Abstract: An apparatus and method for applying a first web to a base web in a nonlinear pattern as the base web is advanced in a machine direction in contact with a back-up roller are disclosed. The apparatus can include a guide roller and a guide roller translations system. The guide roller can be configured to define a nip with the back-up roller. The guide roller translation system can be configured to allow the guide roller to move with respect to the back-up roller to control the position of the nip to allow the first web to be applied to the base web in the non-linear pattern in the machine direction.

Abstract: A method of bonding a first web of material to a second web of material to form a composite material is disclosed herein. First, a first web of material and a second web of material moving in a machine direction is provided. The webs of material pass over a first energy application device extending transverse in the cross-machine direction. The first energy application device includes a primary bonding pattern and a secondary bonding pattern. The primary bonding pattern in combination with the secondary bonding pattern extends continuously across the first energy application device in the cross-machine direction. In addition, a second energy application device is provided. The second energy application device is moved in the cross-machine direction, and thereby extending the second energy application device over the first energy application device and operating the first and second energy application devices in combination to bond a composite web.

Abstract: An applicator for and method of guiding a first web to a base web in a nonlinear pattern as the base web is advanced in a machine direction are disclosed. The applicator can include a support structure, a cantilever arm, a guide roller, and a connecting link. The cantilever arm can be supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction. The guide roller can guide the first web onto the base web and can be pivotally mounted on the cantilever arm for pivotal movement of the guide roller with respect to the cantilever arm. The connecting link can be operatively coupled to the guide roller. Pivotal movement of the guide roller can be dependent on movement of the connecting link. Positioning of the guide roller in the cross machine direction can be dependent on movement of the cantilever arm.

Abstract: An anvil system for use in an ultrasonic bonder includes an anvil assembly including an anvil bar having an anvil aperture in at least one anvil bar longitudinal end, the anvil aperture having an anvil aperture inner surface, a shaft separate from the anvil bar and partially disposed in the anvil aperture, the shaft having a circumferential surface and extending outwardly beyond the anvil bar longitudinal end, and a first elastomeric shaft O-ring disposed on the shaft between the shaft circumferential surface and the anvil aperture inner surface; a mounting bracket with a mounting bracket hole having a hole surface; a bushing disposed in the mounting bracket hole and sized to accommodate an end of the shaft, the bushing having a bushing inner surface; and a second elastomeric shaft O-ring disposed on the shaft between the shaft circumferential surface and the bushing inner surface.

Abstract: An apparatus and method for applying a first web to a base web in a nonlinear pattern as the base web is advanced in a machine direction in contact with a back-up roller are disclosed. The apparatus can include a guide roller and a guide roller translations system. The guide roller can be configured to define a nip with the back-up roller. The guide roller translation system can be configured to allow the guide roller to move with respect to the back-up roller to control the position of the nip to allow the first web to be applied to the base web in the non-linear pattern in the machine direction.

Abstract: An applicator for and method of guiding a first web to a base web in a nonlinear pattern as the base web is advanced in a machine direction are disclosed. The applicator can include a support structure, a cantilever arm, a guide roller, and a connecting link. The cantilever arm can be supported by the support structure and moveable through a range of motion relative to the support structure in a cross machine direction. The guide roller can guide the first web onto the base web and can be pivotally mounted on the cantilever arm for pivotal movement of the guide roller with respect to the cantilever arm. The connecting link can be operatively coupled to the guide roller. Pivotal movement of the guide roller can be dependent on movement of the connecting link. Positioning of the guide roller in the cross machine direction can be dependent on movement of the cantilever arm.

Abstract: A method of bonding a first web of material to a second web of material to form a composite material is disclosed herein. First, a first web of material and a second web of material moving in a machine direction is provided. The webs of material pass over a first energy application device extending transverse in the cross-machine direction. The first energy application device includes a primary bonding pattern and a secondary bonding pattern. The primary bonding pattern in combination with the secondary bonding pattern extends continuously across the first energy application device in the cross-machine direction. In addition, a second energy application device is provided. The second energy application device is moved in the cross-machine direction, and thereby extending the second energy application device over the first energy application device and operating the first and second energy application devices in combination to bond a composite web.

Abstract: An anvil system for use in an ultrasonic bonder includes an anvil assembly including an anvil bar having an anvil aperture in at least one anvil bar longitudinal end, the anvil aperture having an anvil aperture inner surface, a shaft separate from the anvil bar and partially disposed in the anvil aperture, the shaft having a circumferential surface and extending outwardly beyond the anvil bar longitudinal end, and a first elastomeric shaft O-ring disposed on the shaft between the shaft circumferential surface and the anvil aperture inner surface; a mounting bracket with a mounting bracket hole having a hole surface; a bushing disposed in the mounting bracket hole and sized to accommodate an end of the shaft, the bushing having a bushing inner surface; and a second elastomeric shaft O-ring disposed on the shaft between the shaft circumferential surface and the bushing inner surface.

Abstract: An energy system for applying energy to a workpiece includes a first energy application device, mounted such that the first energy application device has a fixed position relative to the workpiece during energy application; a second energy application device, mounted such that the second energy application device has a moveable position relative to the workpiece to apply energy to the workpiece at a point moving progressively across the workpiece, wherein one of the first and second energy application devices is an anvil and the other of the first and second energy application devices is an ultrasonic bonder; and a controller for regulating the application of energy to the workpiece, wherein the controller is configured to adjust progressively across the workpiece one or more of bonder vibration amplitude versus position on the workpiece, bonder pressure versus position on the workpiece, and horn travel velocity versus position on the workpiece.

Abstract: A disposable garment, subassemblies of the garment, and apparatus and methods for making the garment and subassemblies. The garment has elasticized leg and waist openings. The apparatus and methods of the invention facilitate assembling leg elastics and crotch elastics into the garment subassemblies, with the leg elastics extending across the width of the garment, and the crotch elastics extending along the length of the garment, while assembling a series of the garment subassemblies in a continuous web structure at a constant, or relatively constant, continuous and efficient speed. The leg elastics are installed across the crotch. The resulting garment is free from resilient tension across the crotch when the crotch portion is extended across the width of the garment.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to transferring discrete parts to a continuous web, whether paper, film, composite, or the like. Specifically, the invention relates to methods and apparatus for taking discrete parts from a source in a taking zone, optionally taking the discrete parts as components of a continuous web, onto a transport head on a transfer assembly, severing the discrete parts from the continuous web if received as part of a continuous web, rotating the transfer assembly about a first axis and correspondingly rotating the transport head about a second axis radial to the first axis, to thereby present the discrete parts to a receiver in a transfer zone, and transferring the discrete parts to the receiver in the transfer zone.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in festoon systems by connecting corresponding movably mounted festoon rolls to an actuator, sensing parameters such as position, tension, velocity, and acceleration related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the movably mounted festoon rolls to control tension in the web while providing limited accumulation of a length of the web. The festoon control system can be used to attenuate tension disturbances, in the alternative to create controlled tension disturbances.

Abstract: This invention pertains to a three dimensional disposable garment, subassemblies of the garment, and apparatus and methods for making the garment and subassemblies. The garment is designed to hold a primary absorbent sanitary pad. The garment may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. The garment provides backup protection to control egress of fluids that leak or seep around or through the primary sanitary pad. The garment includes a secondary absorbent positioned in the crotch area and extending into the body of the disposable garment, front and back, and preferably over the leg elastics to trap, inside the garment, leakage from the primary absorbent, and to prevent strike through onto e.g. outer clothing and bed linen.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in festoon systems by connecting corresponding movably mounted festoon rolls to an actuator, sensing parameters such as position, tension, velocity, and acceleration related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the movably mounted festoon rolls to control tension in the web while providing limited accumulation of a length of the web. The festoon control system can be used to attenuate tension disturbances, in the alternative to create controlled tension disturbances.

Abstract: This invention pertains to a machine and process for cutting discrete workpiece components from webs of material, precisely registering them with respect to one another, and depositing them with precise registration onto a constantly moving web of material, the webs of material optionally all moving at different speeds. In a particular embodiment of the invention, a process for manufacturing a multi-component absorbent personal hygiene article is described.

Abstract: This invention pertains to a machine and process for cutting discrete workpiece components from webs of material precisely registering them with respect to one another, and depositing them with precise registration onto a constantly moving web of material, the webs of material optionally all moving at different speeds. In a particular embodiment of the invention, a process for manufacturing a multi-component absorbent personal hygiene article is described.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in a festoon system by connecting a corresponding festoon to actuator or the like, sensing variables such as position, tension, velocity, and acceleration parameters related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the upper festoon rolls to control tension disturbances in the web while providing limited accumulation of a length of the web. In some applications of the invention, the festoon control system is used to attenuate tension disturbances.

Abstract: A three dimensional disposable panty for holding a sanitary pad. The panty may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. The panty provides backup leakage protection to the sanitary pad. The panty includes an absorbent barrier composite positioned in the crotch area and extending into the body of the disposable panty front and back and over the leg elastics to trap pad leakage inside the pant and prevent liquid strike through onto outer clothing and bed linen.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in a festoon system by connecting a corresponding festoon to actuator or the like, sensing variables such as position, tension, velocity, and acceleration parameters related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the upper festoon rolls to control tension disturbances in the web while providing limited accumulation of a length of the web. In some applications of the invention, the festoon control system is used to attenuate tension disturbances.

Abstract: A three dimensional disposable panty for holding a sanitary pad. The panty may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. The panty provides backup leakage protection to the sanitary pad. The panty includes an absorbent barrier composite positioned in the crotch area and extending into the body of the disposable panty front and back and over the leg elastics to trap pad leakage inside the pant and prevent liquid strike through onto outer clothing and bed linen.