Abstract: A web unwinding and splicing system includes a turret unwind having a turret arm with rotatable shafts at opposing ends thereof to unwind a running web of an expiring web material roll and unwind a waiting web of a new web material roll. A web splicing unit operable with the turret unwind includes a web deflection device that bumps the running web onto the waiting web to splice the running web with the waiting web and a cutting device that selectively severs the running web, thereby creating a leading portion of the running web that is spliced to the waiting web and a trailing portion of the running web that remains separate from the waiting web. A vacuum system is positioned proximate the running web to suction in the trailing portion of the running web left on the expiring web material roll.

Abstract: An apparatus and method for manufacturing an elastic composite structure for an absorbent sanitary product includes a bonding unit configured to bond a first web layer to a second web layer via a bond pattern that includes at least one bond line having at least one pair of adjacent bonds. The bonding unit secures an elastic thread within a passage defined by the at least one pair of adjacent bonds. The passage has a cross-sectional area smaller than a cross-sectional area of the elastic thread in a non-tensioned state.

Abstract: An apparatus for manufacturing an elastic composite structure for an absorbent sanitary product includes an anvil with weld pattern comprising at least one anchoring region and at least one deactivating region. The anchoring region includes anchoring welds that form anchoring bonds that fuse facing web layers and anchor elastic thread(s) in position relative to the facing web layers. The deactivating region includes a break bar constructed to sever the thread(s). A method of manufacturing the elastic composite structure includes positioning a tensioned elastic thread between web layers, fusing the web layers to form an anchored zone that includes anchoring bonds that fuse the web layers and anchor the tensioned elastic thread therebetween, and cutting the thread to form a deactivated zone between adjacent portions of the anchored zone that is free of tensioned threads. The method further includes fusing the web layers within the deactivated zone.

Abstract: A system and method for folding a discrete absorbent sanitary product includes conveying a product in a machine direction along a main conveyor, folding the product at a first folding station, and later folding the absorbent sanitary product at a second folding station. The product is folded at each of the first and second folding stations by engaging the product with a first drum and rotating the absorbent sanitary product in a first rotational direction, contacting the product with one or more folding fingers traveling in the machine direction, engaging the product with a rotating member adjacent to the first drum and downstream therefrom in the machine direction, the rotating member rotating in the first rotational direction, and folding the product over the one or more folding fingers via rotation of the rotating member in the first rotational direction.

Abstract: A system and method for controlling the speed of both a continuous web and a bonding apparatus is provided in order to effectuate stronger bonds in the web. The bonding system includes a velocity changing device for increasing and decreasing a velocity of the web in a machine direction, an anvil and a corresponding ultrasonic horn that interact to form ultrasonic bonds on the web, and an anvil actuator configured to control a movement of the anvil. A control system is also included in the bonding system for controlling operation of the anvil actuator the velocity changing device, with the control system programmed to decrease a moving velocity of the web from a feed velocity to a bonding velocity as the web passes between the anvil and the ultrasonic horn and control movement of the anvil to synchronize the movement of the anvil with the moving velocity of the web.

Abstract: An apparatus for manufacturing an elastic composite structure is provided. The apparatus includes an anvil having a face with a first edge and a second edge separated in a cross-machine direction and a first contact surface extending out from the face, the first contact surface including a first notch. The first notch has an interior configured to receive a portion of an elastic thread and a portion of a web layer therein, and the first notch includes a first facing surface and a second facing surface defining at least a portion of the interior. Each of the first facing surface and the second facing surface are in a non-perpendicular orientation relative to the first contact surface and angled toward the first edge of the face.

Abstract: An apparatus for splicing comprises a first web support surface configured to support a traveling web thereon and a second web support surface configured to support a replacement web thereon. The first traveling web travels in a machine direction. The splicing assembly also comprises a first web sensor and a web joiner. A controller is configured to determine, via the first web sensor, a position of a trailing end of the traveling web and to, in response to determining the position of the trailing end, cause a leading end of the replacement web to be positioned adjacently to the trailing end. The computer is also configured to control the web joiner to create a joint coupling the trailing end to the leading end.

Abstract: A configurable cutting and transfer apparatus includes a cutter mechanism to cut an incoming web of material into a plurality of discrete articles and a transfer mechanism operable with the cutter mechanism to transfer and rotate the discrete articles from a web receiving location to an article placement location. The transfer mechanism includes a drive shaft rotatable about a transfer axis, a carriage plate mounted to the drive shaft so as to rotate therewith about the transfer axis, and a segmented puck wheel comprising a plurality of carriage units securable to, and repositionable on, the carriage plate so as to rotate therewith to travel along a transfer path about the transfer axis from the web receiving location to the pad placement location, each of the carriage units including a puck operable to provide a rotating and re-pitching of the articles between the web receiving location and the pad placement location.

Abstract: An apparatus for manufacturing an elastic composite structure for an absorbent sanitary product includes an anvil with weld pattern comprising at least one anchoring region and at least one deactivating region. The anchoring region includes anchoring welds that form anchoring bonds that fuse facing web layers and anchor elastic thread(s) in position relative to the facing web layers. The deactivating region includes a break bar constructed to sever the thread(s). A method of manufacturing the elastic composite structure includes positioning a tensioned elastic thread between web layers, fusing the web layers to form an anchored zone that includes anchoring bonds that fuse the web layers and anchor the tensioned elastic thread therebetween, and cutting the thread to form a deactivated zone between adjacent portions of the anchored zone that is free of tensioned threads. The method further includes fusing the web layers within the deactivated zone.

Abstract: An apparatus and method for leveling a bonding device and anvil in an assembly via a closed-loop control system is provided. The assembly includes an anvil, a bonding device positioned adjacent the anvil and configured to interact with the anvil to form the bonds on the web, and an actuator that enables adjustment of an orientation between the bonding device and the anvil. The assembly also includes a closed-loop control system configured to control operation of the actuator, with the closed-loop control system configured to monitor an operational parameter of the assembly indicative of interaction of the bonding device with the anvil, determine whether the bonding device is parallel or substantially parallel with the anvil based on the operational parameter, and when the bonding device is not parallel or substantially parallel with the anvil, cause the actuator to adjust the orientation between the bonding device and the anvil.

Abstract: An apparatus for applying elastics to a running web including a crank and arm, the arm arranged to reciprocate from side to side during use and having a laydown carriage carried on the arm, the laydown carriage including at least one eyelet arranged to support an elastic strand, the assembly further including a shoe guide.

Abstract: The present invention provides a method of providing a disposable product with zero waste ear formation and attaching the ears to a running chassis web.

Abstract: An apparatus and method for leveling a bonding device and anvil in an assembly via a closed-loop control system is provided. The assembly includes an anvil, a bonding device positioned adjacent the anvil and configured to interact with the anvil to form the bonds on the web, and an actuator that enables adjustment of an orientation between the bonding device and the anvil. The assembly also includes a closed-loop control system configured to control operation of the actuator, with the closed-loop control system configured to monitor an operational parameter of the assembly indicative of interaction of the bonding device with the anvil, determine whether the bonding device is parallel or substantially parallel with the anvil based on the operational parameter, and when the bonding device is not parallel or substantially parallel with the anvil, cause the actuator to adjust the orientation between the bonding device and the anvil.

Abstract: A machine for producing disposable products anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. An integrated production facility layout automatically orders and stocks raw material based on production plans, and commands a production machine to produce specific products of differing configurations, and automatically loads appropriately sized raw materials into the process.

Abstract: A system and method for controlling the speed of both a continuous web and a bonding apparatus is provided in order to effectuate stronger bonds in the web. The bonding system includes a velocity changing device for increasing and decreasing a velocity of the web in a machine direction, an anvil and a corresponding ultrasonic horn that interact to form ultrasonic bonds on the web, and an anvil actuator configured to control a movement of the anvil. A control system is also included in the bonding system for controlling operation of the anvil actuator the velocity changing device, with the control system programmed to decrease a moving velocity of the web from a feed velocity to a bonding velocity as the web passes between the anvil and the ultrasonic horn and control movement of the anvil to synchronize the movement of the anvil with the moving velocity of the web.

Abstract: An apparatus for manufacturing an elastic composite structure includes a first roller configured to transport a web layer in a machine direction and a laydown guide configured to guide a laydown pattern of a plurality of elastic threads. A rotary anvil comprises a first weld line having a first notch formed in a contact surface of the first weld line, the first notch having a first interior configured to receive a portion of a first elastic thread of the plurality of elastic threads and a portion of the web layer therein. The first notch comprises a facing surface defining at least a portion of the first interior. A smallest orientation angle of a first face axis normal to the facing surface with respect to a contact surface axis normal to the contact surface is a first angle that is less than 90 degrees.

Abstract: A web splicing apparatus is disclosed that includes a web unwinding unit configured to hold a running web material roll and a new web material roll and to unwind webbing from the running web material roll and a web splicing unit operable with the web unwinding unit to selectively splice the webbing of the running web material roll with webbing of the new web material roll. The web splicing unit further includes a cutting assembly configured to selectively sever the webbing of the running web material roll, a web deflection device, an actuator system configured to linearly translate the web deflection device in a first direction and a second direction opposite the first direction, and a locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection device in the first direction and the second direction.

Abstract: An apparatus and method for applying discrete segments to a continuous web includes feeding a first continuous web to a roller, the first continuous web comprising one or more layers, feeding a second continuous web to a vacuum anvil, cutting the first continuous web into a plurality of discrete segments via interaction of the roller with at least one cutting element selectively positionable adjacent the roller, transferring each of the plurality of discrete segments from the roller onto the second continuous web at a first location and via a vacuum pressure from the vacuum anvil, and bonding each of the plurality of discrete segments to the second continuous web at a second location downstream from the first location in a machine direction, each of the plurality of discrete segments bonded to the second continuous web via interaction of the vacuum anvil with a bonding device positioned at the second location.

Abstract: Apparatus and methods are provided for folding discrete items such as diapers at high speeds. Discrete items are conveyed in a machine direction toward a pair of engaging members rotating in the machine direction and first carrying a top side of a leading edge of the discrete item with a first engaging member away from the conveyor, and then carrying a bottom side of the leading edge with a second engaging member back towards the conveyor. The diaper fold is created at a contact point with a folding finger which travels rotationally and straight in a fixed orientation about a travel path into and out of contact with the diaper.

Abstract: An apparatus for applying elastics to a running web including a crank and arm, the arm arranged to reciprocate from side to side during use and having a laydown carriage carried on the arm, the laydown carriage including at least one eyelet arranged to support an elastic strand, the assembly further including a shoe guide.