WO2025260101A1

WO2025260101A1 - Apparatus and methods for non-continuous (intermittent) elastic entrapment

Info

Publication number: WO2025260101A1
Application number: PCT/US2025/033860
Authority: WO
Inventors: Leo Klinstein; Justin Marshall LAFFERTY; Patrick Sean Mcnichols; Matthew James Dittrich; Michael A. Snyder
Original assignee: Dukane IAS LLC
Current assignee: Dukane IAS LLC
Priority date: 2024-06-14
Filing date: 2025-06-16
Publication date: 2025-12-18
Anticipated expiration: 2026-12-14

Abstract

Systems and methods for non-continuous or intermittent entrapment or intermittent anchoring of elastic strands between non-woven materials using ultrasonic energy. A cutting element, e.g., on the anvil, is positioned so that when the non-woven materials with the elastic strands reach the ultrasonic horn, the strand(s) are cut or severed at that point, allowing the elastic to "snap back" toward the roller, which still pinches the elastic strands and holds them between the non-woven materials. This allows discontinuous or intermittent placement of tensioned elastic between non-woven materials, allowing strategic use of elastic while reducing overall elastic material used in a product compared to conventional techniques. Instead of cutting, other techniques allow intermittent bonding or entrapment of elastic strand portions along a product being made, such as by using ultrasonic energy amplitude cycling, ultrasonic stack force cycling, or a combination of both. Products made according to these techniques are also disclosed.

Description

APPARATUS AND METHODS FOR NON-CONTINUOUS (INTERMITTENT) ELASTIC ENTRAPMENT

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/755,919, filed February 7, 2025, entitled “Apparatus And Methods for Non-Continuous (Intermittent) Elastic Entrapment,” (Attorney Docket No. 072415.11521/73US2), and to U.S. Provisional Patent Application No. 63/660,302, filed June 14, 2024, entitled “Apparatus And Methods for Non-Continuous (Intermittent) Elastic Entrapment,” (Attorney Docket No. 072415.11519/73US1), the respective entireties of which are incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates to non-continuous or intermittent entrapment of elastic between non-woven materials and bonding the same using ultrasonic energy.

BACKGROUND

[0003] Non-continuous elasticized materials are used in making products such as, for example, incontinent products, baby diapers, diaper pants, etc. Non-continuous or intermittent refers to the state of elastic strands that are embedded into the product between non-woven layers. This state can refer to slipping where the strand in a certain area or zone is unbonded and therefore allowed to slip or relax (untensioned) between bonds, or the state can refer to absence of elastic strand in a particular area or zone. Several conventional methods have been considered for creation of a non-woven fabric product with elastic zones and non-elastic zones.

[0004] For example, continuous elastic strands already embedded and bonded within nonwoven layers can be post-cut (after bonding) or “chopped” by a secondary function to create non-elastic zones. Continuous elastic application can include “chopping” bars in the anvil pattern to create the non-elastic zones, such as disclosed in US Patent No. 11254066.

[0005] The anvil can be designed in such a way that the pattern of protrusions includes welding lands spaced apart to create elastic zones and slip (non-elastic) zones. The dimensions of the groove that produces the space between welds are calibrated for a particular product requirements. The groove dimension is determined by the materials being processed to make this fabric. The basis weight of the two facings, usually non-wovens, combined with the decitex (Dtex) of the elastic strand determine the groove width and depth that will either attach the strand or allow it to slip to create those elastic zones and non-elastic zones, such as disclosed in US Patent No. 10259165.

[0006] Traditional means of defining ultrasonic bonds in continuously fed applications include patterned rotary anvils that are spun to match the linear speed of the base material, or reciprocating mechanisms that periodically move the ultrasonic stack into and away from the work to achieve the intermittent bond effect.

[0007] Drawbacks of the patterned rotary anvil include increased anvil complexity and pattern specialization for different products. The specialization often requires manual removal and replacement of anvil if a machine/line changes product.

SUMMARY

[0008] According to an aspect of the present disclosure, an apparatus is disclosed, which is configured to entrap intermittent or non-continuous portions of an elastic strand between nonwoven materials. The apparatus includes: an anvil having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges configured to guide the nonwoven materials across the face of the anvil in a direction of rotation about the rotation axis; a stationary or rotary ultrasonic horn assembly positioned relative to the anvil such that ultrasonic energy from the horn assembly is directed toward the face of the anvil; a roller positioned against the face of the anvil to receive therebetween the nonwoven materials and the tensioned elastic strand; and a cutting element on the anvil or on the horn assembly positioned upstream in the direction of rotation from the roller such that the elastic strand is cut or severed by the cutting element into two portions while at the same time the roller pinches one of the two portions between the nonwoven materials, leaving at least an area of no tensioned elastic, the area having a length corresponding to a circumferential distance between the roller and the horn assembly.

[0009] Each of the ridges can include a plurality of interspaced lands and notches, and each of the ridges can have a width and a length that is longer than the width. The ridges can be spaced circumferentially about the face. The ridges can extend across the face by less than the width dimension. Each of the lands and each of the notches can be oriented parallel to the circumferential axis.

[0010] The elastic strand can be a plurality of elastic strands (e.g., akin to a yarn) having a decitex (dtex) in a relaxed and untensioned state between 150 and 1200 grams per 10 km. The decitex can be between 300 and 800 grams per 10 km. [0011] The cutting element can be on the anvil (or on the horn interface) and can correspond to least one of the ridges. The ultrasonic horn can be stationary (or rotary) relative to the anvil. A height of the cutting element can be higher compared to a height of the plurality of ridges and the cutting element can be positioned on the anvil along a travel path of the elastic strand. Alternately, instead of being higher, a height of the cutting element can be the same as a height of at least one of the plurality of ridges such that a portion of the elastic strand to be cut passes over or across the cutting element. This configuration is easier to manufacture as no changes in the height of the cutting element is needed relative to the ridges.

[0012] A product can be made using the apparatus disclosed herein.

[0013] According to another aspect of the present disclosure, a method of entrapping intermittent or non-continuous portions of an elastic strand between nonwoven materials is disclosed. The method includes the steps of: feeding layers of non-woven material and an elastic strand over an anvil having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges configured to guide the nonwoven materials across the face of the anvil in a direction of rotation about the rotation axis; rotating the anvil relative to an ultrasonic horn assembly positioned relative to the anvil such that ultrasonic energy from the horn assembly is directed toward the face of the anvil; positioning a roller against the face of the anvil to receive therebetween the nonwoven materials and the tensioned elastic strand; cutting the elastic strand into two portions by a cutting element on the anvil or on the horn assembly positioned upstream in the direction of rotation from the roller, while pinching by the roller one of the two portions between the nonwoven materials, leaving at least an area of no elastic having a length corresponding to a circumferential distance between the roller and the horn assembly.

[0014] According to still another aspect of the present disclosure, a product is disclosed, which includes: an elastic-bearing portion composed of at least two non-woven layers bonded together without adhesives with a tensioned elastic strand between the two non-woven layers such that: the tensioned elastic strand is cut or severed creating two pieces having a first end and a second end, wherein the first end is bonded by an ultrasonic weld between the two nonwoven layers and the second end is bonded by another ultrasonic weld between the two nonwoven layers such that an elastic-free space between the first end and the second end is free from elastic strand material; and at least a portion of the elastic strand is continuously bonded between the two non-woven layers to create a zone of continuous entrapment of the tensioned elastic strand and an elastic-free zone bereft of any elastic strand in a tensioned state, wherein a linear density of the untensioned elastic strand in a relaxed state is between 150 and 1200 deci tex (dtex).

[0015] Any dangling or free ends of either of the two pieces of elastic strand present in the elastic-free space between the first and second ends can be in an untensioned or relaxed state. The first and second ends of elastic strand can be applied in the continuous entrapment zone. The zone of continuous entrapment can be immediately adjacent to the elastic-free zone on the product.

[0016] The product can further include a plurality of bond welds in the elastic-free zone directly bonding the two non-woven layers together where the plurality of bond welds are made.

[0017] There can be optionally no ultrasonic bond welds between the two non-woven layers in or adjacent to the elastic-free zone.

[0018] There can be optionally no ultrasonic bond welds between the two non-woven layers on either side immediately adjacent to where the elastic strand would be present if it were not cut or severed.

[0019] According to other aspects, a camming flexible element can be disposed against a horn actuator. Force can be cycled using a high-speed pneumatic valve. Force can be cycled using a second pneumatic pressure pulse to reduce the static pneumatic pressure making the welds at the attachment zone.

[0020] The ultrasonic horn can be controlled by a means to cycle amplitude of the horn working surface to make attachment (elasticized) zones and non-elasticized (slip) zones by reducing amplitude when a non-elastic zone is desired and increasing to an amplitude where welds create the attachment for elasticized zone.

[0021] The force between the ultrasonic horn and anvil tool can be cycled to make attachment (elasticized) zones and non-elasticized (slip) zones by reducing force when a non-elastic zone is desired and increasing to a force where welds create the attachment for elasticized zone.

[0022] Non-continuous or intermittent elastic entrapment can also be implemented by changing process settings on the ultrasonic equipment. The process settings in the equipment that can have an impact on welding quality include:

[0023] Time - determined by process velocity (how long the material is subject to weld energy).

[0024] Force - the static force compressing the material against the vibrating horn face.

[0025] Amplitude - the total excursion of the face (working surface) of the ultrasonic horn. [0026] One way to achieve intermittent or non-continuous elastic entrapment is by amplitude cycling. For example, amplitude can cycle completely for anchor bond and no bond. Amplitude can cycle partially for anchor bond and weak/slipping bond.

[0027] The amplitude setpoint can be utilized to create attachment zones and non-attachment zones (slip zones) on non-woven products or materials. If a material welds and anchors securely at an amplitude setpoint of, for example, 2.4 mils (0.0024” peak-peak) amplitude on the ultrasonic horn face and it does not weld at amplitude setpoints less than 2.0 mils (0.0020” peak-peak), a high-speed control cycles the amplitude to enable production of a product or material with one or more attachment zones and one or more non-attachment zones. The ultrasonic generator is configured to have amplitude cycling capability at speeds up to lOOOppm.

[0028] Instead of cycling amplitude, force can be cycled. A high-speed valve can cycle pressure (force) on the hom/anvil actuator cylinder. Force can be cycled completely for anchor bond and no bond. Force can be cycled partially for anchor bond and weak/slipping bond.

[0029] Like the amplitude setpoint, the force setpoint can additionally or alternately be utilized to create attachment zones and non-attachment zones (slip zones) on products or materials. If a material welds and attaches securely at a forced setpoint, e.g., of 80 lbs. force on the ultrasonic horn face and it does not weld at less than, e.g., 60 lbs. force, then a high-speed control is configured to cycle cycles the force rapidly to enable production of a product or material with attachment zone and non-attachment zone as desired for a product or material.

[0030] At least four methods can be utilized to cycle force: camming the device open and closed; camming against a flexible element mechanically reducing the force with reduced impact; cycling force using a high-speed pneumatic valve; or cycling force by the addition of a second biasing pneumatic valve.

[0031] Another technique is to have a secondary bias pressure valve to provide offsetting pressure to reduce force cyclically. The pressure can be cycled completely for anchor bond and no bond, or partially for an anchor bond and weak/slipping bond.

[0032] Still another technique is to use a mechanically or servo-driven pump to provide offsetting pressure to reduce force cyclically. This offsetting pressure can be cycled completely for anchor bond and no bond or partially for anchor bond and weak/slipping bond.

[0033] Another technique is to use a mechanically or servo-driven elastomeric/spring device valve to provide offsetting force to reduce force cyclically. This offsetting force can be cycled completely for anchor bond and no bond or partially for anchor bond and weak/slipping bond. [0034] Still other techniques can apply any combination of amplitude cycling and force cycling, such as those summarized above. Preferably, but not exclusively, these techniques would not require any change in the anvil pattern from one product to a different product; rather only configuration changes in the software that controls the operation of the anvil and stack.

[0035] Yet other techniques herein involve mechanical configurations, such as pattern changes to the anvil. By altering the patterns of the ridges or protrusions on the rotary anvil, non- continuous or intermittent elastic entrapment patterns are created. For example, staggered guiding welds can be arranged on the anvil but not facing each other. By “guiding” welds, these are bonds between the non-woven layers but the elastic strand passes between the bond without getting “entrapped” between the bond. By staggering the guiding welds, the elastic strand can run freely or in an untensioned state between the staggered guides. Elsewhere on the anvil, bonding weld points can be arranged so that the elastic does become entrapped between those bond points.

[0036] Another anvil design has at least two sets of grooves having different widths between the grooves, both widths being dimensioned to pinch at least a portion of the elastic strand, and one groove type anchors the elastic, and the other groove type allows the elastic to slip.

[0037] Additional techniques involve chopping or severing the elastic strands using added cut bar features in pattern, such as an enhanced height ridge or blade that contacts the horn so that elastic strand trapped between the cutting element and the horn is severed. This is referred to as “deactivating” the elastic strand because in these areas of the fabric product, no elastic will be present.

[0038] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the scope thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES

[0039] Aspects of the present disclosure are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings in which: [0040] FIG. 1 is an illustration of an elastic entrapment setup with two layers of non-woven materials along with an elastic strand being fed across an anvil with an ultrasonic horn positioned to apply bonding energy to the passing materials.

[0041] FIG. 2 is a schematic of the setup shown in FIG. 1.

[0042] FIG. 3 is an illustration of an intermittent feed roller used to pinch the material and elastic against the anvil in embodiments where the elastic strand is cut or severed when reaching the horn — the roller prevents snap-back and running away of the elastic.

[0043] FIGS. 4A-4E illustrate an example sequence of a non-continuous or intermittent elastic entrapment configuration in which the elastic strand is cut by a cutting element and is refed under tension by a roller pressed against the anvil and positioned a distance away from the horn to create an elastic-free zone (free of tensioned elastic).

[0044] FIG. 5 illustrates an example of how moving the roller adjusts the distance of the elastic- free zone, which can abut a continuous elastic entrapment zone.

[0045] FIG. 6 illustrates an example ridge pattern on an anvil creating a zone where elastic can slip or be guided between bonds, thereby creating a non-continuous or intermittent zone where elastic can be present but untensioned.

[0046] FIG. 7 is an example of slip grooves formed in the ridges of an anvil allowing elastic strands to slip in the slip grooves and are thereby guided between the slip grooves while the non-woven material is bonded together on the raised portions of the ridges.

[0047] FIG. 8 is a perspective view of another configuration in which an adjustable force is applied using a servo cam and following bearing to precisely control a lateral position of one bonding module relative to another.

[0048] FIG. 9 is a perspective view of a configuration in which an adjustable force is applied using a linear motor to precisely control a lateral position of one bonding module relative to another.

[0049] To the extent possible, reference numerals have been used to represent like elements in the drawing. Further, those of ordinary skill in the art will appreciate that elements in the drawing are illustrated for simplicity and may have yet to be drawn to scale. For example, the dimension of some of the elements in the drawing may be exaggerated relative to other elements to help to improve the understanding of aspects of the invention. Furthermore, conventional symbols may have represented the elements in the drawing. Finally, the drawings may show only those specific details pertinent to the understanding of the embodiments of the invention so as not to obscure the drawing with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. DETAILED DESCRIPTION OF INVENTION

[0001] The implementations herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting implementations that are illustrated in the accompanying drawings and detailed in the following description. It should be understood, however, that the following descriptions, while indicating preferred implementations and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the implementations herein without departing from the spirit thereof, and the implementations herein include all such modifications. The examples used herein are intended merely to facilitate an understanding of ways in which the implementations herein can be practiced and to further enable those skilled in the art to practice the implementations herein. Accordingly, the examples should not be construed as limiting the scope of the implementations herein.

[0002] Descriptions of well-known components and processing techniques are omitted to avoid unnecessarily obscuring the implementations herein. Also, the various implementations described herein are not necessarily mutually exclusive, as some implementations can be combined with other implementations to form new implementations.

[0003] Referring now to the drawings, where similar reference characters denote corresponding features consistently throughout the figures.

[0004] FIG. 1 illustrates an example setup of a system 100 having a rotary anvil 102 and an ultrasonic horn assembly 104 with various rollers and feeders to bring at least two layers of material 110a, 110b, such as a non-woven material, and an elastic strand (typically a bundle of individual elastic strands) together to be bonded together to make a product. The anvil 102 has one or more patterns arranged about its outer surface, which patterns convey a bond pattern to the layers 110a, 110b where the layers contact the pattern as ultrasonic energy is imparted to the horn assembly 104. As discussed herein, in various places the non-woven layers are bonded together, and sometimes the elastic strand is entrapped or bonded or anchored (including weakly) within a bond or between adjacent bonds, and sometimes the elastic strand is either allowed to slip in an unrestrained or untensioned fashion or is not present at all in certain areas, having been cut or severed. In the latter case, the strand can be weakly bonded at a localized bond or anchor point or area, but due to its weak bond, when the material is stretched, the weak anchor “fails” by design and allows the elastic strand to slip or become free/untethered in that point or area. When the bond is strong, sometimes this will be referred to herein as “anchoring” the elastic strand at the bond point/area. It should be understood that when referring to a “point” corresponding to a bond or anchor, this can mean an area or a zone having multiple bond or anchor points separated by a relatively large distance until the next bond/anchor point/zone/area. A bond is strong enough to entrap or fix the strand between the layers between which it extends, and a weak bond refers to a bond having sufficient strength to initially hold a strand between the layers to be adjoined but not strong enough to retain the elastic therebetween. Under this scenario, a weak bond would by design allow the strand to escape the bond or to otherwise become unbonded at the bond site shortly after the bond is created during the production of an article or product.

[0005] An elastic strand (also variously referred to as filament or fiber or yarn) as used herein can refer to a single strand or a bundle of strands or fibers, such as spandex, and these strands or fibers are typically twisted together to form a twisted bundle. Strands or fibers or filaments bundled or twisted together to form an elastic or elastic “yam” can be measured or quantified according to a unit referred to in the industry as deci tex (dtex). A deci tex is a measure of grams per 10,000 meters, or grams per 10 km. According to aspects herein, an elastic strand can range from a decitex of 150 up to 1200 or between 300 and 800 dtex. Those skilled in the art will appreciate that as the decitex increases, a different bonding or anchoring profile is needed to ensure that the elastic strand remains tethered or anchored at a localized bonding point not only due to its increased cross-sectional area but also tensile strength.

[0006] FIG. 2A is a schematic of an example machine configuration 200 in which two layers of non-woven material (conventionally carried on rollers) are fed to a rotary anvil 202, and one or more elastic strand is/are sandwiched between the two layers as they are urged in a rotating manner toward the ultrasonic stack 204. A roller 206 is positioned relative to the anvil 202 and can be controlled to apply tension or a force against the anvil 202 or moved away from the anvil 202 to allow the layers to run past the roller 206 without contacting the roller 206. As can be seen in greater detail in FIG. 2B, a mechanical assembly 230 such as including a cam 232 can be used to move the roller 206 laterally relative to the anvil 202 to press the roller 206 against the anvil 202 or move the roller 206 a distance away from the anvil 202 under control of a controller, for example. These aspects are discussed in more detail in connection with FIG. 3.

[0007] Using either mechanical or machine software configurations, aspects of the present disclosure contemplate non-continuous or intermittent entrapment/ anchoring of elastic strands captured between at least two non-woven materials. Again, it should be emphasized that this means that the elastic can be relaxed or untensioned in certain zones or areas or not present at all having been cut or severed such that no elastic strand (a dangling free end of a cut or severed strand is contemplated as being “not present” in a zone or area) is present in certain zones or areas but is present under tension (the elastic strand is stretched) in other zones or areas where they have been bonded or entrapped with the non-woven material once exposed to ultrasonic energy or other bonding effect. “Intermittent entrapment” refers to the non- continuous entrapment of an elastic strand between adjacent layers of a material or materials, wherein the elastic strand can be uncut (continuous) or severed into one or more pieces of strand between an area of non-continuous entrapment. Another term is “intermittent anchoring,” which refers to the non-continuous anchoring of an elastic strand between layers of a material. Typically, during a process that entraps or anchors an elastic strand between two layers, a rotary anvil having a bonding pattern about its outer cylindrical surface is used, which would otherwise create a continuous bonding pattern as it rotates relative to the layers. The idea of “intermittent” entrapment or anchoring is to disrupt that pattern so that in some areas where the elastic strand would otherwise be bonded, instead the elastic strand is either not present at all (the presence of an non-tensioned dangling end does not destroy nonpresence in this context) or is allowed to extend freely in a tensioned or untensioned state until the next bond or anchoring point. The elastic strand can be cut or severed along one or more points to allow a free end of the strand to dangle freely off the last anchor or bond point. Because the bonding or anchoring pattern is applied by a rotating drum, unless the bonding pattern is disrupted at localized points, the elastic strand would otherwise be bonded at every point where it becomes entrapped or anchored between the layers when the ultrasonic energy is applied, causing a localized melting of the layers and thereby a localized bond or anchor point. The term “anchor” refers to a point or area between the layers where the elastic strand is weakly or strongly bonded either in a tensioned or untensioned state. The bond can be weak enough that stretching of the layers causes the anchor point to fail deliberately, thereby freeing the elastic strand at that localized point or area to become untethered, whether under tension or not. References to “no elastic” or an “elastic-free” zone contemplate that there can be a small dangling free end of an elastic strand (or portion thereof) partially within the area or zone that is considered to be elastic-free. In a zone having no elastic or being “elastic-free,” there is no (tensioned) strand that spans across the zone or area, even though a small dangling free end in an non-tensioned state of an elastic strand can partially extend into the zone or area. It is expressly contemplated that a small portion of an elastic strand (e.g., a dangling end caused by snap-back of cutting a tensioned elastic strand) can be present in a zone that is referred to herein as having no elastic or being elastic-free. [0008] FIG. 3 illustrates a roller 206 used to pinch the fabric/non-woven layers, which can be leveraged in cutting applications disclosed herein where the elastic strand is cut or severed to create a zone or area where no elastic is present before being picked up again downstream of the product. When cut, an elastic under tension will snap-back, and the function of the roller is to pinch the elastic to prevent snap-back and losing the ability to pick the elastic strand back up as the non-woven material layers pass by the rotary anvil 202. The roller 206 is positioned adjacent to a horn 304 of an ultrasonic assembly stack 204 (just upstream) so that it can pinch the tensioned elastic before being cut or severed, which would otherwise cause the elastic to snap back. Thanks to the force applied by the roller 206 against the anvil 202, the runaway snapback action of the tensioned elastic strand will be controlled such that the roller 206 will retain the elastic strand so it can be re-fed back into the same or different bonding/anchoring pattern on the anvil 202 as it rotates. The angular distance of rotation defines how much space exists between the elastic-free zone, and the skilled person will understand the calculations needed to determine the timing of applying the force to the roller 206 and releasing said force in coordination with the rotational velocity of the rotary anvil 202.

[0009] FIG. 4A is a functional block diagram together with a top view of the assembly 400 showing a continuously anchored elastic strand approaching an ultrasonic horn 304. A roller 206 is present upstream (relative to a direction of travel of the non-woven layers 110a, b) of the horn 304 to pinch the non-woven material layers 110a,b and the corresponding elastic strand 418 sandwiched therebetween against the face of the anvil 202 during rotation. A cutting element 432 depicted here as a raised ridge is on the face of the anvil 202 and is approaching the horn 304 as the anvil 202 rotates in the counterclockwise direction. The height of the raised edge of the cutting element 432 can be slightly higher or equal to a height of the bonding pattern on the anvil 202.

[0010] Continuing as the assembly 400 moves in a counterclockwise direction (per the rotation by the anvil 202), in FIG. 4B, the cutting element 432 has now reached the horn 304, thereby severing the elastic strand(s) 418, which is under tension, causing the elastic strand 418 to snap back (because it is under tension) but the roller 206, which is pressed against the face of the anvil 202, prevents the elastic strand 418 from snapping back further and traps and maintains the elastic strand 418 between the layers 110a,b. A zone 440 between the cutting element 432 and the roller 206 has no elastic strand (except perhaps a dangling free end), creating a non-continuous or intermittent area of elastic entrapment, or an elastic-free zone or area (notwithstanding the possible presence of a dangling free end). It should be noted that only a portion of the entire surface of a product or part of a product (e.g., a diaper) is shown here as it is being assembled and/or manufactured into a finished product. Elsewhere on the same plane as shown other bonding and/or elastic entrapment configurations can be taking place, which are the same or different as those shown in FIGS. 4A-4E. These figures only illustrate a local area of the overall product (or portion of a product, such as a leg cuff for a diaper) is being assembled. For example, in a different area on the same anvil 202, a continuous bonding pattern can be applied simultaneously, some other intermittent entrapment/anchoring configuration can be taking place, no bonding at all can be taking place, and so forth.

[0011] Thanks to the roller 206 pinching the snapped elastic strand between the non-woven materials (by being forced against the face of the anvil 202), as the anvil 202 continues to rotate the cutting element 432 beyond the ultrasonic horn 304, the tensioned elastic strand 418 begins to re-feed as the friction between the roller 206 and the non-woven material layers 110a, b begins to draw them out and to add tension from infeeding strands 418 that are under high tension. This can be seen in the area 432 shown in FIG. 4C, where the roller 206 has trapped the strands 418 to keep them from fully snapping back so that the strands 418 can be refed back into another portion of the apparatus being assembled as dictated by the pattern on the anvil 202 and/or software control of the characteristics of the energy applied by the horn 304.

[0012] With the anvil 202 still rotating in a counterclockwise direction, in FIG. 4D, as the material feed (comprising the layers 110a,b and strand 418) continues to advance and approach the horn 304, the strand 418 is anchored upon passing under the horn 304 between the non-woven layers 110a,b, creating no loose or dangling ends of the strand 418. This creates very well-defined areas of entrapment (bonded or anchored strands between the layers 110a,b) and areas of discontinuous or no elastic along the product without any dangling or stray loose ends of elastic. Moreover, this implementation shown in FIGS. 4A-4E can save between 10% up to 40% of elastic material compared to continuous methods or other intermittent methods that do not cut the elastic strand, which reduces environmental impact.

[0013] In FIG. 4E, the material feed (110a, b, 418) continues to advance and the elastic strand 418 is continuously anchored according to the bonding pattern on the anvil 202 between the non-woven layers 110a, b until an optional next cutting element 442 approaches the horn 304. The pitch between the cutting elements 432, 442 can set the product length, for example. Although only one cutting element 432 is shown in FIGS. 4A-4D, more than one cutting element such as a second cutting element 442 shown in FIG. 4E is of course contemplated to create multiple elastic-free zones along the product. The circumferential length between the roller 206 and the horn 304 defines the non-elastic length (elastic-free distance) proportionally on the product. By “elastic-free” as used herein, this can refer to the absence of any elastic thread or strand after the bond or weld, or the absence of any elastic thread or strand in a tensioned (relaxed) state, such as, for example, a small dangling or free end that is in a relaxed, untensioned state, in contradistinction to elastic entrapped between anchors or bonds or welds, which is under tension. Thus, “elastic-free” can be also stated as “free of tensioned elastic or free from any elastic (strands or threads),” so “elastic-free” is a shorter abbreviation for ease of discussion.

[0014] FIG. 5 illustrates an example of what happens when the roller 206 is moved farther away (al versus a 2) to a roller position 206’ from the horn 304. Here, the elastic-free distance increases as the intermittent refeed roller is moved away from the horn 304 (see roller 206’) in the opposite direction of rotational travel of the anvil 202. The roller’s position 206, 206’ relative to the anvil 202 can be adjusted based on product requirements (e.g., different size products will demand different sizes of elastic-free zones). No adjustments to the anvil pattern are required to accommodate different products being assembled using the layers 110a, b with entrapped elastics 418. The position of the roller 206, 206’ relative to the horn 304 will set a desired spacing 532 of the elastic-free zone before the elastic is taken up again by the bond pattern on the anvil 202.

[0015] A method is also disclosed of entrapping intermittent or non-continuous portions of an elastic strand between nonwoven materials. The method includes feeding layers 110a, 110b of non-woven material and an elastic strand 418 over an anvil 202 having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis. The face has multiple ridges or a ridge pattern configured to guide the nonwoven materials 110a, 110b across the face of the anvil 202 in a direction of rotation about the rotation axis.

[0016] The method includes rotating the anvil 202 relative to an ultrasonic horn assembly 304 positioned relative to the anvil 202 such that ultrasonic energy from the horn assembly 304 is directed toward the face of the anvil 202. A roller 206 is positioned against the face of the anvil 202 to receive therebetween the nonwoven materials 110a, 110b and the tensioned elastic strand 418;

[0017] The elastic strand 418 is cut into two portions by a cutting element on the anvil 202 or on the horn assembly 304 positioned upstream in the direction of rotation from the roller 206, while pinching by the roller 206 one of the two portions between the nonwoven materials, leaving at least an area of no elastic having a length corresponding to a circumferential distance between the roller 206 and the horn assembly 304. [0018] FIG. 6 illustrates an example configuration 600 in which the bonding ridge patterns on an anvil 604 are offset from one another such an elastic strand 418 is allowed to slip or to be guided between the offset ridge patterns 602a, b,c and 606a, b and create therein zones of guiding welds (anchors or bonds) 620, 622 where the non-woven layers are bonded at the ridges (or lands) 630 but the elastic strand 418 is not bonded/welded/anchored herein and therefore runs freely between the ridges 630, such as in the notches 632. The continuous bond pattern 610 shown in FIG. 6 is representative of another portion of the anvil and is shown as a split screen for ease of illustration. This pattern 610 may be on the opposite side, for example, of the anvil 604. On another area of the surface of the anvil 604, there can be a different offset bonding ridge pattern 614a, b,c and 616a, b, with a slip zone 622 therebetween. The ridge pattern defines where the bonding or anchoring occurs between the non-woven layers. The raised ridges create a bonding point between the non-woven layers, and a pattern of ridges can create a bonding or anchoring pattern on the non-woven layers, optionally with or without tensioned/untensioned elastic entrapped or running between them.

[0019] FIG. 7 illustrates an example ridge pattern that can appear on the anvil face showing entrapment grooves. Each groove width does not exceed a width of the elastic when twisted into roughly a round shape. It has been found, for example, that contrary to the disclosure in US Patent No. 11,399,989, which says that the guiding welds have to be spaced apart by a distance greater than a “diameter” of the tensioned elastic thread, in fact this distance can be less than the “diameter” of the tensioned elastic thread. The inventors discovered that when twisting an elastic strand measured in decitex under tension and rolling it into a roughly round shape, that dimension can actually be larger than a distance between guiding welds on the anvil and still “slip” or fail to bond between the guiding welds. So, for example, as shown in FIG. 7, if the distance between ridges or grooves is fixed as 13 mils (13 thousandths of an inch), the elastic can be 14 mils or 15 mils, for example. The “diameter” of the elastic does not have to be smaller than the distance between adjacent grooves, contrary to US Patent No. 11,399,989.

[0020] FIG. 8 is a perspective view of a system 800 in which an adjustable force is applied using one or more linear motors (two shown in this example) 820a, 820b to precisely control a lateral position of one bonding module relative to another. The ultrasonic stack including an ultrasonic horn 304a, 304b coupled to an optional ultrasonic booster 824a, 824b and optional ultrasonic converters 826a, 826b is arranged on slides 830 or other structures permitting lateral movement of the stack 304 relative to the anvil 202 (along direction labeled A in FIG. 8). The linear motor(s) 820a, 820b can be controlled by a controller to precisely control a lateral movement position of the ultrasonic stack 304 (two are shown in this example, each of which is independently controllable, or they can be controlled to operate simultaneously) relative to the anvil 202, such as between a distance of 3000th of one inch to 30000th of one inch. This configuration can be used in connection with any of the implementations disclosed herein and permits precise backing off of a force applied by the stack(s) 304a, 304b to the anvil 202 (and the nonwoven materials passing between them) depending on the application. One application, for example, is for carrying out a splicing operation between rolls of nonwoven materials. The splicing can be carried out in the distance where the stack(s) 304 are backed away from the anvil 202. For example, for an anvil 202 rotating at a rate sufficient to pass 400 meters of material in 15 minutes, the linear motor(s) 820a, 820b can be actuated quickly enough to retract and extend the stack 304 to create a 100mm “jump” across the material. For example, one roll can be completely consumed in 10 minutes, so the linear motor(s) are controlled by the controller to actuate and back the stack(s) away from the anvil to allow a splicing operation to occur, thereby allowing an uninterrupted operation across multiple kilometers of nonwoven material.

[0021] FIG. 9 is a perspective view of a system 900 in which an adjustable force is applied using a servo cam motor 902 and a cam follower bearing 904 to precisely control a lateral position of one bonding module relative to another. A rotation of a cam 906 coupled to the servo motor 902 impacts the cam follower bearing 904 that causes lateral movement of the ultrasonic stack 304 relative to the anvil 202, to cause the ultrasonic stack 304 to retract a distance away (along the direction indicated by arrow B shown in FIG. 9) from the anvil 202 under control of a controller, similar to the operation of the linear encoder in FIG. 8.

ACAR (Adaptive Cyclic Amplitude Regulation)

[0022] In other embodiments, amplitude and/or force modulation in elastic entrapment can be used instead of modifying the anvil ridge pattern. By using amplitude and/or modulation, no change to the ridge/bonding pattern on an anvil is necessary.

[0023] Using a smooth uniform featureless anvil allows a single machine setup to support multiple product sizes and bonding applications without mechanical adjustments. It decouples anvil size from product length. It also allows mechanical wear to be more evenly distributed over the entire circumference of the anvil by adjusting the angular position/phase of the anvil in relation to the working period of the ultrasonic stack. [0024] Reciprocating mechanical systems can utilize the benefits of a smooth anvil, however these come at the expense of increased mechanical and control complexity. These systems control the bond duration by increasing the applied force, and therefore the dampening of the ultrasonic vibrations thus increasing ultrasonic load, during the bond, and then relaxing the applied force during the unbonded portions. The result is larger amounts of ultrasonic energy enter the worked area than the low force area, resulting in bonded and unbonded portions of the continuous base material without a change in regulated ultrasonic amplitude. This motion must be precise in both timing and force regulation during the bond.

[0025] Using alternating levels ultrasonic amplitude to vary the delivered energy to the work, controlling bonded and unbonded areas, provides increased precision compared to mechanical movement. Moving the responsibility for intermittent power delivery control to the ultrasonic system allows for a simpler constant force / position mechanical system that can be more easily controlled and is less susceptible to mechanical wear.

[0026] The sharpness of the transition between bonded and unbonded areas of ultrasonic amplitude defined bonds depends upon the transition time between the two ultrasonic amplitude levels. The regulation of these ultrasonic levels is typically controlled by PID algorithms acting retroactively by minimizing setpoint error as it observed. Feed forward mechanism help with rapid transitions in setpoints, but the most repeatable performance can be achieved with foresight about the eventual steady state conditions needed to obtain regulation at the new setpoint.

[0027] ACAR or Adaptive Cyclic Amplitude Regulation, adapts regulation output during individual bonds by analyzing its performance from previous bonds. These periods include low level amplitude output, periods of high-level output, and the transitions between them. ACAR uses distinct control tunings for each of these phases, ensuring rapid convergence on a regulated state during the bonded and unbonded areas, minimizing the transition times that define the sharpness of the edge of the bond.

[0028] When line synchronization to the material is not needed, user settings of bond period, duration, unbonded amplitude target, and bonded amplitude target allow the system to function with no external inputs. When synchronization is desirable, the system will react to an external “bond control” signal, either a digital input (networked or physical wire) or analog signal representing target amplitude (again, networked or physical wire).

[0029] Instead of or in addition to amplitude, a force applied to the ultrasonic stack/horn can be adjusted dynamically. An apparatus is configured to entrap intermittent or non-continuous portions of an elastic strand between nonwoven materials using force modulation. The apparatus includes a first bonding module having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having protrusions or ridges configured to urge the nonwoven materials across the face of the first bonding module in a direction of rotation about the rotation axis. The apparatus includes a second bonding module positioned relative to the first bonding module and configured to move laterally relative to the first bonding module. A controller is operatively coupled to the ultrasonic horn assembly and is configured to, as the first bonding module is rotating about the rotation axis, cause at least an applied force to be applied to the nonwoven materials to bond or trap a portion of the elastic strand at a first location between adjoined layers of the nonwoven materials. As the first bonding module is rotating about the rotation axis, the controller can modify at least (a) the force applied to the non-woven materials and/or (b) a characteristic of energy applied to cause another portion of the elastic strand to be weakly bonded or not bonded at a second location between the nonwoven layers, thereby creating a first area of entrapped elastic in which the elastic strand is entrapped under tension between or bonded to the layers and a second area of unentrapped elastic in which the elastic strand is not entrapped or weakly bonded to the nonwoven layers to produce an intermittent pattern of bonding of the elastic strand relative to the nonwoven materials.

[0030] A peak force applied to the non-woven materials is modified by reducing the peak force by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to a peak force applied at the first location. The characteristic of energy can be a peak amplitude, which can be modified by reducing the peak amplitude by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to a peak amplitude applied at the first location.

[0031] The characteristic of energy can be a peak amplitude, which can be modified by reducing the peak amplitude by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to the peak amplitude applied at the first location. [0032] A peak force applied to the non-woven materials can be modified by reducing the peak force by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to the peak force applied at the first location.

[0033] The controller can be further configured to, as the first bonding module is rotating about the rotation axis, increase (a) the force applied to the non-woven materials and/or (b) the characteristic of energy to cause a third portion of the elastic strand to be severed or cut at a third location between the nonwoven layers, thereby creating an elastic-free area in which there exists no elastic strand between the layers. [0034] The force applied to the non-woven materials can be modified by increasing the peak force by at least 20% or by at least 30% or by at least 40% or by at least 50% or by no more than 300% relative to the peak force applied at the first location.

[0035] The apparatus can further include a human-machine interface (HMI) configured to provide one or more controls to cause a modification or adjustment of one or more of the force or the characteristic of energy. The characteristic of energy is not necessarily constant and follows a profile to bond or trap the portion of the elastic strand at the first location.

[0036] The second bonding module can be an ultrasonic horn assembly. Ultrasonic energy from an ultrasonic horn of the horn assembly can be directed toward the face of the anvil, and the ultrasonic horn assembly includes a stack. The ultrasonic horn has a sonotrode tip in which at least a portion thereof has a concave shape relative to an exterior surface of the first bonding module, which has a convex shape, at least a portion of the sonotrode tip having a radius of curvature that corresponds to a radius of curvature of the convex shape of the exterior surface of the anvil.

[0037] The apparatus can further include a cam (see FIG. 9) arranged relative to the first bonding module or the second bonding module to cause at least one of them to move away from the other during rotation of the cam under control of the controller such that responsive to the controller modifying the force at the second location, the controller causes the cam to rotate.

[0038] The apparatus can further include a linear encoder (see FIG. 8) arranged relative to the first bonding module or the second bonding module to cause at least one of them to move away from the other by operation of the linear encoder under control of the controller such that responsive to the controller modifying the force at the second location, the controller causes the linear encoder to move.

[0039] The applied force can be imparted from an external source to the first bonding module or to the second bonding module. The first bonding module can be a rotary anvil.

[0040] The ultrasonic horn assembly can be stationary or rotary. Ultrasonic energy includes an amplitude, and an ultrasonic frequency is applied to a horn of the ultrasonic horn assembly as the force is applied.

[0041] FIG. 10 illustrates a portion of a product 1000 having an elastic-free space or zone 1010. The product 1000 has an elastic-bearing portion composed of at least two non-woven layers bonded together without adhesives with a tensioned elastic strand between the two nonwoven layers. In this example, three bond or anchor points are shown 1002a, 1002b, 1002c that anchor the elastic between the non-woven materials of the product 1000, and arbitrary bond or anchor points 1004 that bond the multiple non-woven layers together at that site or area 1006 without any elastic strand being present.

[0042] The tensioned elastic strand 418 is cut or severed (see area 1010) creating two pieces having a first end 1018a and a second end 1018a. The first end 1018a is bonded by an ultrasonic weld 1002b between the two non-woven layers and the second end 1018b is bonded by another ultrasonic weld 1002b between the two non-woven layers such that an elastic-free space 1010 between the first end 1018a and the second end 1018b is free from elastic strand material. Note as shown a dangling free end is shown as the first end 1018a, but the presence of this non-tensioned or untensioned “dangler” is still considered to be within an elastic-free space 1010. Note the shape of the bonds or anchor points 1004, 1002a,b,c being shown as diamond shape is merely an example for ease of illustration and discussion, nor are they shown to scale but rather have been exaggerated again for ease of illustration and discussion. The shape of the anchor or welds can be any regular, irregular, or arbitrary shape. Likewise, the spacing between adjacent bonds is not to scale and has been shown arbitrarily for ease of illustration.

[0043] At least a portion of the elastic strand 418 is continuously bonded between the two non-woven layers to create a zone of continuous entrapment 1020 of the tensioned elastic strand 418 and an elastic-free zone 1010 bereft of any elastic strand (in a tensioned state). One or more dangling free ends, which are in an untensioned state, such as the first end 1018a, does not detract from the zone 1010 being elastic-free. In this example, a linear density of the untensioned elastic strand 418 in a relaxed state is between 150 and 1200 decitex (dtex). [0044] In this example, the first and second ends 1018a, b are applied in the continuous entrapment zone 1020, which can be (but does not have to be) immediately adjacent to the elastic-free zone 1010 on the product 1000.

[0045] In the elastic free zone 1010, optionally multiple bond welds 1030 can be present directly bonding the two non-woven layers together where the bond welds are made. In the area 1030 shown in FIG. 10, the two non-woven layers will be bonded directly to each other without any elastic running or being captured therebetween.

[0046] Alternatively, there can exist no ultrasonic bond welds between the two non-woven layers in or adjacent to the elastic-free zone 1010.

[0047] Alternately, there can exist no ultrasonic bond welds (anchors) between the two nonwoven layers on either side immediately adjacent to where the elastic strand 418 would be present if it were not cut or severed. [0048] FIG. 11 illustrates an article 1100 having an elastic-free zone 1110. The article includes an elastic-bearing portion 1120, 1106 composed of at least two non-woven layers bonded together without adhesives with a tensioned elastic strand 418 between the two nonwoven layers such that the tensioned elastic strand is cut or severed creating two pieces having a first end 1118a and a second end 1118b. The first end 1118a is bonded by an ultrasonic weld 1102a between the two non-woven layers and the second end 1118b is bonded by another ultrasonic weld 1102c between the two non-woven layers such that an elastic-free space 1110 present between the first end 1118a and the second end 1118b is free from elastic strand material. At least a portion of the elastic strand 418 is continuously bonded between the two non-woven layers to create a zone of continuous entrapment 1120 of the tensioned elastic strand and an elastic-free zone 1110 bereft of any elastic strand in a tensioned state. A linear density of the untensioned elastic strand in a relaxed state can be between 150 and 1200 deci tex (dtex).

[0049] FIG. 12 is a product or an article 1200 (e.g., a diaper) having slip and anchoring zones. The article 1200 has a non-woven layer having an edge portion folded over to create a folded region 1204 that includes a first fold surface 1206 (top) and a second fold surface 1208 (under the paper). The article 1200 includes an elastic strand 418 extending at least partially within the folded region 1204. Multiple anchoring bonds 1202a, b in an anchoring zone 1220 which anchor or entrap a first portion of the elastic strand 418 between the first fold surface 1206 and the second fold surface 1208.

[0050] Multiple lamination (anchoring) bonds 1230a, 1230b in a slip zone 1210 of the folded region 1204 which laminate or bond the first fold surface 1206 directly to the second fold surface 1208 either without entrapping any portion of the elastic strand present in the folded region or wherein no elastic strand is present in the slip zone 1210. The folded region 1204 is free of adhesive. The anchoring bonds 1202a, b and the lamination bonds 1230a, b together provide a majority (more than 51%) or a substantial majority (more than 60%) of bonding strength between the first fold surface 1206 and the second fold surface 1208.

[0051] In this example, there is no elastic strand 418 present in the slip zone 1210. The elastic strand 418 is multiple elastic strands (not shown but could be parallel with the strand 418 shown) extending at least partially within the folded region 1204.

[0052] In the slip zone 1210, at least a portion of the elastic strand 418a can be present in the folded region 1204 but is not entrapped between the first fold surface 1206 and the second fold surface 1208. In this example, the elastic strand is in a free or relaxed or non-tensioned state in the slip zone when no external force is applied to the article 1200. [0053] A bond density in the slip zone 1210 is no more than 40% or no more than 50% of a bond density in the anchoring zone, wherein the bond density is a percentage of a surface area across a surface where a bond is present compared to the area of the same surface where no bond is present, the bond joining or laminating at least two parts together.

[0054] The bond density in the anchoring zone 1220 can be between 30%-5%, and the bond density is a percentage of a surface area across a surface where a bond is present compared to the area of the same surface where no bond is present, the bond joining or laminating at least two parts together, namely, in this case the first fold surface 1206 and the second fold surface 1208. The bond density in the slip zone 1210 can be between 15%-2.5%.

[0055] Note that the article 1200 is shown as a rectangle for ease of illustration and discussion. The article 1200 can have any arbitrary shape or form. The article 1200 can be completely free of adhesive.

[0056] The article 1200 can be or include a leg cuff for a disposable diaper or protective underwear, and the folded region can correspond to a standing gather of the leg cuff. Again, the rectangular form is merely for ease of illustration and not intended to convey the actual shape of the article 1200 or portion thereof.

[0057] The non-woven layer shown in FIG. 12 can further include a second edge portion folded over to create a second folded region 1214 that includes a first fold surface 1216 (top) and a second fold surface 1218 (underneath). A second elastic strand 418b extends at least partially into the second folded region 1214. Multiple anchoring bonds 1242a, b in a second anchoring zone 1240 anchor or entrap a first portion of the second elastic strand 418b between the first fold surface 4126 and the second fold surface 1218 of the second folded region.

[0058] Multiple lamination bonds 1250a, b in a second slip zone 1270 of the second folded region 1214 laminate or bond the first fold surface 1216 of the second folded region directly to the second fold surface 1218 of the second folded region either without entrapping any portion of the second elastic strand present in the second folded region or wherein no elastic strand is present in the second slip zone 1270 (as shown). The second folded region 1214 can be free of adhesive. The anchoring bonds 1242a,b in the second anchoring zone 1240 and the lamination bonds 1250a, b in the second slip zone 1270 together provide a majority of bonding strength between the first fold surface 1216 of the second folded region and the second fold surface 1218 of the second folded region 1214.

[0059] The elastic strand 418b can be multiple elastic strands extending side-by-side separated by a distance in the folded region. Although one is shown in FIG. 12, in this example, the strands can run parallel to one another. [0060] A second article (not shown) can be bonded with the article 1200 to produce a product, which is completely free of adhesive.

[0061] FIG. 13 illustrates an article 1300 having an untensioned elastic present in a slip zone of a folded region 1304. The article 1300 includes a non-woven layer having an edge portion folded over to create a folded region 1304 that includes a first fold surface 1306 (top) and a second fold surface 1308 (underneath). An elastic strand 418 extends at least partially within the folded region 1304. Multiple anchoring bonds 1302a, b in an anchoring zone 1320 which anchor or entrap a first portion of the elastic strand 418 between the first fold surface 1306 and the second fold surface 1308. Multiple lamination bonds 1330a, b in a slip zone 1310 of the folded region 1304 laminate or bond the first fold surface 1306 directly to the second fold surface 1308 without entrapping any portion of the elastic strand present 418a in the slip zone 1310. The folded region 1304 is free of adhesive, and the anchoring bonds 1320 and the lamination bonds 1310 together provide a majority of bonding strength between the first fold surface 1306 and the second fold surface 1308 of the article 1300.

[0062] FIG. 14 illustrates an example electronic interface 1400 configured to receive inputs, such as human-machine inputs. The inputs include a process speed 1402 indicative of a throughput or a speed through which an article of manufacture is continuously assembled into a product by a machine 1450.

[0063] The interface 1400 includes a product length 1404 indicative of a length of the product, an anchor setpoint 1406 indicative of an anchor force and/or an anchor amplitude applied to create an ultrasonic bond or a weld on the article of manufacture in an anchor area to anchor or fix an elastic strand between layers of the article of manufacture where the ultrasonic bond or weld is formed. The interface 1400 includes an unanchored setpoint 1408 indicative of an unanchored force and/or an unanchored amplitude applied to the article of manufacture in an unanchored area of the article sufficient to cause the elastic strand to not be anchored or to not be present between ultrasonic welds or bonds in the unanchored area.

[0064] An operator can set these inputs, such as via a touchscreen or other human-machine interface, which are provided to the machine 1450 to configure the machine according to the received inputs 1410. The machine 1450, which can be any machine disclosed herein, is operated to produce or make or assemble the product or article according to at least the received inputs 1410.

[0065] Likewise, a method of configuring a machine can include storing in an electronic memory device configuration parameters, which include: a process speed 1402 indicative of a throughput or a speed through which an article of manufacture is continuously assembled into a product by a machine; a product length 1404 indicative of a length of the product; an anchor setpoint 1406 indicative of an anchor force and/or an anchor amplitude applied to create an ultrasonic bond or a weld on the article of manufacture in an anchor area to anchor or fix an elastic strand between layers of the article of manufacture where the ultrasonic bond or weld is formed; an unanchored setpoint 1408 indicative of an unanchored force and/or an unanchored amplitude applied to the article of manufacture in an unanchored area of the article sufficient to cause the elastic strand to not be anchored or to not be present between ultrasonic welds or bonds in the unanchored area.

[0066] Responsive to receiving the configuration parameters 1410, the machine 1450 is caused to be configured according to at least the received configuration parameters. The machine is further caused to be operated to assemble or produce or make the product or article according to at least the received configuration parameters 1410.

[0067] The foregoing description of the specific implementations will so fully reveal the general nature of the implementations herein that others can, by applying current knowledge, readily modify and/or adapt for various applications without departing from the generic concept, and, therefore, such modifications and adaptations should and are intended to be comprehended within the meaning and range of equivalents of the disclosed implementations. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the implementations herein have been described in terms of preferred implementations, those skilled in the art will recognize that the implementations herein can be practiced with modification within the spirit and scope of the implementations as described herein.

Claims

What is claimed is:

1. An apparatus configured to entrap intermittent or non-continuous portions of an elastic strand between nonwoven materials, comprising: an anvil having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges configured to guide the nonwoven materials across the face of the anvil in a direction of rotation about the rotation axis; a stationary or rotary ultrasonic horn assembly positioned relative to the anvil such that ultrasonic energy from the horn assembly is directed toward the face of the anvil; a roller positioned against the face of the anvil to receive therebetween the nonwoven materials and the tensioned elastic strand; and a cutting element on the anvil or on the horn assembly positioned upstream in the direction of rotation from the roller such that the elastic strand is cut or severed by the cutting element into two portions while at the same time the roller pinches one of the two portions between the nonwoven materials, leaving at least an area of no tensioned elastic, the area having a length corresponding to a circumferential distance between the roller and the horn assembly.

2. The apparatus of claim 1, wherein each of the ridges includes a plurality of interspaced lands and notches, and each of the ridges having a width and a length that is longer than the width, the ridges being spaced circumferentially about the face, wherein the ridges extend across the face by less than the width dimension, and wherein each of the lands and each of the notches are oriented parallel to the circumferential axis.

3. The apparatus of claim 1, wherein the elastic strand is a plurality of elastic strands having a decitex (dtex) in a relaxed and untensioned state between 150 and 1200 grams per 10 km.

4. The apparatus of claim 3, wherein the decitex is between 300 and 800 grams per 10 km.

5. The apparatus of claim 1, wherein the cutting element is on the anvil and corresponds to least one of the ridges, wherein the ultrasonic horn is stationary relative to the anvil, and wherein a height of the cutting element is higher compared to a height of the plurality of ridges and the cutting element is positioned on the anvil along a travel path of the elastic strand, or wherein a height of the cutting element is the same as a height of at least one of the plurality of ridges such that a portion of the elastic strand to be cut passes over or across the cutting element.

6. A product made using the apparatus of claim 1.

7. A method of entrapping intermittent or non-continuous portions of an elastic strand between nonwoven materials, comprising the steps of: feeding layers of non-woven material and an elastic strand over an anvil having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges configured to guide the nonwoven materials across the face of the anvil in a direction of rotation about the rotation axis; rotating the anvil relative to an ultrasonic horn assembly positioned relative to the anvil such that ultrasonic energy from the horn assembly is directed toward the face of the anvil; positioning a roller against the face of the anvil to receive therebetween the nonwoven materials and the tensioned elastic strand; cutting the elastic strand into two portions by a cutting element on the anvil or on the horn assembly positioned upstream in the direction of rotation from the roller, while pinching by the roller one of the two portions between the nonwoven materials, leaving at least an area of no elastic having a length corresponding to a circumferential distance between the roller and the horn assembly.

8. A product, comprising: an elastic-bearing portion composed of at least two non-woven layers bonded together without adhesives with a tensioned elastic strand between the two non-woven layers such that: the tensioned elastic strand is cut or severed creating two pieces having a first end and a second end, wherein the first end is bonded by an ultrasonic weld between the two non-woven layers and the second end is bonded by another ultrasonic weld between the two non-woven layers such that an elastic-free space between the first end and the second end is free from elastic strand material; and at least a portion of the elastic strand is continuously bonded between the two non-woven layers to create a zone of continuous entrapment of the tensioned elastic strand and an elastic-free zone bereft of any elastic strand in a tensioned state, wherein a linear density of the untensioned elastic strand in a relaxed state is between 150 and 1200 deci tex (dtex).

9. The product of claim 8, wherein any dangling or free ends of either of the two pieces of elastic strand present in the elastic-free space between the first and second ends are in an untensioned state.

10. The product of claim 8, wherein the first and second ends of elastic strand are applied in the continuous entrapment zone.

11. The product of claim 8, wherein the zone of continuous entrapment is immediately adjacent to the elastic-free zone on the product.

12. The product of claim 8, further comprising a plurality of bond welds in the elastic-free zone directly bonding the two non-woven layers together where the plurality of bond welds are made.

13. The product of claim 8, wherein there are no ultrasonic bond welds between the two non-woven layers in or adjacent to the elastic-free zone.

14. The product of claim 8, wherein there are no ultrasonic bond welds between the two non-woven layers on either side immediately adjacent to where the elastic strand would be present if it were not cut or severed.

15. An apparatus configured to entrap intermittent or non-continuous portions of an elastic strand between nonwoven materials, comprising: a first bonding module having a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of protrusions or ridges configured to urge the nonwoven materials across the face of the first bonding module in a direction of rotation about the rotation axis; a second bonding module positioned relative to the first bonding module and configured to move laterally relative to the first bonding module; and a controller operatively coupled to the ultrasonic horn assembly and configured to: as the first bonding module is rotating about the rotation axis, cause at least an applied force to be applied to the nonwoven materials to bond or trap a portion of the elastic strand at a first location between adjoined layers of the nonwoven materials; and as the first bonding module is rotating about the rotation axis, modify at least (a) the force applied to the non-woven materials and/or (b) a characteristic of energy applied to cause another portion of the elastic strand to be weakly bonded or not bonded at a second location between the nonwoven layers, thereby creating a first area of entrapped elastic in which the elastic strand is entrapped under tension between or bonded to the layers and a second area of unentrapped elastic in which the elastic strand is not entrapped or weakly bonded to the nonwoven layers to produce an intermittent pattern of bonding of the elastic strand relative to the nonwoven materials.

16. The apparatus of claim 15, wherein a peak force applied to the non-woven materials is modified by reducing the peak force by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to a peak force applied at the first location.

17. The apparatus of claim 15, wherein the characteristic of energy is peak amplitude, which is modified by reducing the peak amplitude by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to a peak amplitude applied at the first location.

19. The apparatus of claim 16, wherein the characteristic of energy is peak amplitude, which is modified by reducing the peak amplitude by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to the peak amplitude applied at the first location.

21. The apparatus of claim 18, wherein a peak force applied to the non-woven materials is modified by reducing the peak force by at least 50% or by at least 60% or by at least 70% or by at least 80% or by no more than 90% relative to the peak force applied at the first location.

22. The apparatus of claim 15, wherein the controller is further configured to: as the first bonding module is rotating about the rotation axis, increase (a) the force applied to the non-woven materials and/or (b) the characteristic of energy to cause a third portion of the elastic strand to be severed or cut at a third location between the nonwoven layers, thereby creating an elastic-free area in which there exists no elastic strand between the layers.

23. The apparatus of claim 22, wherein the force applied to the non-woven materials is modified by increasing the peak force by at least 20% or by at least 30% or by at least 40% or by at least 50% or by no more than 300% relative to the peak force applied at the first location.

24. The apparatus of claim 22, wherein the characteristic of energy is peak amplitude, which is modified by increasing the peak amplitude by at least 20% or by at least 30% or by at least 40% or by at least 50% or by no more than 300% relative to the peak amplitude applied at the first location.

26. The apparatus of claim 15, further comprising a human-machine interface configured to provide one or more controls to cause a modification or adjustment of one or more of the force or the characteristic of energy.

27. The apparatus of claim 15, wherein the characteristic of energy is not constant and follows a profile to bond or trap the portion of the elastic strand at the first location.

28. The apparatus of claim 15, wherein the second bonding module is an ultrasonic horn assembly, and wherein ultrasonic energy from an ultrasonic horn of the horn assembly is directed toward the face of the anvil, the ultrasonic horn assembly including a stack, wherein the ultrasonic horn has a sonotrode tip in which at least a portion thereof has a concave shape relative to an exterior surface of the first bonding module, which has a convex shape, at least a portion of the sonotrode tip having a radius of curvature that corresponds to a radius of curvature of the convex shape of the exterior surface of the anvil.

29. The apparatus of claim 15, further comprising a cam arranged relative to the first bonding module or the second bonding module to cause at least one of them to move away from the other during rotation of the cam under control of the controller such that responsive to the controller modifying the force at the second location, the controller causes the cam to rotate.

30. The apparatus of claim 15, further comprising a linear encoder arranged relative to the first bonding module or the second bonding module to cause at least one of them to move away from the other by operation of the linear encoder under control of the controller such that responsive to the controller modifying the force at the second location, the controller causes the linear encoder to move.

31. The apparatus of claim 15, wherein the applied force is imparted from an external source to the first bonding module or to the second bonding module.

32. The apparatus of claim 15, wherein the first bonding module is a rotary anvil.

33. The apparatus of claim 32, wherein the second bonding module is an ultrasonic horn assembly, and wherein ultrasonic energy from the horn assembly is directed toward the face of the anvil, the ultrasonic horn assembly including a stack.

34. The apparatus of claim 33, wherein the ultrasonic horn assembly is stationary.

35. The apparatus of claim 34, wherein ultrasonic energy includes an amplitude and a frequency is applied to a horn of the ultrasonic horn assembly as the force is applied.

36. An article, comprising: an elastic-bearing portion composed of at least two non-woven layers bonded together without adhesives with a tensioned elastic strand between the two non-woven layers such that: the tensioned elastic strand is cut or severed creating two pieces having a first end and a second end, wherein the first end is bonded by an ultrasonic weld between the two non-woven layers and the second end is bonded by another ultrasonic weld between the two non-woven layers such that an elastic-free space between the first end and the second end is free from elastic strand material; and at least a portion of the elastic strand is continuously bonded between the two non-woven layers to create a zone of continuous entrapment of the tensioned elastic strand and an elastic-free zone bereft of any elastic strand in a tensioned state, wherein a linear density of the untensioned elastic strand in a relaxed state is between 150 and 1200 deci tex (dtex).

37. An article, comprising: a non-woven layer having an edge portion folded over to create a folded region that includes a first fold surface and a second fold surface; an elastic strand extending at least partially within the folded region; a plurality of anchoring bonds in an anchoring zone which anchor or entrap a first portion of the elastic strand between the first fold surface and the second fold surface; a plurality of lamination bonds in a slip zone of the folded region which laminate or bond the first fold surface directly to the second fold surface either without entrapping any portion of the elastic strand present in the folded region or wherein no elastic strand is present in the slip zone, wherein the folded region is free of adhesive or wherein the plurality of anchoring bonds and the plurality of lamination bonds together provide a majority of bonding strength between the first fold surface and the second fold surface.

38. The article of claim 37, wherein there is no elastic strand present in the slip zone, and wherein the elastic strand is a plurality of elastic strands extending at least partially within the folded region.

39. The article of claim 37, wherein in the slip zone, at least a portion of the elastic strand is present in the folded region but is not entrapped between the first fold surface and the second fold surface, the elastic strand being in a relaxed or non-tensioned state in the slip zone when no external force is applied to the article.

40. The article of claim 37, wherein a bond density in the slip zone is no more than 40% or no more than 50% of a bond density in the anchoring zone, wherein the bond density is a percentage of a surface area across a surface where a bond is present compared to the area of the same surface where no bond is present, the bond joining or laminating at least two parts together.

41. The article of claim 37, wherein a bond density in the anchoring zone is between 30%- 5%, wherein the bond density is a percentage of a surface area across a surface where a bond is present compared to the area of the same surface where no bond is present, the bond joining or laminating at least two parts together, namely, in this case the first fold surface and the second fold surface.

42. The article of claim 41, wherein a bond density in the slip zone is between 15%-2.5%.

43. The article of claim 37, wherein the article is free of adhesive.

44. The article of claim 37, wherein the article includes a leg cuff for a disposable diaper or protective underwear, and wherein the folded region corresponds to a standing gather of the leg cuff.

45. The article of claim 37, wherein the non-woven layer includes a second edge portion folded over to create a second folded region that includes a first fold surface and a second fold surface, the article further comprising: a second elastic strand extending at least partially into the second folded region; a plurality of anchoring bonds in a second anchoring zone which anchor or entrap a first portion of the second elastic strand between the first fold surface and the second fold surface of the second folded region; a plurality of lamination bonds in a second slip zone of the second folded region which laminate or bond the first fold surface of the second folded region directly to the second fold surface of the second folded region either without entrapping any portion of the second elastic strand present in the second folded region or wherein no elastic strand is present in the second slip zone, wherein the second folded region is free of adhesive or wherein the plurality of anchoring bonds in the second anchoring zone and the plurality of lamination bonds in the second slip zone together provide a majority of bonding strength between the first fold surface of the second folded region and the second fold surface of the second folded region.

46. The article of claim 37, wherein the elastic strand is a plurality of elastic strands extending side-by-side separated by a distance in the folded region.

47. The article of claim 37, being completely free of adhesive, in combination with a second article that is bonded to the article.

48. The article of claim 37, wherein a linear density of the elastic strand in a non-tensioned or relaxed state is between 150 and 1200 decitex (dtex).

49. An article, comprising: a non-woven layer having an edge portion folded over to create a folded region that includes a first fold surface and a second fold surface; an elastic strand extending at least partially within the folded region; a plurality of anchoring bonds in an anchoring zone which anchor or entrap a first portion of the elastic strand between the first fold surface and the second fold surface; a plurality of lamination bonds in a slip zone of the folded region which laminate or bond the first fold surface directly to the second fold surface either without entrapping any portion of the elastic strand present in the folded region or wherein no elastic strand is present in the slip zone, wherein the folded region is free of adhesive or wherein the plurality of anchoring bonds and the plurality of lamination bonds together provide a majority of bonding strength between the first fold surface and the second fold surface.

50. A method, comprising the steps of: providing an electronic interface configured to receive a plurality of inputs, the plurality of inputs including: a process speed indicative of a throughput or a speed through which an article of manufacture is continuously assembled into a product by a machine; a product length indicative of a length of the product; an anchor setpoint indicative of an anchor force and/or an anchor amplitude applied to create an ultrasonic bond or a weld on the article of manufacture in an anchor area to anchor or fix an elastic strand between layers of the article of manufacture where the ultrasonic bond or weld is formed; an unanchored setpoint indicative of an unanchored force and/or an unanchored amplitude applied to the article of manufacture in an unanchored area of the article sufficient to cause the elastic strand to not be anchored or to not be present between ultrasonic welds or bonds in the unanchored area; responsive to receiving the plurality of inputs, causing the machine to be configured according to at least the received plurality of inputs; and causing the machine to operate to assemble the product according to at least the received plurality of inputs.

51. The method of claim 50, wherein the plurality of inputs further includes a speed scale factor indicative of a fraction or percentage of the process speed.

52. The method of claim 50, wherein the plurality of inputs further include: an activated region dimension indicative of a region where a plurality of ultrasonic bonds or welds are formed on the article in the anchor area; and/or a non-activated region dimension indicative of a region where no elastic strand is present or where one or more elastic strands is present in a non-tensioned or relaxed state.

53. The method of claim 52, wherein the dimension is a length or a width or a radius, wherein the length dimension extends along the same direction as the product length.

54. The method of claim 52, wherein the activated region dimension is adjustable via the electronic interface to be or to be representative of a percentage of the activated region dimension relative to the product length.

55. The method of claim 54, wherein the percentage is adjustable between 50% and 75% or any range therebetween.

56. The method of claim 50, wherein the anchored area is free of adhesive.

57. The method of claim 50, wherein the anchor setpoint is a plurality of anchor setpoints, a first of the plurality of anchor setpoints being indicative of the anchor force applied to create the ultrasonic bond or weld and a second of the plurality of anchor setpoints being indicative of the anchor amplitude applied to the article, the anchor amplitude being an amplitude of ultrasonic energy used to create the ultrasonic bond or weld on the article.

58. The method of claim 50, wherein the unanchored setpoint is a plurality of unanchored setpoints, a first of the unanchored setpoints being indicative of an unanchored force applied to the article and a second of the plurality of unanchored setpoints being indicative of an unanchored amplitude, the unanchored amplitude being an amplitude of ultrasonic energy applied to create a weld or bond in the unanchored area of the article.

59. The method of claim 50, further the causing the machine to operate to assemble the product includes causing a rotary anvil to rotate according to a rotary speed that carries out the process speed, the layers of the article of manufacture passing over the rotary anvil.

60. The method of claim 50, wherein the ultrasonic bond or weld is formed by ultrasonic energy imparted by an ultrasonic horn.

61. The method of claim 60, wherein the ultrasonic horn is a rotary ultrasonic horn or a fixed ultrasonic horn having a linearly moving ultrasonic stack terminating with a sonotrode that contacts the article of manufacture being assembled by the machine.

62. The method of claim 50, wherein a linear density of the elastic strand in a non-tensioned or relaxed state is between 150 and 1200 decitex (dtex).

63. The method of claim 50, wherein the electronic interface includes a wired or wireless communications interface, an electronic data interface, a human-machine interface, an electronic keyboard, or a touchscreen.

64. The method of claim 50, wherein the process speed is adjustable via the electronic interface across a range that includes a minimum of no fewer than 100 parts per minute (ppm) up to 200 ppm or 300 ppm or 400 ppm or any subset within the range.

65. A method, comprising the steps of: storing in an electronic memory device a plurality of configuration parameters, the plurality of configuration parameters including: a process speed indicative of a throughput or a speed through which an article of manufacture is continuously assembled into a product by a machine; a product length indicative of a length of the product; an anchor setpoint indicative of an anchor force and/or an anchor amplitude applied to create an ultrasonic bond or a weld on the article of manufacture in an anchor area to anchor or fix an elastic strand between layers of the article of manufacture where the ultrasonic bond or weld is formed; an unanchored setpoint indicative of an unanchored force and/or an unanchored amplitude applied to the article of manufacture in an unanchored area of the article sufficient to cause the elastic strand to not be anchored or to not be present between ultrasonic welds or bonds in the unanchored area; responsive to receiving the plurality of configuration parameters, causing the machine to be configured according to at least the received plurality of configuration parameters; and causing the machine to operate to assemble the product according to at least the received plurality of configuration parameters.