the waistband.

The protrusion receiving zone <NUM> may include any suitable material that engages with the surface protrusions <NUM>. In an embodiment, the protrusion receiving zone <NUM> of <FIG> may comprise fiber loops or at least one nonwoven layer of material. As a non-limiting example, the protrusion receiving zone <NUM> may include a nonwoven substrate <NUM> as shown in <FIG>. Referring to <FIG>, the nonwoven substrate <NUM> may be applied in overlying relationship to the outwardly-facing surface of a polymeric layer <NUM> to provide a plurality of loops that may define spaced open areas bounded by interengaged individual fibers.

The term "nonwoven" or "non-woven" refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. In some configurations, a nonwoven may comprise a polyolefin based nonwoven, including but not limited to nonwovens having polypropylene fibers and/or polyethylene fibers and/or bicomponent fibers comprising a polyolefin. Nonlimiting examples of suitable fibers include spunbond, spunlaid, meltblown, spunmelt, solvent-spun, electrospun, carded, film fibrillated, melt-film fibrillated, air-laid, dry-laid, wet-laid staple fibers, and other nonwoven web materials formed in part or in whole of polymer fibers as known in the art, and workable combinations thereof. Nonwovens do not have a woven or knitted filament pattern. It is to be appreciated that nonwovens having various basis weights can be used in accordance with the methods herein. In embodiments, bicomponent fibers of the nonwoven material may include additives to be configured to more easily be susceptible to heating such as through infrared, which may aid with, for example, pre-heating or other heating of the nonwoven material as described herein.

As shown in <FIG>, a first area including the surface protrusions 102B engage with a second area including the protrusion receiving zone <NUM> in inwardly adjacent the surface protrusions 102C, which may be disposed on a tape. Engaging the first area including surface protrusions 102B with the second area including the protrusion receiving zone <NUM> may provide a minimal resistance to peel mode disengagement and may cause an increase in friction or shear mode disengagement resistance between the portions of the garment being engaged. The surface protrusions <NUM> of the primary fastening system <NUM> of a rear waist region may engage with the protrusion receiving zone <NUM> of a front waist region, and the surface protrusions <NUM> of the secondary fastening system <NUM> of the front waist region may engage with the protrusion receiving zone <NUM> of the rear waist region.

<FIG> depicts a non-limiting example of a configuration of features for diapers with hook-and-loop fastening systems. A disposable diaper such as the diaper <NUM> may include, as shown in <FIG>, a front waist region <NUM>, a rear waist region <NUM>, a front waist edge <NUM>, and a rear waist edge <NUM>. A liquid-impermeable backsheet <NUM> may form the liquid impervious backsheet <NUM> of the diaper <NUM> and a large portion of the outward-facing surfaces. The front waist region <NUM> may include a landing zone <NUM> formed by, or including, a section of web material <NUM> on which one or more areas of hooks 212F of the surface protrusions <NUM> are integrally molded. The section of web material <NUM> may be adapted to serve as a section of loops material <NUM> with a pattern of bonds so as to fastenably engage with areas or patches of hooks 212R attached to or integrally molded on fastening members <NUM>. The fastening members <NUM> may similarly be formed at least in part of a section of web material adapted to serve as the loops material <NUM> to fastenably engage with hooks 212F. In such a configuration, two pairs of hook-and-loop combinations engage each other as fastening pairs.

Referring to <FIG>, the surface protrusions <NUM> may have one or more of a cross-sectional configuration, a height, a width, a length, an angular inclination, and a hook end configuration. The one or more surface protrusions <NUM> may be hooks formed normal to or at angle with respect to a garment surface of a garment material. Further, the one or more surface protrusions <NUM> as described herein may be of various modifiable configurations in any directionality of the hook end with respect to the garment surface, such as a left, right, angled, curved, or straight up direction. A surface protrusion <NUM> may be a projection <NUM> that is normal to the garment surface as shown in <FIG>. The cross-sectional configuration of surface protrusions <NUM> in <FIG> is shown as a sectional view taken generally perpendicular to a surface <NUM> of a garment material <NUM> so to divide an individual surface protrusion 102A into equal halves, extending generally parallel to a direction defined by a projection of an individual surface protrusion 102A on surface <NUM>. A further cross-sectional configuration of the surface protrusions <NUM> is a sectional view taken generally parallel to the surface <NUM> of the garment material <NUM>. The further cross-sectional configuration may be of any configuration, for example, a circle, an ellipse, an oval, a triangle, a square, a rectangle, an elongated rectangle and a polygonal. The further cross-sectional configuration can be substantially consistent dimension-wise throughout the height H of the individual surface protrusion 102A, or it can be substantially tapered by being larger at the surface of the garment material <NUM>.

The height H of surface protrusions <NUM> is the distance taken generally perpendicular between the surface <NUM> of the garment material <NUM> and the highest point of the individual surface protrusion 102A extending above the surface <NUM>. The width W of the surface protrusions <NUM> is taken from the base of the individual surface protrusion 102A in a direction defined by a projection of the individual surface protrusion 102A on the surface <NUM> of the garment material <NUM>. An angular inclination <NUM> of the surface protrusions <NUM> may be relative to the surface <NUM> of the garment material <NUM>. Distal end forms <NUM> of the surface protrusions <NUM> may have various configurations as illustrated by the non-limiting examples of <FIG>.

Referring to <FIG>, a schematic side view of an apparatus for forming protrusions on an advancing substrate is shown. As shown in <FIG>, a continuous substrate <NUM> may advance in a machine direction (MD) adjacent a protrusion forming apparatus or system <NUM> that is configured to form discrete zones <NUM> of first body parts <NUM> and distal hook ends <NUM> at respective distal ends <NUM> on the substrate <NUM>. The substrate may comprise polymeric material. The substrate may comprise a nonwoven, a film or combinations thereof. In nonlimiting examples, the substrate comprises a nonwoven. In particular, the protrusion forming apparatus or system <NUM> includes energy source <NUM> and a die surface <NUM>. The energy source <NUM> applies energy to the advancing substrate <NUM> such that softened material of the substrate <NUM> may be pressed or otherwise move or flow into the openings (e.g., cavities <NUM>) of the die surface <NUM> to form a zone <NUM> of surface protrusions <NUM>, <NUM>, <NUM>. In turn, the surface protrusions <NUM> are formed directly from and integrally with the material of the substrate <NUM>. It is to be appreciated that various configurations of protrusion forming systems <NUM> may be used to integrally mold surface protrusions <NUM> directly on a substrate <NUM>, wherein the substrate material may serve not only as a structural component material for other purposes, but also as a source of material, such as a polymer for example, for formation of the surface protrusions <NUM>.

The substrate <NUM> may advance through a nip <NUM> between the energy source <NUM> and the die surface <NUM>. As shown in <FIG>, the substrate <NUM> may also define a width extending in the cross direction CD between longitudinal side edges <NUM>. Referring again to <FIG>, before, during, or after forming the discrete zones <NUM> of surface protrusions <NUM>, it is to be appreciated that the substrate <NUM> may be subjected to additional manufacturing operations, such as combining, bonding, printing, cutting and/or folding operations. The substrate <NUM> with the protrusions formed thereon may advance to a cutter apparatus that separates the continuous substrate <NUM> into separate pieces <NUM> as discrete parts of the substrate <NUM>. In other configurations, an apparatus assembly <NUM> including the system <NUM> may be configured with one or more bonding devices adapted to bond substrates <NUM>, <NUM>, including a first substrate <NUM> and a second substrate <NUM>, together with an applied adhesive, pressure, heat, and combinations thereof and/or other suitable bonding techniques. In embodiments, the substrate <NUM> may advance through an accumulator apparatus <NUM> that decelerates a portion 200a of the substrate <NUM> to a second speed S2 less than a first speed S1. The processing lines of the apparatus assembly <NUM> may include an accumulator apparatus <NUM> that decelerates a portion 200a of an advancing substrate <NUM> from the first speed S1 to the second speed S2 while advancing past the protrusion forming system <NUM>.

The energy source <NUM> may be configured to heat and/or otherwise apply energy to soften material of the substrate <NUM> such that the softened material may be pressed, drawn, or otherwise moved into the cavities <NUM> of the die surface <NUM> to form the surface protrusions <NUM> as described herein on the substrate <NUM>. In some configurations, as the substrate <NUM> advances through the nip <NUM>, heating of the polymeric material of the filaments, by application of heating energy, softens the material so that the material may be deformed and forced in the nip <NUM> and into the cavities <NUM> of the die surface <NUM>. In some configurations, the die surface <NUM> may be cooled or otherwise temperature-controlled to help assure that the finished substrate <NUM> will advance from the nip <NUM> with formations of surface protrusions <NUM> that are stably formed and solidified. The formed surface protrusions <NUM> and areas thereof on the substrate <NUM> will be molded from and thereby physically integral with material(s) of which the substrate is formed. The zone <NUM> of surface protrusions <NUM> may approximately correspond with the arrangement and features of the cavities <NUM> in the die surface <NUM>.

The energy source <NUM> as presently claimed comprise at least two sonotrodes mounted in a rotary drum. In embodiments, the energy source <NUM> may include an ultrasonic horn <NUM> having an energy transfer surface <NUM>. As such, the ultrasonic horn <NUM> may be configured to impart ultrasonic energy to the substrate <NUM> advancing through the nip <NUM>. For example, the substrate <NUM> may advance through the nip <NUM> such that the second surface <NUM> of the substrate <NUM> is arranged in facing relationship with the die surface <NUM>. In turn, the ultrasonic horn <NUM> may apply energy to the first surface <NUM> of the substrate <NUM> advancing through the nip <NUM>. Energy from the ultrasonic horn <NUM> softens material of the substrate <NUM> and such softened material moves into the cavities <NUM> to form surface protrusions <NUM> that extend outward from the second surface <NUM> of the substrate <NUM>. It is to be appreciated that aspects of the ultrasonic horn <NUM> may be configured in various ways, such as for example linear or rotary type configurations. In some configurations, the ultrasonic horn <NUM> may be configured as a linear oscillating type sonotrode. In some configurations, the sonotrode may include a plurality of sonotrodes nested together in the cross direction CD.

The die surface <NUM> and/or the cavities <NUM> therein may be configured in various ways. For example, the protrusion forming apparatus <NUM> may include a roll <NUM> with an outer circumferential <NUM> surface adapted to rotate about an axis <NUM> of rotation. In turn, the die surface <NUM> may be formed to define a portion of the outer circumferential surface <NUM> of the roll <NUM>. During protrusion forming operations, the substrate <NUM> may advance through the nip <NUM> with the second surface <NUM> in a facing relationship with the outer circumferential surface <NUM> of the rotating roll <NUM>. In embodiments, the roll <NUM> may define various cross sectional shapes, such circular or oblong and/or may be configured to constantly or intermittently contact the substrate <NUM> advancing through nip <NUM>.

Referring to <FIG>, a portion of a substrate <NUM> is a thermoplastic material substrate. The portion of the substrate <NUM> as referenced herein to form the one or more surface protrusions <NUM> includes the garment material <NUM> such that a referenced surface <NUM> of the garment material <NUM> is also the surface <NUM> of the substrate <NUM>. The portion of the substrate <NUM> of <FIG> is in contact with the molding roll <NUM> and vibrating energy source <NUM> and may be softened by the vibration energy from the energy source <NUM> and a desired portion of the thermoplastic material caused to enter into one or more cavities <NUM> of the molding roll <NUM> forming hook-shaped or otherwise shaped elements or projections <NUM> on the surface of a substrate <NUM> as the roll turns in a rotary forming process. In the rotary forming process, a requisite amount of pressure may be applied to the thermoplastic material to assist in its entry and fill-out of the cavities <NUM>. The remaining portions of the thermoplastic substrate <NUM> may function as a carrying strip for the hook projections <NUM>.

<FIG> depicts a forming die as the roll <NUM> including openings as cavities <NUM> formed from a stacked disc configuration. <FIG> shows a detailed view of a portion of the openings as a pair of cavities <NUM> of the roll <NUM>. The pair of cavities <NUM> may be spaced apart at an inclined angle <NUM>. In an embodiment, the inclined angle may be at a <NUM> degrees level of inclination between initial edge portions of the pair of cavities <NUM>.

Referring to <FIG>, a side view is depicted of yet another apparatus for forming protrusions on an advancing substrate <NUM> including a conveyor assembly <NUM> and linear die as a linear molding roll <NUM>. The conveyor assembly <NUM> includes and advances the linear molding roll <NUM> in a machine direction, and the substrate advances in a linear direction to at times be disposed between the linear molding roll <NUM> and an energy source <NUM>. One or more linear molding rolls <NUM> may be included on the conveyor assembly <NUM>. Each linear molding roll <NUM> may include the same or different configurations of the plurality of openings. As a non-limiting example, the linear molding roll <NUM> includes cavities <NUM> to form the surface protrusions <NUM> as projections <NUM> shown on the substrate <NUM> by use of the energy source <NUM>. The speed of the linear molding roll may be slowed or paused when forming the surface protrusions <NUM>. The energy source <NUM> may include modules 602A, 602B, and 602C. The energy source <NUM> may include the separate modular units to assist with maintaining a straight alignment of portions of the substrate <NUM> with respect to respective portions of modules 602A, 602B, and 602C of the energy source <NUM> during energy application to and movement of the substrate <NUM> in the machine direction and further allow for an extended contact time between the energy source <NUM> and the substrate <NUM>.

The energy source may be configured as a sonotrode to act as a heat control loop in which a heat control system is communicatively coupled to the sonotrode. The heat control system may be configured to detect when the sonotrode is overheating above a desired temperature and/or to the cool the sonotrode, such as with ambient air. It is contemplated and within the scope of this disclosure that such heat control systems may be used with other sources of energy as described herein.

In embodiments, a forming die may be configured to provide heating, cooling, or combinations thereof. The forming die may be formed of copper, steel, or combinations thereof configured to effect such heating and/or cooling changes. Other types of materials may be used as suitable and understood to those skilled in the art to effect such heating and/or cooling changes with other thermal growth rates or capacities and/or different metallurgies to treat air resistance on the surface of the forming die. The forming die may be configured to include an exterior copper surface and a plurality of openings as cavities <NUM> formed of steel. In embodiments, the cavities <NUM> may be coated to aid with release of the formed surface protrusions <NUM> from respective cavities <NUM>. The cavities and/or portions of the exterior surface could have a permanent or renewable release agent, e.g., a fluorochemical or silicone. A renewable release agent can be added continuously in the process at a low add-on level. A suitable renewable release agent is described in <CIT>. Permanent release coatings for process components are also known to the art and typically comprise fluoropolymers or silicone resins. Additionally, or alternatively, the forming die may be configured to aid with cooling that aids in shrinkage, which helps to release the formed surface protrusions <NUM> with minimum or without deformation upon release.

The forming die may be configured to be heated when forming the one or more surface protrusions <NUM> and cooled when releasing the formed one or more surface protrusions <NUM>. The forming die may include one or more temperature zones, such as one or more heating or cooling zones. The forming die may be configured to provide cooling through fluid such as glycol or other cooling media, air blasts, a cooling surface, or combinations thereof. In an embodiment, prior to formation of the surface protrusions <NUM>, an infrared source may be used to heat a die surface to conduct a heated temperature into the garment material <NUM> disposed on the forming die to assist with reducing an amount of energy needed to soften the garment material <NUM> to form the protrusions <NUM>.

In the embodiments of <FIG>, views of linear die conveyor systems <NUM>, <NUM>, and <NUM> are shown to form surface protrusions on discrete portions of a substrate <NUM> that are depicted as discrete substrates <NUM> that may be cut portions of the substrate <NUM>. While discrete substrates <NUM> are shown in a standing configuration, and may be disposed around another longitudinal apparatus in the standing configuration, it is contemplated by this disclosure that the discrete substrates <NUM> may be disposed in a flat configuration along an assembly line prior to receipt by a linear molding roll as described herein.

Referring to <FIG>, a side perspective view of a linear die conveyor system <NUM> is shown. The linear die conveyor system <NUM> includes an energy source <NUM>, a linear molding roll 604A, and a conveyor assembly 606A. The linear molding roll 604A is disposed on the conveyor assembly 606A, which moves in a rotational direction about an axis. Discrete substrates <NUM> as pieces of a substrate <NUM> advance along an assembly, such as another conveyor assembly, for receipt within respective discrete substrate receiving slots <NUM> of the linear molding roll 604A. At a position when the linear molding roll 604A is disposed in a facing relationship to the energy source <NUM>, the energy source <NUM> is configured to soften discrete substrates <NUM> disposed in discrete substrate receiving slots <NUM> of the linear molding roll 604A. The linear molding roll 604A includes cavities to form surface protrusions <NUM> as described herein. The softened substrates <NUM> are advanced to be disposed onto another assembly, which may be another conveyor assembly, of the linear die conveyor system <NUM> to advance to a next stage. In an embodiment, the softened substrates <NUM> may be advanced to a stage at which the discrete units with the formed surface protrusions are adhesively applied to a diaper.

Referring to <FIG>, a side perspective view of another linear die conveyor system <NUM> is shown. In <FIG>, a rear perspective view of the linear die conveyor system <NUM> is shown. The linear die conveyor system <NUM> includes an energy source <NUM>, a linear molding roll 604B, and a conveyor assembly 606B. The linear molding roll 604B is disposed on the conveyor assembly 606B, which moves in a rotational direction about an axis via use of a motor gear assembly <NUM>. Discrete substrates <NUM> as pieces of a substrate <NUM> advance along an assembly, such as another conveyor assembly and rotational peg <NUM>, for receipt within respective discrete substrate receiving slots <NUM> of the linear molding roll 604B. At a position when the linear molding roll 604B is disposed in a facing relationship to the energy source <NUM>, which is shown as a rear-facing position in <FIG>, the energy source <NUM> is configured to soften discrete substrates <NUM> disposed in discrete substrate receiving slots <NUM> of the linear molding roll 604B. The linear molding roll 604B includes cavities to form surface protrusions <NUM> as described herein. The softened substrates <NUM> are advanced through another rotational peg <NUM> and disposed onto another assembly, which may be another conveyor assembly, of the linear die conveyor system <NUM> to advance to a next stage.

Referring to <FIG>, a rear perspective view of another linear die conveyor system <NUM> is shown. The linear die conveyor system <NUM> includes an energy source <NUM>, a linear molding roll 604C, and a conveyor assembly 606C. The linear molding roll 604C is disposed on the conveyor assembly 606C, which moves in a rotational direction about an axis via use of a motor gear assembly <NUM>. The motor gear assembly <NUM> includes motors arranged in a different configuration than those of the motor gear assembly <NUM> of <FIG> to allow for a longer portion of a linear molding roll 604C to be exposed to a longer modular form of the energy source <NUM>, which also aids to extend a dwell (i.e., exposure) time to soften the substrate <NUM>. As an example, and not as a limitation, either motor gear assembly <NUM>, <NUM> may be a gear assembly of a controlled motion system as set forth in <CIT>. With respect to the linear die conveyor system <NUM>, discrete substrates <NUM> as pieces of the substrate <NUM> advance along an assembly, such as another conveyor assembly and rotational peg <NUM>, for receipt within respective discrete substrate receiving slots <NUM> of the linear molding roll 604C. At a position when the linear molding roll 604C is disposed in a facing relationship to the energy source <NUM>, which is shown as a rear-facing position in <FIG>, the energy source <NUM> is configured to soften discrete substrates <NUM> disposed in discrete substrate receiving slots <NUM> of the linear molding roll 604C. The linear molding roll 604C includes cavities to form surface protrusions <NUM> as described herein. The softened substrates <NUM> are advanced through another rotational peg <NUM> and disposed onto another assembly, which may be another conveyor assembly, of the linear die conveyor system <NUM> to advance to a next stage.

In embodiments, extended dwell time (i.e., extended contact time) between a garment material <NUM> of a substrate <NUM> and a source of energy may be achieved through a configuration of a forming die assembly as described herein, such as the linear die conveyor systems of <FIG> and the assemblies of <FIG> described in greater detail below. The sonotrodes may be configured to be in a modular table form that includes a sonotrode blade or one or more block sonotrodes. Such a modular table form may be paired with a linear form of the forming die that is moving such as in the embodiment of <FIG> described herein. The linear form of the forming die may be configured to move through use of a linear actuator, a conveyor assembly, or the like. In an embodiment, a blade sonotrode rotated <NUM> degrees may include a cross-section that is aligned with a machine direction to extend dwell time between a substrate <NUM> on a linear forming die following the machine direction and the blade sonotrode.

<FIG> depict another apparatus embodiments to extend a dwell time to soften a substrate <NUM> during the forming processes as described herein. Referring to <FIG>, a side view of an apparatus and multiple energy source system as an extended dwell assembly <NUM> for forming surface protrusions <NUM> on an advancing substrate <NUM> is shown. The extended dwell assembly <NUM> includes a molding roll <NUM> that rotates in a rotational direction and includes a plurality of cavities <NUM> to form the surface protrusions <NUM> on the substrate <NUM> when exposed to one or more energy sources <NUM> as described herein. By utilizing a plurality of energy sources <NUM>, a dwell time to form the surface protrusions <NUM> on the substrate <NUM> is extended more than through use of one of the energy sources <NUM> alone. Thus, the rotary forming die of <FIG> as the molding roll <NUM> may be a multi-hit system having multiple applications of energy from the multiple sonotrodes as the energy sources <NUM> applied in multiple steps to form the one or more surface protrusions <NUM> increasingly more at each of the multiple steps (e.g., positioning the material into a cavity <NUM> more at each step). The multiple sonotrodes are static relative to the molding roll <NUM>, and the substrate <NUM> is placed onto the molding roll <NUM> to received applied energy in sequential energy stations. At least two sonotrodes may be static relative to the forming die. In an embodiment, a sonotrode may be a rotary sonotrode while being static relative to a position with respective to the molding roll <NUM>.

Referring to <FIG>, a side view of a multiple energy source and multiple apparatus system as an extended dwell assembly <NUM> for forming surface protrusions <NUM> on an advancing substrate <NUM> is shown. The extended dwell assembly <NUM> includes one or more anvils 504A that may be molding dies including cavities <NUM> to form surface protrusions <NUM> on the substrate <NUM>. The extended dwell assembly further includes a rotary drum 504B and one or more energy sources <NUM>. The rotary drum 504B rotates in a rotational direction about an axis. Each anvil 504A may be disposed in a fixed position and held in the fixed position with respect to the rotary drum 504B by an arm mechanism. The one or more energy sources <NUM> are disposed around and attached to the rotary drum 504B. Each energy source <NUM> is disposed in a configured aligned with a respective anvil 504A. By utilizing a plurality of energy sources <NUM> and a corresponding plurality of anvils 504A, a dwell time to form the surface protrusions <NUM> on the substrate <NUM> is extended than through use of one of the energy sources <NUM> and paired anvil 504A alone. The rotary drum 504B may act as a multi-station drum with energy sources disposed close together with the substrate <NUM> traveling with the anvils 504A. Sonotrodes as the energy sources <NUM> may be mounted within the rotary drum 504B while an arm extends from the rotary drum 504B to attach to an anvil 504A and compress the substrate <NUM> between the anvil 504A and the rotary drum 504B. A higher dwell time is achieved as the sonotrode maintains contact with the anvil 504A while the rotary drum 504B is rotating.

Referring to <FIG>, a two-part process <NUM> for forming surface protrusions <NUM> including a separate tip deformation process is depicted as a method for mechanically forming one or more surface protrusions <NUM> integrally from a garment material <NUM> such as for the diaper <NUM> of <FIG>. The garment material <NUM> may include a diaper that includes a loops material section (e.g., loops material <NUM> of <FIG>), and the one or more surface protrusions <NUM> may include an array of hooks (e.g., hooks 212R, 212F of <FIG>) configured to fasten to the loops material section as described herein. As shown in <FIG>, the one or more surface protrusions <NUM> extend outwardly from a garment surface <NUM> of the garment material <NUM>.

In block <NUM>, a garment surface of the substrate <NUM> is placed against a forming die. The forming die may be any of the forming die assemblies that include openings such as cavities <NUM> as described herein. Thus, the method includes placing at least one selected area of the garment surface <NUM> against a first surface (e.g., die surface <NUM>) of a forming die. The garment surface <NUM> may include a polymeric material, such as a section of nonwoven web material that includes filaments of polymeric material. The forming die may be any of the forming dies as described herein and may have the first surface and a second surface opposed to the first surface. The first surface includes a plurality of openings (e.g., cavities <NUM>) which have a configuration and orientation corresponding with the configuration and orientation of a first body part <NUM> of the one or more surface protrusions <NUM> of the garment material <NUM>. The configuration of the plurality of openings may include a circle, an ellipse, an oval, a triangle, a rectangle, an extended rectangle, a polygon, a bore, a slot, or combinations thereof.

In a non-limiting example, the plurality of openings are formed from a stacked disc configuration of the forming die. Such a stacked disc configuration may be formed from a stacked disc concentric axial design (e.g., as shown in <FIG>) to fabricate the openings (e.g., cavities <NUM>) of the forming dies described herein instead of or in addition to using alternative machining methods. The stacked disc configuration may include multiple layers respectively machined to form opening portions and/or channels and configured to be fastened together to form one or more forming dies as described herein. In some embodiments, the plurality of openings may be formed from a segmented configuration that may include fastening multiple pieces together to form the forming die via one or more fastening mechanisms. Such fastening mechanisms may include mechanical fasteners, threaded components, clamps, and the like. The segmented and/or stacked disk configurations described herein may be used to form a forming die of the embodiments described herein.

In block <NUM>, the garment surface <NUM> may be softened by application of a source of energy from an energy source <NUM>, <NUM> as described herein. The source of energy include ultrasonic vibrations The one or more surface protrusions <NUM> may include hooks, and the garment material <NUM> including the garment surface <NUM> may include a nonwoven material. The source of energy may include an ultrasonic horn, a linear horn, a rotary horn, or combinations thereof, and the first surface of the forming die may include an outer circumferential surface of a roll that may be configured for rotation at a variable angular velocity, constant angular velocity, or combinations thereof. In an embodiment, and as shown in <FIG>, the source of energy may include at least two sonotrodes <NUM>, and the forming die may include a rotary form <NUM>. In another embodiment, and as shown in <FIG>, the source of energy may include at least two sonotrodes <NUM> mounted in a rotary drum 504B, and the forming die comprises one or more anvils 504A disposed about the rotary drum 504B.

In block <NUM> of <FIG>, at least some of the garment surface <NUM> may be positioned into the openings of the forming die to shape the surface protrusions <NUM> as described herein. At least some of the softened garment surface <NUM> may be positioned into at least one opening as a cavity <NUM> of the plurality of openings from the first surface of the forming die. Such positioning as described herein may include drawing the softened garment surface <NUM> into a respective opening (e.g., cavity <NUM>). In an embodiment, the drawing may occur through use of a vacuum process to draw a portion of the garment surface <NUM> into the respective opening through a negative pressure suctioning effect by use of a vacuum mechanism interacting with the openings.

In block <NUM>, the forming die may be separated from the garment surface <NUM> to form the first body part <NUM> (<FIG> and <FIG>) of the one or more surface protrusions <NUM>. In block <NUM>, a tip of the first body part <NUM> may be plastically deformed to form a hook portion such as the hook ends <NUM> at distal ends <NUM> of the first body part <NUM> of the surface protrusions <NUM>. Thus, the tip of and at a distal end <NUM> of the first body part <NUM> may be plastically deformed to the hook portion that is distal to the first body part <NUM> of the one or more surface protrusions <NUM>. In block <NUM>, the tip may be plastically deformed through a re-heating process, a capping process to force a structural change, or combinations thereof. Heat may be applied through fluid such as air, conductive surfaces, or combinations thereof.

Referring to <FIG>, another two-part process <NUM> for forming surface protrusions <NUM> including a pre-heating prior to forming process is depicted as a method for mechanically forming one or more surface protrusions <NUM> integrally from a garment material <NUM> such as for the diaper <NUM> of <FIG>. As shown in <FIG>, the one or more surface protrusions <NUM> extend outwardly from the garment surface <NUM> of the garment material <NUM>. The garment material <NUM> may be a diaper that includes a loops material section (e.g., loops material <NUM> of <FIG>), and the one or more surface protrusions <NUM> may include an array of hooks (e.g., hooks 212R, 212F of <FIG>) configured to fasten to the loops material section.

In block <NUM>, a garment surface <NUM> of the substrate <NUM> is pre-heated. Heat may be applied through fluid such as air including convection heat (i.e., moving preheated air), radiation, conductive surfaces, energy sources such as ultrasonic energy sources, or combinations thereof. The garment surface <NUM> may include polymeric material, such as a section of nonwoven web material that includes filaments of polymeric material. In embodiments, the one or more surface protrusions <NUM> include hooks, the garment material <NUM> includes a nonwoven material, the source of energy may include an ultrasonic horn, a linear horn, a rotary horn, or combinations thereof, and the first surface of the forming die may include an outer circumferential surface of a roll. The roll may be configured for rotation at a variable angular velocity, at a constant angular velocity, or combinations thereof.

In block <NUM>, the garment surface <NUM> of the substrate <NUM> that is pre-heated is placed against a forming die. The forming die may be any of the forming die assemblies that include openings such as cavities <NUM> as described herein. The configuration of the plurality of openings may include a circle, an ellipse, an oval, a triangle, a rectangle, an extended rectangle, a polygon, a bore, a slot, or combinations thereof. The plurality of openings may be formed from a stacked disk configuration of the forming die.

In block <NUM>, the garment surface <NUM> may be softened by applying a source of energy from an energy source <NUM>, <NUM> as described herein. As the garment surface <NUM> has been pre-heated, less energy is required from the source of energy to soften the garment surface <NUM> to a desired amount to form the surface protrusions <NUM> as described herein. Wwhen the source of energy includes ultrasonic vibrations, less ultrasonic energy is required when the garment surface <NUM> has been pre-heated when forming the surface protrusions <NUM>. The source of energy include at least two sonotrodes, and the forming die may include a rotary form. As shown in <FIG>, the source of energy include two or more sonotrodes <NUM> mounted in a rotary drum 504B, and the forming die may include one or more anvils 504A disposed about the rotary drum 504B.

In block <NUM> of <FIG>, at least some of the garment surface <NUM> may be positioned into the openings such as cavities <NUM> of the forming die to shape the surface protrusions <NUM> as described herein. In block <NUM>, the forming die may be separated from the garment surface <NUM> to form the surface protrusions <NUM>.

Referring to <FIG>, an extended contact process <NUM> for forming surface protrusions <NUM> is depicted as a method for mechanically forming one or more surface protrusions <NUM> integrally from a garment material <NUM> such as for the diaper <NUM> of <FIG>. As shown in <FIG>, the one or more surface protrusions <NUM> extend outwardly from the garment surface <NUM> of the garment material <NUM>.

In block <NUM>, a garment surface <NUM> of the substrate <NUM> is placed against a forming die. The garment surface <NUM> may include a polymeric material, such as a section of nonwoven web material. The garment material <NUM> of the garment surface <NUM> may be used to form a diaper having a loops material section (e.g., loops material <NUM> of <FIG>), and the one or more formed surface protrusions <NUM> may include an array of hooks (e.g., hooks 212R, 212F of <FIG>) configured to fasten to the loops material section. In some embodiments, the loops material section may include a plurality of loops, and at least a portion of the plurality of loops may be integrally formed from the section of nonwoven web material.

The forming die may be any of the forming die assemblies that are of a linear form advanced on a conveyor assembly such as the linear die conveyor systems <NUM>, <NUM>, and <NUM> of <FIG> and that include openings such as cavities <NUM> as described herein. At least one selected area of the garment surface <NUM> may be placed against a first surface of a forming die of a linear die conveyor system <NUM>, <NUM>, <NUM>. The forming die is of a linear form and may have a second surface opposed to the first surface. The first surface has a plurality of openings (e.g., cavities <NUM>) which have a configuration and orientation corresponding with the configuration and orientation of the one or more surface protrusions <NUM> of the garment material <NUM>. The plurality of openings may provide communication between the first surface and the second surface of the forming die such as when a vacuum is disposed at or near the second surface. The linear form of the forming die is disposed on a conveyor assembly such as shown in <FIG>.

In block <NUM> of <FIG>, the garment surface <NUM> may be softened by applying a source of energy from an energy source <NUM>, <NUM> as described herein that may include a modular form to extend contact time with the linear form of the forming die. The garment surface <NUM> may be softened by application of a source of energy that includes a modular form configured for an extended contact with the linear form of the forming die when conveyed by the conveyor assembly compared to contact time using a non-modular form. The source of energy includes at least two sonotrodes. - In embodiments, the one or more surface protrusions <NUM> may include at least one hook, the garment material may include a nonwoven material, and the source of energy may include an ultrasonic horn, a linear horn, or combinations thereof.

In block <NUM>, at least some of the garment surface <NUM> may be positioned into the openings such as cavities <NUM> of the forming die to shape the surface protrusions <NUM> as described herein. At least some of the softened garment surface <NUM> is positioned into at least one opening of the plurality of openings from the first surface of the forming die. The configuration of the plurality of openings may include a circle, an ellipse, an oval, a triangle, a rectangle, an extended rectangle, a polygon, a bore, a slot, or combinations thereof.

In block <NUM>, the forming die may be separated from the garment surface <NUM> to form the one or more surface protrusions <NUM>. Embodiments of the formed surfaced protrusions <NUM> may be in various configurations such as those depicted in <FIG>. In an embodiment directed to festooning and affecting a speed of manufacture, separating the forming die from the garment surface <NUM> may occur at an infeed speed different from an outfeed speed at which the at least one selected area of the garment surface <NUM> is placed against the first surface of the forming die. Thus, the difference in the infeed speed and the outfeed speed causes a variable speed when the at least some of the softened garment surface <NUM> are being positioned into the plurality of openings. The variable speed is may be slower than the infeed speed. A first accumulator may be configured to collect a portion of the substrate <NUM> at the infeed speed, and a second accumulator may be configured to release a portion of the substrate <NUM> at the outfeed speed, and a speed variance as described herein may be utilized to slow the substrate <NUM> speed down in the machine direction to increase a dwell time between a forming die and a source of energy and the substrate disposed therebetween.

Referring to <FIG>, a process <NUM> for bonding substrates <NUM>, <NUM> and forming surface protrusions <NUM> using a dual-purpose forming die is depicted. An ultrasonic back ear formation bonding process as set forth in <CIT> may be utilized. The method herein may be used for an online surface protrusion and ear formation process utilizing a single forming die for ear laminate bonding and surface protrusion formation. Thus, the same forming die and source of energy assembly may be utilized to form ultrasonic back ear patterns and surface protrusions, such as hooks. The forming die may include bonding nubs for lamination as well as openings such as cavities <NUM> from which to form protrusions. Bonding may be applied to one region of the material, and surface protrusions may be formed on another region of the material by the dual-purpose forming die. The method may be used to assemble laminates by a forming die and also for mechanically forming with the forming die one or more surface protrusions <NUM> integrally from one or more garment materials <NUM>, such as for the diaper <NUM> of <FIG>. The garment material <NUM> may include a section of nonwoven web material that includes filaments of polymeric material. The garment material <NUM> may form a diaper that includes a loops material section (e.g., loops material <NUM> of <FIG>), and the one or more surface protrusions <NUM> may include an array of hooks (e.g., hooks 212R, 212F of <FIG>) configured to fasten to the loops material section. As shown in <FIG>, the one or more surface protrusions <NUM> extend outwardly from a first surface (e.g., the garment surface <NUM>) of the garment material <NUM>.

In some embodiments, the method may utilize the forming die to assemble a laminate of two materials and form hooks on at least one of the materials. For example, two different substrates may advance through the processes on the same machine such that a first substrate is laminated to a second substrate, and the first substrate has hooks formed thereon and as described herein. As another non-limiting example, the method may utilize the forming die to assemble a laminate of two materials and to form protrusions on a third material, which may be attached to one or both of the two materials upstream or downstream of the protrusion forming process. As a further non-limiting example, two separated materials may be advanced to utilize the forming die to assemble laminates and form protrusions on at least one of the materials and the two separated materials may further downstream be bonded together when forming the diaper <NUM>.

In block <NUM>, a garment surface <NUM> is wrapped against a circumferential surface of a forming die including openings such as cavities <NUM>, with an elastic film disposed on the opposite garment surface (<FIG>). The first surface of a first substrate <NUM> of the garment material <NUM> may be wrapped onto an outer circumferential surface of a forming die that has a first surface and a second surface opposed to the first surface. The first surface includes a plurality of openings (e.g., cavities <NUM>) which have a configuration and orientation corresponding with the configuration and orientation of the one or more surface protrusions <NUM> of the garment material <NUM>. The plurality of openings may provide communication between the first surface and the second surface of the forming die. The configuration of the plurality of openings may include a circle, an ellipse, an oval, a triangle, a rectangle, an extended rectangle, a polygon, a bore, a slot, or combinations thereof.

In block <NUM>, a second substrate <NUM> (<FIG>) is advanced to be in contact with the elastic film and ultrasonically bonded by a source of energy, such as an energy source <NUM>, <NUM> as described herein. The elastic film is positioned to be in contact with a second surface of the first substrate <NUM> on the forming die. A second substrate <NUM> is advanced to position a first surface of the second substrate <NUM> in contact with the elastic film and the second surface of the first substrate <NUM> on the forming die. The source of energy is used to ultrasonically bond the first substrate <NUM> together with the second substrate <NUM> with the elastic film positioned between the first substrate <NUM> and the second substrate <NUM>. In embodiments, the source of energy may include induction heating, ultrasonic vibrations, micro waves, radio waves, infrared waves, a laser beam, an electron beam, or combinations thereof. In embodiments, the one or more surface protrusions <NUM> include hooks, the garment material <NUM> includes a nonwoven material, the source of energy includes an ultrasonic horn, a linear horn, a rotary horn, or combinations thereof, and the first surface of the forming die includes an outer circumferential surface of a roll. The roll may be configured for rotation at a variable angular velocity.

The method may include advancing the elastic film to a spreader mechanism. The elastic film may include a first edge and a second edge separated from the first edge in a cross direction by a central region. The elastic film may be stretched at the spreader mechanism in the cross direction to a first elongation. The elastic film may be advanced from the spreader mechanism to the forming die. The elastic film may be consolidated to a second elongation in the cross direction. The second elongation may be less than the first elongation, and the elastic film may remain stretched in the cross direction at the second elongation. The spreader mechanism may include a ring rolling apparatus and a first disk and a second disk canted relative each other. Each disk may include an outer rim. As the first and second disks rotate, the outer rims may be separated from each other by a distance that increases from a minimum distance at a first location to a maximum distance at a second location. The elastic film may be advanced from the ring rolling apparatus to the first disk and the second disk. The elastic film may be consolidated to the second elongation by advancing the elastic film on the rotating first disk and second disk downstream of the second location.

In block <NUM>, the garment surface <NUM> is softened by applying the source of energy and positioning at least some of the garment surface <NUM> into the openings (e.g., cavities <NUM>) of the forming die to shape the surface protrusions <NUM>. For example, the first surface of the first substrate <NUM> is softened by the source of energy, and at least some of the softened first surface is positioned into at least one opening of the plurality of openings from the first surface of the forming die.

In block <NUM>, the forming die is separated from the garment surface <NUM> to form the surface protrusions <NUM> as described herein. The forming die may be separated from the garment material <NUM> to form the one or more surface protrusions <NUM> integrally from the first surface (e.g., garment surface <NUM>) of the first substrate <NUM> of the garment material <NUM>.

In any of the foregoing embodiments described herein, the material may be pretreated to facilitate the heating and/or softening of the material. In non-limiting examples, the material may be combined with receptor material and subjected to radio frequencies or microwave frequencies, which initiates a thermo, electromagnetic and/or chemical reaction. The receptor material may be combined with the garment material during formation of the garment material or via lamination. An exemplary receptor material is <CIT> obtained from Johnson Polymer Company. In embodiments, the section of nonwoven may be combined with a radiofrequency receptor and exposed to radioactivity. An example of such exposure is disclosed in <CIT>.

In post formation of any of the forming embodiments described herein, the formed one or more surface protrusions <NUM> may be provided with a coating or additive to achieve a desired quality such as softness to a desired level or the like. Polymers may be applied to the protrusions via spraying or coating. Suitable polymers have lower Young's modulus values, such as elastomers and other polymers having Young's modulus values in the MPa range as compared to plastic materials that have modulus in GPa range. In another approach, sleek chemical finish can be coated on the protrusions. Chemical finishes based on oil, silicone, esters, fatty acids, surfactant etc. can be employed. Softeners such as anionic, cationic or nonionic can also be used to improve drape, and touch. Various coating techniques, like roll coating, screen coating, gravure coating, slot coating, spray coating, can be used to apply finish. For some applications, additives can be compounded with garment material forming polymers. The additives migrate to surface after protrusion formation and as the protrusions cool down. Amine and amide-based additives may be used up to <NUM>% to impart softness. In embodiments, the one or more protrusions may be coated with a softening agent, may utilize one or more melt additives in the garment material, or combinations thereof.

Additionally, or alternatively, a radiation treatment may be applied as a curing treatment to the formed one or more surface protrusions <NUM> to build a strength of the formed protrusions <NUM> through resulting chemical crosslinking. In particular, where the garment comprises a polymeric material, the garment may be combined with commonly known radiation susceptible agents (e.g., acrylates) and treated with ultraviolent light or electron beam energy waves. When exposed to the radiation, a chemical reaction may occur, causing the modulus of the protrusion to increase, resulting in increased stiffness.

In any of the embodiments described herein, the formed one or more surface protrusions <NUM> may be configured to be used for registration and/or quality reference as a registration mark, quality mark, or combinations thereof. As a non-limiting example, an opacity of a patch may be determined and used to register a landing zone <NUM> (<FIG>) of a product, such as a diaper <NUM> (<FIG>). The characteristics of the surface protrusions <NUM> such as opacity may be used to register components to the product and make sure components are in correct positions. Further, opacity or other qualities of the surface protrusions <NUM> may be utilized for quality checks such as where a desired opacity of the surface protrusions <NUM> is to be achieved to obtain an acceptable quality rating.

Claim 1:
A method for mechanically forming one or more surface protrusions (<NUM>) integrally from a garment material (<NUM>), the one or more surface protrusions extending outwardly from a garment surface (<NUM>) of the garment material, the method comprising:
i) placing at least one selected area of the garment surface (<NUM>) against a first surface of a forming die, the first surface having a plurality of openings (<NUM>) which have a configuration and orientation corresponding with the configuration and orientation of the one or more surface protrusions of the garment material;
ii) softening the garment surface by application of a source of ultrasonic energy, wherein the source of ultrasonic energy comprises at least two sonotrodes (<NUM>) mounted in a rotary drum;
iii) positioning at least some of the softened garment surface into at least one opening of the plurality of openings from the first surface of the forming die; and
iv) separating the forming die from the garment surface to form the one or more surface protrusions.