Abstract: A distinctive method and apparatus for forming an article includes a moving of at least one first strand of material, such as strand (22), along an appointed machine-direction (34). The at least one first strand of material is attached to a base layer of material (42) to provide a substrate composite (40), and a laminate layer (44) can be placed adjacent the at least one first strand of material to provide a laminate composite web (48). In a particular aspect, at least one second strand of material, such as strand (56), can be moved along its appointed machine-direction, and the at least one second strand of material can be attached to the base layer (42). In another aspect, an appointed portion of the base layer (42) can be folded to substantially enclose the at least one second strand (56) with the base layer material.

Abstract: An improved apparatus and method for effecting an operation on at least one continuously moving substrate web is disclosed. In particular, the apparatus includes a patterned anvil roll which includes a plurality of projections arranged in a predetermined pattern for effecting an operation on the web such as, for example, bonding, cutting, embossing, perforating and the like. The anvil roll includes recesses between the projections and resilient release material located in the recesses to improve the release of the substrate web from the anvil roll.

Abstract: This invention relates to apparatus and methods for intermittently bonding a substrate web in fabricating a blank subassembly for an absorbent article. The invention comprises ultrasonic bonding apparatus including an anvil roll, a substrate web thereon, and at least one rotary ultrasonic horn. The substrate web can comprise at least first and second layers of material. The rotary ultrasonic horn, in combination with the anvil roll, ultrasonically bonds intermittent segments of the first and second layers of the substrate web to each other. Such intermittent bonds can comprise end seals for the absorbent articles. The ultrasonic horn and anvil roll are periodically separated from each other to provide the intermittent bonding of the substrate web. An actuator apparatus periodically moves the anvil roll and ultrasonic horn from engaging contact with each other preventing bond formation.

Abstract: This invention relates to apparatus and methods for fabricating a web or consolidating web precursor material in fabricating a web. The invention comprises ultrasonic bonding apparatus including an anvil roll receiving web materials thereon and receiving first and second rotary ultrasonic horns. The rotary ultrasonic horns, in combination with the anvil roll, ultrasonically bond segments of e.g. first and second webs to each other. Third and fourth rotary ultrasonic horns spaced about the circumference of the anvil roll, in combination with the anvil roll, ultrasonically bond other segments of the webs to each other. The full widths of the webs can be ultrasonically bonded using the rotary ultrasonic horns. An outer surface of the anvil roll preferably carries a bonding pattern defining the locations where bonding of the webs occurs. Additional e.g. third and fourth webs can be bonded by the ultrasonic bonding apparatus.