Patent Description:
Along an assembly line, various types of articles, such as for example, diapers and other absorbent articles, may be assembled by adding components to and/or otherwise modifying an advancing, continuous web of material. For example, in some processes, advancing webs of material are combined with other advancing webs of material. In other examples, individual components created from advancing webs of material are combined with advancing webs of material, which in turn, are then combined with other advancing webs of material. In some cases, individual components created from an advancing web or webs are combined with other individual components created from other advancing web or webs. Webs of material and component parts used to manufacture diapers may include: backsheets, topsheets, leg cuffs, waist bands, absorbent core components, front and/or back ears, and fastening components. Once the desired component parts are assembled, the advancing web(s) and component parts may be subjected to a final knife cut to separate the web(s) into discrete diapers or other absorbent articles.

Some diaper components, such as leg elastics, barrier leg cuff elastics, stretch side panels, and waist elastics, are constructed from elastic laminates. Such elastic laminates may be assembled in various ways depending on the particular diaper design. For example, some elastic laminates may be constructed from one or more nonwoven substrates bonded to an elastic film. In some configurations, the elastic film may be stretched and then bonded with the nonwoven substrates to form an elastic laminate.

Desirable need exists to provide improved, more efficient, and more adaptable assemblies and methods for manufacturing absorbent articles.

<CIT> relates to an apparatus and method for applying discrete segments to a continuous web and includes feeding a first continuous web to a roller, feeding a second continuous web to a vacuum anvil, cutting the first continuous web into a plurality of discrete segments, transferring each of the plurality of discrete segments from the roller onto the second continuous web at a first location, and bonding each of the plurality of discrete segments to the second continuous web at a second location.

<CIT> discloses a method for manufacturing a stretchable sheet with the intent to surpress neck-in.

<CIT> concerns an apparatus for embossing a pattern into absorbent articles. The apparatus comprises an embosser assembly having a patterned die roll and an anvil roll.

<CIT> discloses an apparatus and method for depositing particulate matter onto a supply of absorbent core fibrous substrate material.

<CIT> relates to a method and apparatus to transfer and fold a partially folded absorbent article.

In one embodiment, a system for ultrasonic bonding of elastic laminates includes a rotating roll having an axis of rotation and an exterior surface. The exterior surface is formed radially about the axis of rotation of the rotating roll and includes one or more roll anchoring mechanisms. The system further includes a removable shell layer that includes one or more patterned segments configured to removably attach to at least a portion of the exterior surface of the rotating roll. The one or more patterned segments include a plurality of shell channels formed through the removable shell layer to form a pattern. The one or more patterned segments further includes an anchoring mechanism configured to anchor and fasten each patterned segment to at least one of the one or more roll anchoring mechanisms of the rotating roll.

In yet another embodiment, a rotating roll for ultrasonic bonding of elastic laminates is described. The rotating roll includes an exterior surface formed radially about an axis of rotation of the rotating roll. The rotating roll further includes a vacuum source disposed within the rotating roll and configured to automate a vacuum action about the axis of rotation of the rotating roll. Further, the rotating roll includes plurality of vacuum apertures disposed on the exterior surface in communication with the vacuum source to enable the vacuum action. The plurality of vacuum apertures are configured to align with a corresponding plurality of apertures in a removable shell layer to form a vacuum path such that the vacuum action occurs through the vacuum path. The rotating roll includes a plurality of magnets, mechanical anchoring mechanisms, or combinations thereof disposed at least one of within or on the exterior surface. The plurality of magnets, mechanical anchoring mechanisms, or combinations thereof are configured to attach to the removable shell layer to fasten the removable shell layer to the rotating roll.

In another embodiment, which is not part of the present invention, a method for ultrasonically bonding elastic laminates includes attaching a removable shell layer including a plurality of shell channels to form a shell pattern to at least a portion of an exterior surface of a rotating roll. The rotating roll includes an axis of rotation. The exterior surface is formed radially about the axis of rotation. The method further includes advancing at least a laminate material assembly along a machine direction to dispose the laminate material assembly on the removable shell layer. The laminate material assembly includes a pair of substrate materials with at least an elastic material positioned therebetween. The method further includes applying a vacuum pressure to the laminate material assembly through a plurality of roll channels of the rotating roll aligned with the plurality of shell channels of the removable shell layer to draw the laminate material assembly into the plurality of shell channels forming the shell pattern. The method further includes ultrasonically bonding the laminate material assembly to bond the pair of substrate materials and the elastic material positioned therebetween to form an elastic laminate including a laminate pattern corresponding to the shell pattern, and advancing the elastic laminate including the laminate pattern along the machine direction.

Embodiments of the present disclosure generally relate to systems, apparatuses, and methods of ultrasonically bonding elastic laminates, and more particularly, systems, apparatuses and methods for assembling elastic laminates that may be used to make absorbent article components. A system can include an anvil that includes a rotating roll having an axis of rotation and an exterior surface. A removable shell layer can be configured to removably attach to at least a portion of the exterior surface of the rotating roll. The removable shell layer can include one or more patterned segments. The one or more patterned segments may include a plurality of shell channels formed through the removable shell layer to form a pattern. Further, the system can include an anchoring mechanism configured to anchor and fasten each patterned segment to anchoring mechanisms of the rotating roll. The removable shell layer <NUM> can be removed or replaced with a new removable shell layer <NUM> such that different patterns can be formed on absorbent articles without requiring complete replacement of an entire assembly. This may reduce cost, increase efficiency, and allow for greater variations in patterns on absorbent articles.

The following term explanations may be useful in understanding the present disclosure:
"Absorbent article" is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. Absorbent articles can inlcude sanitary napkins, tampons, panty liners, interlabial devices, wound dressings, wipes, disposable diapers including taped diapers and diaper pants, inserts for diapers with a reusable outer cover, adult incontinent diapers, adult incontinent pads, and adult incontinent pants. The term "disposable" is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner). "Diaper" is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso.

The term "pant" (also referred to as "training pant", "pre-closed diaper", "diaper pant", "pant diaper", and "pull-on diaper") refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can be configured with a continuous or closed waist opening and at least one continuous, closed, leg opening prior to the article being applied to the wearer. A pant can be preformed or pre-fastened by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be preformed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed). Example diaper pants in various configurations are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>, all.

An "elastic," "elastomer" or "elastomeric" refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than <NUM>% greater than its initial length and will substantially recover back to a length that is about <NUM>% greater than the initial length or less upon release of the applied force.

As used herein, the term "joined" encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

The term "substrate" is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. <NUM>/<NUM> or less) in comparison to its length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers or fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may include two or more layers laminated together. As such, a web is a substrate.

The term "nonwoven" refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.

The term "machine direction" (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

The term "cross direction" (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.

"Consolidation," "consolidating," and "consolidated" refers to a material undergoing a reduction in elongation from a first stretched length to a second stretched length that is less than the first stretched length and greater than zero.

"Relaxed state" defines a length of material when not stretched by an applied force.

In the context of the present description, an elongation of <NUM>% refers to a material in relaxed state having a relaxed length of L, and elongation of <NUM>% represents <NUM>. 5x the relaxed length, L, of the material. For example, an elastic film having a relaxed length of <NUM> millimeters would have a length of <NUM> millimeters at <NUM>% elongation. And an elastic film having a relaxed length of <NUM> millimeters would have a length of <NUM> millimeters at <NUM>% elongation.

Referring to the figures in detail, <FIG> illustrate an exemplary apparatus <NUM> for ultrasonic bonding of elastic laminates including a rotating roll <NUM> with a removable shell layer <NUM>. In <FIG>, the removable shell layer <NUM> is in the process of being attached to a rotating roll <NUM>. The rotating roll <NUM> includes an exterior surface <NUM> formed radially about an axis of rotation. <FIG> illustrates the removable shell layer <NUM> in a plan view, and <FIG> illustrates the removable shell layer <NUM> attached to the exterior surface <NUM> of the rotating roll <NUM>.

The rotating roll <NUM> may combine substrates and elastic materials to form an elastic laminate as described herein. It is to be appreciated that the substrates and elastic materials may be configured in various ways. For example, the substrates may be configured as nonwovens, and the elastic materials may be configured as elastic films and/or elastic laminates.

The removable shell layer <NUM> can include a body <NUM> having a first edge <NUM> and a second edge <NUM> (<FIG> and <FIG>). The body <NUM> may include a garment facing or external side <NUM> and a rotating roll facing or internal side <NUM>. The body <NUM> may be radially wrapped around the exterior surface <NUM> or other portion of the rotating roll <NUM> such that the first edge <NUM> abuts the second edge <NUM>.

In embodiments, the body <NUM> may include a preselected size and shape. In examples, the length and width of the body <NUM> may be selected based on the size of the exterior surface <NUM> of the rotating roll <NUM>. Moreover, the thickness of the body <NUM> may be selected based on the material utilized for the body <NUM>. For instance, the body <NUM> may be a predetermined thickness to allow the body <NUM> to be bent or deformed around the exterior surface <NUM>, while providing structural strength to general prevent or reduce cracking or other damage to the body <NUM>. The material utilized may be a metal or alloy, such as steel, aluminum, or other material. While <FIG> illustrates the removable shell layer <NUM> as having a unitarily constructed body <NUM>, it is noted that the body <NUM> may be formed of a plurality of sections or disparately formed segments that can be attached together and/or to the rotating roll <NUM>. The plurality of removable segment can be configured to removably attach to at least the portion of the exterior surface <NUM> of the rotating roll <NUM> to partially or substantially cover the exterior surface <NUM> of the rotating roll <NUM>.

Still referring to <FIG>, the removable shell layer <NUM> can include one or more patterned segments, such as pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> of <FIG>. The pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may include protrusions arranged in a predetermined pattern and/or shape. The protrusions extend radially outward from the external side <NUM> of the body <NUM>. During an ultrasonic bonding process, energy is applied to impart bonds into an elastic laminate to correspond with patterns and/or shapes defined by the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. It is noted that the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be arranged to form any appropriate shape, such as n-sided polygonal shapes (where n is a number), lines, zig-zags, alphanumerical shapes, hearts, stars, or other desired shapes. In some examples, the pattern segments <NUM>, <NUM>, <NUM>, <NUM> and <NUM> may include a plurality of shell channels formed through the removable shell layer to form a pattern. Moreover, each pattern segment <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may include the same, similar, or different patterns or shapes.

As shown in <FIG>, the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be configured such that the pattern is generally unbroken and/or uninterrupted where the first edge <NUM> and the second edge <NUM> interface. Accordingly, the rotating roll <NUM> may be utilized to continuously impart patterns as it is rotated. Additionally, the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be utilized in aligning or assisting in aligning the first edge <NUM> with the second edge <NUM>.

Moreover, as further shown in <FIG> and <FIG>, the exterior surface <NUM> of the rotating roll <NUM> may include a plurality of vacuum apertures or plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> (<FIG>) formed through the exterior surface <NUM>. The plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> may be fluidly connected to a vacuum source (e.g., vacuum source <NUM> of <FIG>) through an air tunnel network of the rotating roll <NUM>. The removable shell layer <NUM> further includes a plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM> formed through the removable shell layer <NUM>. When the removable shell layer <NUM> is attached to the exterior surface <NUM>, the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM> and the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> are fluidly connected. The rotating roll <NUM> includes an air tunnel network that is configured to fluidly connect to the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM>, and the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>. During an ultrasonic bonding process, the air tunnel network may apply vacuum pressure through the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM> that are fluidly connected and aligned to enable a vacuum action in a vacuum path on a substrate. It is noted that the vacuum source (e.g., vacuum source <NUM> of <FIG>) may be disposed within the rotating roll <NUM> and configured to automate the vacuum pressure through the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>. As described herein, the vacuum pressure may hold or assist in holding substrates to the rotating roll <NUM>. The removable shell layer <NUM> and/or exterior surface <NUM> may include a plurality of support members extending across one or more of the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM> to the help prevent the elastic material from being drawn into the channels <NUM> by the vacuum air pressure.

In at least some embodiments, the removable shell layer <NUM> may include a plurality of nubs <NUM> (<FIG>) that protrude radially outward from the external side <NUM> of the removable shell layer <NUM>. The plurality of nubs <NUM> may be arranged in a pattern (e.g., a nub pattern), which may allow for formation of patterns on an elastic laminate. The plurality of nubs <NUM> may further act to help prevent the elastic laminate from sliding into the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and/or the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>. It is to be appreciated that additional nubs <NUM> may be positioned inboard or outboard of the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and/or the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>. Moreover, the plurality of nubs <NUM> may include a first set of nubs extending a first distance from the exterior surface and a second set of nubs extending a second distance from the exterior surface. For instance, second set of nubs may be located near the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> and/or the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>, while the first set of nubs are not located bear the channels. The second set of nubs may extend radially further or shorter from the external side <NUM> of the removable shell layer <NUM>. In some embodiments, having the nubs proximal channels being shorter may allow for increased vacuum action. However, in other embodiments, having the nubs proximal channels being longer may be desired.

In embodiments, the exterior surface <NUM>, removable shell layer <NUM>, or other portion of the rotating roll <NUM> includes an anchoring mechanism <NUM> configured to anchor or fasten the removable shell layer <NUM> to the exterior surface <NUM>. For instance, the anchoring mechanism <NUM> may include cooperating mechanism on the exterior surface <NUM> and the removable shell layer <NUM>, such as opposing magnets which may attract the exterior surface <NUM> to the removable shell layer <NUM>.

Still referring to <FIG>, the anchoring mechanism <NUM> can include a plurality of magnets, mechanical anchoring mechanisms, or combinations thereof disposed at least one of within or on the exterior surface <NUM>, wherein the plurality of magnets, mechanical anchoring mechanisms, or combinations thereof are configured to attach to the removable shell layer <NUM> to fasten the removable shell layer <NUM> to the rotating roll <NUM>.

In embodiments, such mechanical anchoring mechanisms can include a leading edge interlock disposed at the first edge <NUM> of the removable shell layer <NUM> and a trailing edge interlock disposed at a trailing edge of the removable shell layer <NUM> wherein the leading edge interlock is configured to interface with the trailing edge interlock. According to an embodiment, the leading edge interlock may be a male or female edge that engages with the trailing edge, where the trailing edge includes a complimentary male or female edge, such as ridges, slots, channels, protrusions, or the like. In another embodiment, the mechanical interlock can include one or more protrusions removably engagable with one or more pockets to anchor the removable shell layer <NUM> to the exterior surface <NUM>, and wherein at least one of the exterior surface <NUM> or the removable shell layer <NUM> includes the one or more protrusions, and the other of the exterior surface <NUM> or the removable shell layer <NUM> includes the one or more pockets.

In an example, the anchoring mechanism <NUM> can include a plurality of magnets disposed at least one of within or on the exterior surface <NUM>, wherein the plurality of magnets are configured to magnetically attach to one or more magnets of the removable shell layer <NUM> to fasten the removable shell layer <NUM> to the rotating roll <NUM>. In at least some examples, the plurality of magnets may be disposed at various locations about the rotating roll <NUM> and the removable shell layer <NUM>, such as along the first edge <NUM> and the second edge <NUM>, at or proximal the one or more pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, at or proximal the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM>, and/or at or proximal the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>.

In an embodiment, the plurality of magnets can form a first magnetized zone of the rotating roll <NUM> and a second magnetized zone of the rotating roll <NUM>. The first magnetized zone can be configured to anchor a leading edge or first edge <NUM> of the removable shell layer <NUM> and a trailing edge or second edge <NUM> of the removable shell layer <NUM>. The first magnetized zone can include a higher magnetism than the second magnetized zone. As such, the strengths of magnets may vary as appropriate. For instance, the strength of magnets may increase along the first edge <NUM> and the second edge <NUM> in comparison with other portions of the body <NUM>. Moreover, the strength of magnets may increase at or proximal the plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM>, and/or at or proximal the plurality of shell channels <NUM>, <NUM>, <NUM>, and <NUM>.

Moreover, the anchoring mechanism <NUM> can include other mechanisms, such as a threaded member that secures the removable shell layer <NUM> to the exterior surface <NUM>. In another example, the anchoring mechanism <NUM> can include a recessed pocket and an angled end, and wherein at least one of the exterior surface <NUM> or the removable shell layer <NUM> includes the recessed pocket, and the other of the at least one of the exterior surface <NUM> or the removable shell layer <NUM> includes at least one angled end configured to be inserted within the recessed pocket to apply circumferential tension. The angled end can be inserted within the recessed pocket and may secure the removable shell layer <NUM> via a friction fit. It is noted that various anchoring mechanism <NUM> may be used in combination, such as an angled end and recessed pocket utilized in combination with a plurality of magnets.

In another embodiment, the anchoring mechanism <NUM> can include one or more protrusions or pins removably engagable with one or more pockets or apertures to anchor the removable shell layer <NUM> to the exterior surface <NUM>. The exterior surface <NUM> or the removable shell layer <NUM> includes the one or more protrusions, and the other of the exterior surface <NUM> or the removable shell layer <NUM> includes the one or more pockets. As such, the exterior surface <NUM> or the removable shell layer <NUM> can include complementary formations that enable the anchoring mechanism <NUM> to anchor the exterior surface <NUM> to the removable shell layer <NUM>.

For instance, the anchoring mechanism <NUM> can include a plurality of pins extending radially from the exterior surface <NUM> along a split line <NUM> (<FIG>). The anchoring mechanism <NUM> further includes a plurality of apertures formed in or through the removable shell layer <NUM> and configured to receive the plurality of pins. The pins may be generally D-shaped or may include other shapes. The pins may be rotated from a loading to a locking position within the apertures. The plurality of pins extend radially a smaller height than a plurality of nubs <NUM> extending from the removable shell layer <NUM>. The pins may interlock with the apertures to secure the removable shell layer <NUM> to the exterior surface <NUM>.

Referring now to <FIG>, there is a schematic side views of an apparatus <NUM> configured to assemble elastic laminates. As shown in <FIG>, the apparatus includes a rotating roll <NUM> having a removable shell layer <NUM> and an exterior surface <NUM>. The rotating roll <NUM> may be referred to as an anvil in an ultrasonic bonding process.

The rotating roll <NUM> is adapted to rotate in a first direction Dir1 about an axis of rotation <NUM>. Although the first direction Dir1 is depicted as clockwise, it is to be appreciated that the rotating roll <NUM> may be configured to rotate such that the first direction Dir1 is counterclockwise.

As shown in <FIG>, <FIG>, and <FIG>, the rotating roll <NUM>, and more particularly, the exterior surface <NUM> may also be fluidly connected with a vacuum source <NUM>. As such, vacuum source <NUM> may generate vacuum air pressure to hold or assist in holding one or more substrates, such as substrate <NUM> and one or more laminate materials <NUM> onto the exterior surface <NUM> of the rotating roll <NUM> during operation. The exterior surface <NUM> of the rotating roll <NUM> may include one or more plurality of roll channels <NUM>, <NUM>, <NUM>, and <NUM> (<FIG>) which may include apertures fluidly connected with the vacuum source <NUM>. In turn, the roll channels <NUM>, <NUM>, <NUM>, and <NUM> may define a vacuum zone extending axially or in the cross direction CD.

The laminate material <NUM> and substrates <NUM> can include elastic materials, such as elastic films, which may include one or more layers (e.g., a base layer, a surface layers or skin, etc.). During formation, the films may be extended or stretched to create a plurality of cracks and tears in the skins at a microscopic scale, wherein such cracks and tears may help reduce the skin contribution to the extension forces of the elastic film. The apparatus <NUM> may also include a spreader mechanism which may operate to activate the elastic material by stretching the elastic material in a MD to a first elongation during the elastic laminate assembly process. The stretched elastic material is then consolidated to a second elongation, wherein the second elongation is less than the first elongation. The elastic material is advanced from the spreader mechanism onto a substrate on the rotating roll <NUM>. It is to be appreciated that the apparatus <NUM> may include more than one spreader mechanisms configured in various ways, such as disclosed for example in <CIT>.

In embodiments, stretched elastic materials and substrates are combined on the rotating roll <NUM>. The combined substrates and elastic materials may then be ultrasonically bonded together on the rotating roll <NUM> to form elastic laminates. The apparatus <NUM> may include one or more ultrasonic mechanisms <NUM> adjacent the rotating roll <NUM>. The ultrasonic mechanism <NUM> includes a horn configured to impart ultrasonic energy to the combined substrates and elastic materials on the rotating roll <NUM>. In at least some examples, the ultrasonic mechanism <NUM> or a separate heater may apply heat to the laminate material assembly at least one of before, during, or after the ultrasonically bonding.

As described herein, the removable shell layer <NUM> includes pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> extending radially outward from the external side <NUM> of the body <NUM>. The ultrasonic mechanisms <NUM> may apply energy to create resonance at frequencies and amplitudes so a horn of the ultrasonic mechanisms <NUM> vibrates rapidly in a direction generally perpendicular to the substrates and elastic materials being advanced past the ultrasonic mechanisms <NUM> on the removable shell layer <NUM>. The vibration generates heat to melt and bond the substrates and elastic material together in areas supported by the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> on the removable shell layer <NUM>. During the ultrasonic bonding process, bonds imparted into the elastic laminate from the ultrasonic mechanism <NUM> may correspond with patterns and/or shapes defined by the pattern segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. It is to be appreciated that an elastic laminate <NUM> may include various portions of components bonded together in various ways and with differing or identical bond patterns. It is to be appreciated that the apparatus <NUM> may be adapted to create various types of bond configurations, such as disclosed, for example, in <CIT>.

Further, the ultrasonic mechanisms <NUM> may be configured in various ways, such as disclosed for example in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. In some configurations, the ultrasonic mechanism 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.

In various embodiments, the apparatus <NUM> described herein may operate to assemble elastic laminates configured in various ways. For instance, substrates <NUM> and/or laminate material <NUM> may be advanced in MD or otherwise onto the rotating roll <NUM>. During the assembly process, a spreader mechanism activates an elastic material by stretching the elastic material to a first elongation in the cross direction CD. The stretched elastic material is then consolidated to a second elongation that is less than the first elongation. And the consolidated elastic material is positioned into contact with the second surface of the first substrate <NUM>. The stretched elastic material may be consolidated before advancing to the rotating roll <NUM>, and in some configurations, the elastic material may be consolidated after advancing to the rotating roll <NUM>. In turn, the elastic laminate <NUM> may be formed by ultrasonically bonding the first substrate <NUM> and the elastic laminate material <NUM> together with a second substrate on the rotating roll <NUM>
Referring now to <FIG>, there is a plan view of an absorbent article that includes one or more elastic laminates assembled during manufacture. As described herein, apparatuses and methods of the present disclosure may be utilized to assembly various forms of elastic laminates used in the manufacture of absorbent articles. Such elastic laminates may be utilized in absorbent article components such as, for example: backsheets, topsheets, absorbent cores, front and/or back ears, fastener components, and various types of elastic webs and components such as leg elastics, barrier leg cuff elastics, and waist elastics. The absorbent article <NUM> may include one or more elastic laminates assembled during manufacture according to the apparatuses and methods disclosed herein with the portion of the absorbent article <NUM> with the portion of the diaper that faces toward a wearer visible in the plan view of <FIG>.

For the purposes of a specific illustration, <FIG> shows an example of a disposable absorbent article <NUM> in the form of a diaper <NUM> that may be constructed from such elastic laminates manipulated during manufacture according to the apparatuses and methods disclosed herein. The diaper <NUM> includes a chassis <NUM> having a first ear <NUM>, a second ear <NUM>, a third ear <NUM>, and a fourth ear <NUM>. The chassis <NUM> can include with a longitudinal axis <NUM> and a lateral axis <NUM>. The chassis <NUM> can include a first waist region <NUM>, a second waist region <NUM>, and a crotch region <NUM> disposed intermediate the first and second waist regions. The periphery of the chassis <NUM> may be defined by a pair of longitudinally extending side edges <NUM>, <NUM>; a first outer edge <NUM> extending laterally adjacent the first waist region <NUM>; and a second outer edge <NUM> extending laterally adjacent the second waist region <NUM>.

In embodiments, the chassis <NUM> includes an inner, body-facing surface <NUM>, and an outer, garment-facing surface (not shown). The chassis <NUM> of the diaper <NUM> may include a topsheet <NUM> defining the inner, body-facing surface <NUM>, and a backsheet (not shown) defining the outer, garment-facing surface. An absorbent core <NUM> may be disposed between a portion of the topsheet <NUM> and the backsheet. As discussed in more detail below, any one or more of the regions may be stretchable and may include an elastomeric material or laminate as described herein. As such, the diaper <NUM> may be configured to adapt to a specific wearer's anatomy upon application and to maintain coordination with the wearer's anatomy during wear.

The diaper <NUM> may include an elastic waist feature <NUM>. The elastic waist feature <NUM> may include a waist band and may provide improved fit and waste containment. The elastic waist feature <NUM> may be configured to elastically expand and contract to dynamically fit the wearer's waist. The elastic waist feature <NUM> can be incorporated into the diaper and may extend at least longitudinally outwardly from the absorbent core <NUM> and generally form at least a portion of the first and/or second outer edges <NUM>, <NUM> of the diaper <NUM>. In addition, the elastic waist feature may extend laterally to include the ears. While the elastic waist feature <NUM> or any constituent elements thereof may include one or more separate elements affixed to the diaper <NUM>, the elastic waist feature may be constructed as an extension of other elements of the diaper, such as the backsheet, the topsheet <NUM>, or both the backsheet and the topsheet <NUM>. In addition, the elastic waist feature <NUM> may be disposed on the outer, garment-facing surface of the chassis <NUM>; the inner, body-facing surface <NUM>; or between the inner and outer facing surfaces. The elastic waist feature <NUM> may be constructed in a number of different configurations including those described in <CIT> and <CIT>,.

Still referring to <FIG>, the diaper <NUM> may include leg cuffs <NUM> that may provide improved containment of liquids and other body exudates. In particular, elastic gasketing leg cuffs can provide a sealing effect around the wearer's thighs to prevent leakage. It is to be appreciated that when the diaper <NUM> is worn, the leg cuffs <NUM> may be placed in contact with the wearer's thighs, and the extent of that contact and contact pressure may be determined in part by the orientation of diaper on the body of the wearer. The leg cuffs <NUM> may be disposed in various ways on the diaper <NUM>.

The diaper <NUM> may be provided in the form of a pant-type diaper or may alternatively be provided with a re-closable fastening system, which may include fastener elements in various locations to help secure the diaper in position on the wearer. For example, fastener elements <NUM> may be located on the ears and may be adapted to releasably connect with one or more corresponding fastening elements located in the first or second waist regions. For example, the diaper <NUM> may include a connection zone on the first ear <NUM> or a second ear <NUM>, sometimes referred to as a landing zone. It is to be appreciated that various types of fastening elements may be used with the diaper.

Turning now to <FIG>, a process <NUM> is shown for use with the apparatus <NUM> of <FIG> for ultrasonically bonding elastic laminates to form an absorbent article, such as absorbent article <NUM> of <FIG>. It is noted that a greater or fewer number of steps may be included without departing from the scope of the present disclosure.

At block <NUM> of the process <NUM> includes attaching a removable shell layer <NUM> to at least a portion of an exterior surface of a rotating roll <NUM>. The removable shell layer <NUM> can include a plurality of shell channels to form a shell pattern, and the rotating roll <NUM> including an axis of rotation and the exterior surface <NUM> formed radially about the axis of rotation. The removable shell layer <NUM> can be attached to the rotating roll <NUM> by deforming the removable shell layer radially around the exterior surface <NUM>. In other embodiments, the removable shell layer <NUM> can be attached as a plurality of segments. Moreover, at block <NUM> the removable shell layer <NUM> that is being attached may be replacing a prior removable shell.

As described herein, the removable shell layer <NUM> can be attached to the exterior surface of a rotating roll <NUM> via an attachment mechanism. The attachment mechanism can include mechanical attachment mechanisms, magnets, or a combination thereof. It is noted that the removable shell layer <NUM> can be attached to the exterior surface <NUM> via a manual process or automated process. In examples, the removable shell layer <NUM> can be tensioned on the exterior surface of a rotating roll <NUM> such that a method includes tensioning the removable shell layer <NUM>.

At block <NUM> of the process <NUM> includes advancing at least a laminate material assembly with at least an elastic material along a machine direction to dispose the laminate material assembly on the removable shell layer <NUM>. In some examples, a spreader mechanism can activate the elastic material by stretching the elastic material in a MD to a first elongation during the elastic laminate assembly process. The stretched elastic material is then consolidated to a second elongation, wherein the second elongation is less than the first elongation. The elastic material is advanced from the spreader mechanism onto a substrate on the rotating roll <NUM>.

At block <NUM> of the process <NUM> includes applying a vacuum pressure to the laminate material assembly through a plurality of roll channels of the rotating roll. The plurality of roll channels of the rotating rolls <NUM> can be aligned with the plurality of shell channels of the removable shell layer <NUM> to draw the laminate material assembly into the plurality of shell channels forming the shell pattern. The vacuum pressure may be applied through a air tunnel network that is configured to (i) fluidly connect to the plurality of roll channels and the plurality of shell channels when the plurality of roll channels are aligned with the plurality of shell channels and (ii) apply vacuum pressure through the plurality of roll channels and the plurality of shell channels that are fluidly connected and aligned. The vacuum pressure may thus hold or assist in holding substrate and laminate materials to the rotating roll <NUM>.

At block <NUM> of the process <NUM> includes ultrasonically bonding the laminate material assembly to bond the pair of substrate materials and the elastic material positioned therebetween to form an elastic laminate. The elastic laminate can include a laminate pattern corresponding to the shell pattern of the removable shell layer. Ultrasonically bonding the laminate material can include applying energy to impart bonds into an elastic laminate to correspond with patterns and/or shapes defined by the pattern segments. In an example, the energy can create vibrations and/or heat that cause the substrate materials and elastic materials to bond at positions of the pattern. In examples, heat can be applied to the laminate material assembly at least one of before, during, or after the ultrasonically bonding.

At block <NUM> of the process <NUM> includes advancing the elastic laminate including the laminate pattern along the machine direction. For instance, as shown in <FIG>, the substrates and laminate materials can be processes as a roll or sheet. Thus, patterns may be formed in elastic laminates. The elastic laminates can be formed as the rotating roll rotates and a ultrasonic mechanisms applies energy to woven, non-woven and laminates.

Claim 1:
A system for ultrasonic bonding of elastic laminates comprising:
a rotating roll (<NUM>) having an axis of rotation (<NUM>) and an exterior surface, the exterior surface (<NUM>) formed radially about the axis of rotation (<NUM>) of the rotating roll (<NUM>) and comprising one or more roll anchoring mechanisms, and
a removable shell layer (<NUM>) comprising one or more patterned segments configured to removably attach to at least a portion of the exterior surface (<NUM>) of the rotating roll (<NUM>), wherein
the one or more patterned segments comprise a plurality of shell channels (<NUM>, <NUM>, <NUM>, <NUM>) formed through the removable shell layer (<NUM>) to form a pattern, and
the one or more patterned segments comprising an anchoring mechanism (<NUM>) configured to anchor and fasten each patterned segment to at least one of the one or more roll anchoring mechanisms of the rotating roll (<NUM>).