Abstract: An ultrasonic processing method and apparatus (20) can include a rotatable, ultrasonic horn member (28) that is operatively joined to an isolation member (42) which has high rigidity. Additionally, a rotatable anvil member (86) can be cooperatively positioned to provide a selected horn-anvil gap (106) between the anvil member (86) and the horn member (28). A transfer device (110) can be configured to selectively adjust the horn-anvil gap (106), and an automated drive (130) can be operatively connected to the transfer device (110) to selectively modify the horn-anvil gap (106). A force sensor (126) can be configured to detect a gap force at the horn-anvil gap (106), and an electronic processor (128) can be configured to employ an output from the force sensor (126) to monitor the gap force, and provide a drive signal to the automated drive (130) to thereby adjust the horn-anvil gap (106).

Abstract: An ultrasonic processing method and apparatus (20) can include a rotatable, ultrasonic horn member (28) that is operatively joined to an isolation member (42) which has high rigidity. Additionally, a rotatable anvil member (86) can be cooperatively positioned to provide a selected horn-anvil gap (106) between the anvil member (86) and the horn member (28). A transfer device (110) can be configured to selectively adjust the horn-anvil gap (106), and an automated drive (130) can be operatively connected to the transfer device (110) to selectively modify the horn-anvil gap (106). A force sensor (126) can be configured to detect a gap force at the horn-anvil gap (106), and an electronic processor (128) can be configured to employ an output from the force sensor (126) to monitor the gap force, and provide a drive signal to the automated drive (130) to thereby adjust the horn-anvil gap (106).

Abstract: An ultrasonic processing method and apparatus (20) can include a rotatable, ultrasonic horn member (28) that is operatively joined to an isolation member (42) which has high rigidity. A rotatable anvil member (86) can be cooperatively positioned to provide a selected horn-anvil gap (106), and an automated drive (130) can be connected to an actuator (110), or other transfer device, to automatically adjust the horn-anvil gap (106). An electronic processor (128) can be configured to monitor an intermittent gap force detected from an output provided by a force sensor (126), and can provide a drive signal to the automated drive (130) to thereby adjust the horn-anvil gap (106) to operatively maintain a target, gap force value.

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.