Method and apparatus for improving ultrasound formation

Abstract

Aspects disclosed herein relate to improvements in forming contact fasteners on non-woven materials or other thermoplastic and non-thermoplastic materials using ultrasound forming techniques. The improvement can be applied to a rotary type ultrasonic generator or a blade type ultrasonic generator. These improvements may include raised or recessed features in the functional surface of the sonotrode, methods and arrangements to preheat and / or cool the functional surface of the sonotrode, varying or fixing the surface velocity of the rotary sonotrode relative to the molding roller to form contact fasteners at desired pitches, and methods and arrangements to preheat and / or cool the functional surface of the sonotrode. And including a supplemental material with the substrate. Various molding rollers are also disclosed.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of U.S. Application Serial No. 63 / 403,022, filed on September 1, 2022, entitled "METHOD AND APPARATUS FOR IMPROVED ULTRASONIC FORMATION", and U.S. Application Serial No. 63 / 459,362, filed on April 14, 2023, entitled "METHOD AND APPARATUS FOR IMPROVED ULTRASONIC FORMATION", each of which is incorporated herein by reference in its entirety. Technical field

[0003] The disclosed embodiments relate to ultrasonic components and methods and apparatuses for improving the bonding and formation of products processed using ultrasonic techniques. Background art

[0004] Various types of contact fasteners are commonly used in applications including but not limited to baby diapers, adult diapers, feminine hygiene products, surgical gowns, wipes, agricultural fabrics, absorbent pads, and other industrial and consumer products. Two common types of contact fasteners include hook - and - loop fasteners and mushroom - and - loop fasteners. Hook - and - loop fasteners typically include a fabric strip having a plurality of monofilament fastener elements shaped like hooks that project from one surface and mate with a complementary fabric strip having a plurality of annular protrusions. Mushroom - and - loop fasteners similarly comprise complementary fabric strips with protruding elements, but the fastener elements alternatively comprise mushroom - shaped heads. Several processes and methods for producing contact fasteners are known to those skilled in the art. These methods include thermoplastic extrusion and molding, thermal bonding using rollers, needle punching and water jet techniques, and ultrasonic formation techniques. Specifically, ultrasonic formation techniques utilize the energy from ultrasonic vibrations to create a friction - like motion, thereby generating heat to allow the shaping of the base material. Summary of the invention

[0005] According to one aspect of the present invention, a system for ultrasonically forming a contact fastener is provided. The system may include a sonotrode having a functional surface and a molding roller having a plurality of fastener cavities. The functional surface of the sonotrode may be configured to apply ultrasonic vibrations to a substrate disposed between the functional surface of the sonotrode and the molding roller to form a contact fastener from the substrate. The sonotrode may also have one or more raised and / or recessed features disposed on the functional surface, and the raised and / or recessed features may be configured to progressively form the contact fastener from the substrate.

[0006] According to another aspect of the present invention, there is provided a system for ultrasonically forming contact fasteners. The system may include a rotary ultrasonic generator having a functional surface and a molding roller having a plurality of fastener cavities. The functional surface of the rotary ultrasonic generator may be configured to apply ultrasonic vibrations to a substrate disposed between the functional surface of the ultrasonic generator and the molding roller to form contact fasteners from the substrate. The rotary ultrasonic generator may include one or more raised and / or recessed features disposed on the functional surface. The rotary ultrasonic generator and the molding roller may also be driven at varying ratios. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Non-limiting embodiments incorporating one or more aspects of the present invention will be described by way of example with reference to the accompanying drawings, which are not necessarily to scale. For clarity, not all components are labeled in each figure, and not every component of each embodiment of the present invention is shown where illustration is not necessary for one of ordinary skill in the art to understand the present invention. In the drawings:

[0008] FIG. 1A is a prior art schematic view of an embodiment of a rotary ultrasonic generator device including a molding roller and a substrate;

[0009] FIG. 1B is an enlarged schematic view of region 1B of FIG. 1A;

[0010] FIG. 1C is a prior art schematic view of an embodiment of a vane ultrasonic generator device including a molding roller and a substrate;

[0011] FIG. 1D is a prior art schematic cross-sectional view of another embodiment of a vane ultrasonic generator device including a molding roller;

[0012] FIG. 2 is a prior art schematic view of an embodiment of a rotary ultrasonic generator device including a molding roller and a substrate, wherein the molding roller has a discontinuous region with fastener cavities;

[0013] Figure 3 is a schematic view of an embodiment of a rotary ultrasonic generator device having one or more discontinuous raised features and including a molding roller and a substrate;

[0014] Figure 4A is a schematic perspective view of an embodiment of a rotary ultrasonic generator device having one or more raised features of different heights;

[0015] Figure 4B is Figure 4A a cross-sectional view taken along line 4B-4B of the substrate of

[0016] Figure 5Schematic diagram of an embodiment of a rotary ultrasonic generator and including a molding roll;

[0017] Figure 6 Schematic diagram of an embodiment of a rotary ultrasonic generator device, the rotary ultrasonic generator device comprising one or more rolls around the periphery of the rotary ultrasonic generator and including a molding roll and a substrate;

[0018] Figure 7A Schematic perspective view of an embodiment of a vane ultrasonic generator device having one or more bleed channels and including a molding roll and a substrate;

[0019] Figure 7B Is Figure 7A Cross-sectional view taken along line 7B-7B of the substrate;

[0020] Figure 7C Schematic perspective view of an embodiment of a rotary ultrasonic generator device having one or more bleed channels and including a molding roll and a substrate;

[0021] Figure 7D Schematic diagram of an embodiment of the pattern of the undisturbed portion of the substrate;

[0022] Figure 7E Schematic diagram of another embodiment of the pattern of the undisturbed portion of the substrate;

[0023] Figure 7F Schematic diagram of another embodiment of the pattern of the undisturbed portion of the substrate;

[0024] Figure 7G Schematic diagram of another embodiment of the pattern of the undisturbed portion of the substrate;

[0025] Figure 7H Schematic diagram of another embodiment of the pattern of the undisturbed portion of the substrate;

[0026] Figure 7I Schematic diagram of another embodiment of the pattern of the undisturbed portion of the substrate;

[0027] Figure 8A Schematic diagram of an embodiment of a vane ultrasonic generator;

[0028] Figure 8B Schematic diagram of another embodiment of a vane ultrasonic generator;

[0029] Figure 9A Schematic diagram of an embodiment of a vane ultrasonic generator;

[0030] Figure 9BSchematic diagram of another embodiment of a vane type ultrasonic generator;

[0031] Figure 9C Schematic perspective view of another embodiment of a vane type ultrasonic generator;

[0032] Figure 10 Schematic perspective view of an embodiment of a vane type ultrasonic generator device, and shows a molding roll and a substrate;

[0033] Figure 11A Schematic perspective view of an embodiment of a vane type ultrasonic generator, which includes one or more passages;

[0034] Figure 11B Is Figure 11A Schematic side view of a vane type ultrasonic generator device, and includes a molding roll and a substrate;

[0035] Figure 11C Schematic perspective view of another embodiment of a vane type ultrasonic generator, which includes one or more passages;

[0036] Figure 12 Schematic diagram of an embodiment of a vane type ultrasonic generator device, and shows a molding roll and a substrate;

[0037] Figure 13A Schematic diagram of another embodiment of a vane type ultrasonic generator device, and shows a molding roll and a substrate;

[0038] Figure 13B Schematic diagram of another embodiment of a vane type ultrasonic generator device, and shows a molding roll and a substrate;

[0039] Figure 13C Schematic diagram of another embodiment of a vane type ultrasonic generator device, and shows a molding roll and a substrate;

[0040] Figure 13D Is Figure 13C Schematic diagram of a part of;

[0041] Figure 14A Schematic perspective view of an embodiment of a vane type ultrasonic generator;

[0042] Figure 14B Is along Figure 14A Cross-sectional view taken along line 14B-14B;

[0043] Figure 15 Schematic diagram of an embodiment of a vane type ultrasonic generator device bridging the features of the molding roll in Figure 2;

[0044] Figure 16 is a schematic diagram of the prior art of a vane type ultrasonic generator device and includes a molding roll and a substrate, which shows the remaining material formed on the substrate;

[0045] Figure 17 is a schematic diagram of an embodiment of a vane type ultrasonic generator device, which includes a molding roll and a substrate;

[0046] Figure 18A is a schematic perspective view of an embodiment of a vane type ultrasonic generator device, which includes a molding roll;

[0047] Figure 18B is Figure 18A an enlarged radial view of region 18B of

[0048] Figure 18C is a schematic diagram of an embodiment of a block of a fastener cavity;

[0049] Figure 18D is a schematic diagram of another embodiment of a block of a fastener cavity;

[0050] Figure 18E is a schematic diagram of another embodiment of a block of a fastener cavity;

[0051] Figure 19 is a prior art perspective view of an embodiment of a sleeve for mounting to a reel;

[0052] Figure 20A is a schematic diagram of an embodiment of a rotary ultrasonic generator device, which shows the substrate and the molding roll;

[0053] Figure 20B is Figure 20A a schematic perspective view of the substrate of leaving the molding reel;

[0054] Figure 21 is Figure 20A a schematic diagram of an enlarged view of a part of the rotary ultrasonic generator device of and shows the first substrate material;

[0055] Figure 22A is Figure 20A a schematic diagram of an enlarged view of a part of the rotary ultrasonic generator device of and shows the second substrate material;

[0056] Figure 22B is Figure 22A an enlarged view of region 22B of

[0057] Figure 23A is a schematic diagram of an embodiment of a vane type ultrasonic generator device and shows the substrate and the molding roll;

[0058] Figure 23Bis a schematic cross-sectional view of a molding roll including a sleeve fixed to a reel;

[0059] Figure 24 is a schematic cross-sectional view of another embodiment of the molding roll.

[0060] Figure 25 is a schematic cross-sectional view of another embodiment of the molding roll; and

[0061] Figure 26 is a schematic view of another embodiment of the molding roll. DETAILED DESCRIPTION

[0062] The inventors have found that ultrasonic forming techniques have limitations in the production of contact fasteners. These limitations exist in the use of both rotary and blade ultrasonic generators in combination with a molding roll to form contact fastener elements from a substrate material. The prior art US8784722 discloses the use of ultrasonic forming techniques using an ultrasonic generator device, a molding roll, and a substrate, the entire content of which is incorporated herein by reference. This prior art arrangement discloses the use of a rotary ultrasonic generator as shown in FIGS. 1A and 1B and the use of a blade ultrasonic generator as shown in FIGS. 1C and 1D.

[0063] As shown in FIG. 1A, the rotary ultrasonic generator device 1 can function by rotating together with the molding roll 3, wherein the outer periphery 5 of the molding roll can include a fastener cavity 4. As the substrate material 6 approaches the tangential contact area (i.e., the clamping portion) formed by the functional surface of the rotary ultrasonic generator and the molding roll (as shown in FIG. 1B), the compression on the substrate increases due to the large amount of ultrasonic energy applied in this area. This increased ultrasonic energy caused by the ultrasonic vibration of the rotary ultrasonic generator results in an increase in the heat and pressure applied to the substrate. The substrate material softens due to the applied heat and pressure, allowing some of the material to flow into the fastener cavity on the molding roll side of the substrate 14A, thereby forming a portion of the substrate into a contact fastener 13 (or other element, depending on the shape of the cavity in the molding roll). In this embodiment, since the rotary ultrasonic generator side of the substrate 14B does not contact the fastener cavity, no fastener element is produced on the rotary ultrasonic generator side of the substrate 14B. However, in other embodiments, the rotary ultrasonic generator can include a cavity for forming a corresponding element (e.g., a contact fastener). Additionally, both the rotary ultrasonic generator and the molding roll can include cavities, which can have the same shape or can have different shapes.

[0064] The inventors have recognized that the use of a rotary ultrasonic generator with the above configuration inherently limits the effectiveness of the device in softening the substrate because the limited tangential contact area requires a sufficiently high amount of compressive force to generate the sufficient heat and pressure required to soften the substrate. Therefore, the inventors have found that increasing the dwell time of the substrate under compression would be beneficial. One way is to increase the compression area of the device, which can be achieved by implementing a larger diameter ultrasonic generator or a molding roll. However, this method may lead to an increase in manufacturing costs and may have limited effectiveness due to the need for a larger amount of energy to operate. Additionally, due to the size limitations of a larger diameter ultrasonic generator or molding roll, this method may be limited by the available ultrasonic frequency range.

[0065] As an alternative to the rotary ultrasonic generator, a vane ultrasonic generator device 2 can be used in combination with a molding roll 3 to soften the incoming substrate material by ultrasonic vibration (Figure 1C). The vane ultrasonic generator can be used to overcome the problem of limited contact area associated with the rotary ultrasonic generator and can provide a longer dwell time under compression. Specifically, this can be achieved by designing the profile of the functional surface 7 (as shown in Figure 1D) such that the vane ultrasonic generator surface is substantially aligned with the molding roll to provide a larger compression area when applying ultrasonic energy to the substrate. Similarly, the molding roll can include a fastener cavity 4 along the outer periphery of the molding roll 5, and the fastener cavity is used to form a contact fastener by a portion of the incoming substrate. These vane ultrasonic generator devices impart ultrasonic energy to the substrate by vibrating relative to the molding roll, which generates a sufficient amount of the required pressure and heat to soften the substrate and form it into a contact fastener or other element in a manner similar to that described above.

[0066] However, the inventors have recognized that the vane ultrasonic generator configuration disclosed above has certain limitations that result from the profiling of the functional surface to achieve a longer dwell time under compression. Due to the continuous ultrasonic energy and the friction of the substrate passing through the vane ultrasonic generator device, the functional surface of the vane ultrasonic generator may become overheated. If the functional surface becomes overheated, the substrate may adhere to or be damaged by the functional surface of the vane ultrasonic generator. It is known to those skilled in the art that certain arrangements can be used to cool the ultrasonic generator surface, such as implementing with an ultrasonic generator material having heat transfer limiting characteristics, or using air or a similar medium to cool the functional surface of the vane ultrasonic generator.

[0067] In addition, during the forming process, the vane type ultrasonic generator device may not be able to sufficiently smooth the substrate surface, which may generate unwanted artifacts or irregularities in the processed substrate material. Specifically, the inventors have realized that during the formation of fastening elements (e.g., hook elements), the portion of the element formed on the substrate by the molding roller may protrude onto the side of the substrate that contacts the ultrasonic generator. This may be due to the air trapped in the compression area, which provides excessive heat to the substrate, making the substrate more prone to deformation and damage. In addition, the trapped air may cause microvoids to form in the substrate, and these microvoids may burst or rupture, leaving a rough surface finish. Artifacts may also occur during the extraction of the formed hook-shaped elements, resulting in deformation of the substrate surface. In some embodiments, the artifacts may appear in the form of remaining substrate material, which is deposited along the outer edge of the line of the fastening element during the processing. The inventors have also recognized that while artifacts mainly occur during the formation of the fastening elements as disclosed above, artifacts can also be generated by the composition of the substrate before processing. For example, if a composite substrate is used in an application, one or more components of the composite substrate may not be sufficiently softened or melted during processing, resulting in artifacts in the substrate surface. Although the formation of artifacts due to the use of a vane type ultrasonic generator has been discussed, artifacts may also be formed using a rotary ultrasonic generator. These artifacts may have undesirable effects, such as causing discomfort to the end user in contact fastener applications (e.g., diapers).

[0068] In addition to the limitations of the ultrasonic forming method using both the rotary and vane type ultrasonic generator techniques discussed previously, there are also limitations in forming discontinuous patches of fasteners rather than continuous lines of fasteners on the substrate. Traditionally, discontinuous patches of fasteners can be produced by manufacturing a molding roller with discontinuous regions or patches 8 with fastener cavities 4, as shown in the additional prior art embodiment of FIG. 2. In this embodiment, the regions of the fastener cavities can be raised above the outer surface of the molding roller 9 to limit the ultrasonic energy applied to the substrate between the regions by a rotary or vane type ultrasonic generator.

[0069] Another limitation that may occur is that some portions of the substrate may be lacking in material before processing. Any change in the density or mass or thickness of the substrate during the application of ultrasonic energy from the ultrasonic generator to the substrate will affect the formation of the fastening elements. Although it is possible to increase the average thickness of the incoming substrate material, this is not always beneficial because only certain regions may have a deficient amount of substrate. In addition, increasing the average thickness of the substrate may increase the manufacturing cost and may change the flexibility of the substrate to an unacceptable degree for a given application.

[0070] In view of the above, the inventors have recognized and understood that the rotary and vane ultrasonic generators can be improved to overcome these deficiencies. It should be understood that the concepts disclosed herein can be arranged in any suitable combination, as the present disclosure is not limited in this regard. Further, when considered in conjunction with the accompanying drawings, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments. For clarity, the numbering of the elements disclosed in the figures remains the same in the different illustrative embodiments. Additionally, the common terms disclosed herein are described below.

[0071] As used herein, the term "compression zone" is used to describe the area of the contact area formed by the contact of a substrate with a rotary or vane ultrasonic generator and a molding roll, wherein ultrasonic energy is applied to soften the incoming substrate material for forming fastener elements.

[0072] When referring to the material fed into the compression zone between a rotary or vane ultrasonic generator and a molding roll, the terms "substrate" or "substrate material" are used interchangeably herein. The substrate can include any suitable material, although nonwoven materials are cited in the present disclosure.

[0073] As used herein, the term "fastener element" or "contact fastener" is used to describe the protrusions formed by applying ultrasonic energy from an ultrasonic generator device to a substrate.

[0074] When referring to additional materials that can be included with a substrate, the terms "secondary material" or "supplemental material" are used interchangeably herein.

[0075] When referring to the outer surface of a rotary or vane ultrasonic generator that is at least partially in contact with the incoming substrate material, the term "functional surface" is used herein.

[0076] As used herein, the term "molding roll" or "molding reel" is used to describe a roll that can include a set of stacked rings mounted thereon, wherein the rings include or define cavities of a suitable shape (e.g., hook-shaped, pin-shaped, etc.). These terms can also be used to describe a screen-like sleeve having cavities mounted on a roll for manufacturing fasteners (e.g., mushroom-shaped elements). In the case of using a screen-like sleeve, the interface between the screen and the roll can allow the cavities to exhaust while preventing overfilling of the cavities with molten or semi-molten polymer or the like. The screen-like sleeve can also be produced in a more economical manner in a wider format and a greater range of diameters compared to a set of stacked rings precisely manufactured to include a certain arrangement of cavities.

[0077] The following disclosure relates to methods of using ultrasonic forming techniques to improve the formation of contact fasteners on nonwoven materials or other thermoplastic and non-thermoplastic materials. Various aspects disclosed herein may also relate to methods of improving the bonding of these materials, as well as other applications that can benefit from more effective control of ultrasonic welding or forming processes. Additionally, while the present disclosure details the benefits of improvements to nonwoven materials, the same benefits can apply to a wide variety of other materials, such as films, woven fabrics, laminates, elastomeric materials, thermoplastic and non-thermoplastic materials, cotton, paper, metal, foil, or combinations thereof. Moreover, although the present disclosure primarily describes the formation of fasteners (e.g., fasteners used as contact fasteners), the improvements disclosed herein can be used to form hook elements, pins, mushroom pieces, and other features that can be formed or molded using ultrasonic techniques. Further, although some embodiments disclosed herein are discussed with reference to rotary or blade ultrasonic generators, such improvements can be applied to any type of ultrasonic generator, as the present disclosure is not limited in this regard. In some embodiments, the fasteners disclosed herein can be "gradually" formed. In particular, multiple raised and / or recessed features of an ultrasonic generator can apply ultrasonic vibrations to a substrate disposed between a functional surface of the ultrasonic generator and a molding roll to gradually form a fastener. For example, as the substrate advances through a compression zone, the ultrasonic vibrations cumulatively form the final fastener.

[0078] In some embodiments, a rotary ultrasonic generator can include one or more discontinuous raised features. These raised features can be implemented to form discontinuous blocks of fasteners, rather than continuous lines of fasteners, on a substrate. For aesthetic or functional purposes, it may be desirable to form discontinuous blocks of fasteners on a substrate, such as manufacturing fasteners that can vary in size according to the requirements of adult or baby disposable diapers. These features can also be applied to applications including incontinence, hygiene, and cleaning products, or any other suitable application where continuous lines of fasteners may not be required.

[0079] Figure 3 An illustrative embodiment shows a rotary ultrasonic generator 1, a molding roll 3, and a substrate material 6. The rotary ultrasonic generator includes discontinuous raised features 10 for forming discontinuous hook-shaped fasteners 12 on the substrate. By applying ultrasonic energy in a compression zone between the discontinuous raised features of the rotary ultrasonic generator and the molding roll perimeter 5 of a region containing a fastener cavity 4, hook-shaped fasteners can be formed on the substrate. Using discontinuous raised features on the rotary ultrasonic generator can allow the use of a molding roll having a continuous region of fastener cavities. In an alternative embodiment, a rotary ultrasonic generator having multiple-piece cavities can be used in combination with a flat molding roll or a molding roll having hook-shaped cavities.

[0080] In some embodiments, using intermittent raised features on a rotary ultrasonic generator can provide undisturbed substrate sections positioned between regions of a fastener. These substrate portions may not be subjected to the same ultrasonic energy loads and pressures as the rest of the substrate, and thus the material in these sections can retain its original material properties. The intermittent raised features can be arranged on the rotary ultrasonic generator in any suitable configuration, as the present disclosure is not limited in this regard. Thus, for a given fastener application, the dimensions or shapes of the fastener regions or undisturbed substrate portions may vary.

[0081] In some embodiments, a rotary ultrasonic generator can be actuated using any suitable mechanism, including a servo. Actuating the rotary ultrasonic generator allows the surface speed of the rotary ultrasonic generator to be changed relative to the surface speed of the molding roll. Thus, the surface speed of the rotary ultrasonic generator can be greater than, less than, or synchronized with the surface speed of the molding roll in order to form fastener blocks at any desired spacing.

[0082] When ultrasonically forming fastener elements using a rotary ultrasonic generator, it may be beneficial to control the surface speed of the ultrasonic generator to be synchronized with the surface speed of the molding roll. An example of a molding roll that can be implemented in rotary ultrasonics is an anvil roll, but those skilled in the art will recognize that the use of the molding roll disclosed herein is not limited in this regard. When an anvil roll or other type of molding roll is used in combination with a rotary ultrasonic generator to manufacture fastener elements, they can be driven at a fixed ratio by using gears mounted on both the rotary ultrasonic generator and the molding roll, which can fix the relative rotational speeds of the components during operation. While this specific example discloses the use of a gear arrangement to provide a fixed rotational speed, other suitable arrangements can also be used to drive the rotary ultrasonic generator and the molding roll at a fixed or variable ratio.

[0083] In some embodiments, the surface speed of the rotary ultrasonic generator can vary in an intermittent manner such that the surface speed of the rotary ultrasonic generator alternates between being greater than, less than, or synchronized with the surface speed of the molding roll in any suitable order. For example, during the formation of contact fasteners, the surface speed of the ultrasonic generator can be synchronized with the surface speed of the molding roll. After a given set of contact fasteners has been formed, the surface speed of the ultrasonic generator can be accelerated or decelerated to form subsequent fastener blocks at the desired spacing. In such an example, by accelerating or decelerating the surface speed of the ultrasonic generator, fastener blocks can be formed that have smaller or larger spacings between the blocks, respectively.

[0084] In view of the foregoing, the inventors have recognized the benefits associated with using a molded roll having various continuous fastener cavity patterns disposed thereon in combination with a rotary ultrasonic generator whose surface speed can be varied as discussed above. In particular, such a configuration may require only a single molded roll to form a wide variety of contact fastener blocks, where the spacing between the blocks varies in the machine direction (MD) or the cross direction (CD). As used herein, the machine direction refers to the direction in which the substrate is fed into the ultrasonic generator for processing, and the cross direction refers to the direction transverse to the machine direction. In some embodiments where a molded roll having various patterns disposed thereon is used, the rotary ultrasonic generator may include various raised features and may be driven by any suitable actuator (e.g., a servo) as disclosed herein. In some such embodiments, the spacing of the fastener blocks in the machine direction can be controlled by programming the servo or other actuator to accelerate or decelerate the rotary ultrasonic generator, thereby forming fastener blocks having different spacings as described above. The spacing of the fastener blocks in the cross direction can also be controlled by sliding the rotary ultrasonic generator to a desired lateral position corresponding to the area on the molded roll where a series of contact fasteners are to be formed. Thus, the molded roll can have blocks of fastener cavities in any suitable configuration disposed along the machine direction or the cross direction such that corresponding contact fasteners can be formed at any desired spacing by varying the surface speed of the rotary ultrasonic generator or its position relative to the molded roll.

[0085] In some embodiments, the surface speeds of the control molding roller and the rotary ultrasonic generator can also be varied to improve the formation or filling of the fastener cavity by ensuring that sufficient substrate is accumulated near the area of the fastener cavity before significant ultrasonic energy is applied to that portion of the substrate. The functional surface of the rotary ultrasonic generator can include additional features such as ribs, grooves, protrusions, cavities, or any other suitable features, which can also be included in linear or non-linear configurations to apply ultrasonic energy to selected areas of the substrate. In another embodiment, both the surface features of the rotary ultrasonic generator and the variation in the surface speed of the ultrasonic generator can be employed to assist in filling or forming the fastener cavity. By varying the surface speed and features of the rotary ultrasonic generator, a directional force can be generated during the application of ultrasonic energy to the substrate, which can direct the softened material in the machine direction, cross direction, or other directions of the ultrasonic generator to enhance the filling of the fastener cavity or enhance the physical properties of the processed substrate. The process of selectively forming portions of the substrate in the fastener cavity is herein referred to as “aggregating” the substrate. Aggregating the substrate can be beneficial when forming fastener elements using a rotary ultrasonic generator in that it allows for a selective increase in the mass of the incoming substrate material at the location where the fastener is formed, which reduces or eliminates the need to increase the mass of the entire substrate material. Some examples of aggregation can be found in U.S. Patent No. 10953592, which is incorporated herein by reference.

[0086] The inventors have found that due to the directional forces caused by varying the surface speed of the rotary ultrasonic generator and providing external features along the surface of the ultrasonic generator, portions of the substrate material can be subject to shear forces during processing. These shear forces can affect the molecular orientation in the processed substrate, which can provide a variety of beneficial features. In certain embodiments where the shear results in a favorable molecular orientation of the substrate, the induced shear forces can provide texture differences, aesthetic differences, or an increase in the tensile strength of the final product. These shear forces can further provide additional heat input to the substrate, which will reduce the viscosity of the substrate material during processing, thus allowing for easier filling of the fastener cavity to form the fastener element.

[0087] In some embodiments, the functional surface of the rotary ultrasonic generator 1 can include raised features 17 on the surface 18 of the rotary ultrasonic generator, as Figure 4A illustrated in the illustrative embodiment of. In some embodiments, the raised features 17 can all have the same height starting from the surface 18 or can have different heights. These raised features on the surface of the ultrasonic generator can also have a sufficient height to prevent the functional surface of the ultrasonic generator from applying a large amount of ultrasonic energy to the entire substrate. Figure 4AThe illustrative embodiments also include a molding roller 3 having a region of a fastener cavity 4 for forming contact fasteners 13 (e.g., hook elements) on a substrate 6. The raised feature 17 can be a rib, gasket, bump, graphic design, logo, or any other suitable shape configuration. In some embodiments, the surface of the ultrasonic generator can include recessed features having the same or different depths, such as cavities or grooves. The ultrasonic energy can be applied to the substrate at the portion where the ultrasonic generator contacts the substrate, thereby selectively generating fastener elements at these locations. The ultrasonic energy applied from these features may also create depressions in the portion of the substrate on the side facing the ultrasonic generator. The inventors have recognized that using raised and / or recessed features can also result in less energy required to operate the ultrasonic generator, which can provide a more efficient manufacturing process.

[0088] When a rotary ultrasonic generator having raised or recessed features is used to ultrasonically form contact fastener elements from a substrate, there may be undisturbed portions of the substrate. Figure 4B The illustrative embodiments show a treated substrate material that includes undisturbed portions on the side 31 of the substrate facing the rotary ultrasonic generator. The substrate material can be, for example, a nonwoven material, which can retain its original material properties in the undisturbed portions of the treated substrate. In some embodiments, the substrate material having undisturbed portions can also include fastener elements formed on the side of the substrate facing the molding roller, the fastener elements being generated by selectively applying ultrasonic energy from raised or reduced features. However, in other embodiments, the substrate material can include undisturbed portions and formed fastener elements on the same side of the substrate.

[0089] In some embodiments, secondary materials can be added in a rotary ultrasonic generator device by feeding the secondary materials between the rotary ultrasonic generator and the substrate or between the substrate and the molding roller. The secondary materials can be fed continuously or intermittently into the compression region. Any suitable thermoplastic or non-thermoplastic secondary materials can be used, including but not limited to polypropylene, nylon, polyethylene, polyester, acetate, paper, cotton, foil, metal, or glass. In another embodiment, the rotary ultrasonic generator can include features that allow for the accurate positioning of a mass of secondary material during the process. Such features include the use of vacuum, mechanical arrangements (such as pins), or surface features on the ultrasonic generator, but any suitable features for accurately positioning secondary materials can be used, as the present disclosure is not limited in this regard.

[0090] In a further embodiment, the secondary material may be in the form of a film or web of material. The material may similarly be supplied continuously or intermittently into the compression zone between the ultrasonic generator and the molding roll as a supplementary material for areas of the fastener cavity that may be lacking material. When using a rotary ultrasonic generator with raised features, portions of the secondary material may be selectively incorporated into the area of the substrate where the fastener is being formed. As disclosed herein, the use of raised features on the rotary ultrasonic generator may keep multiple portions of the substrate undisturbed. In such an embodiment, the incorporation of the secondary material may result in excess material appearing on the surface of the processed substrate. In some embodiments, the excess material may be removed to leave only the secondary material for the substrate that supplements the fastener cavity. In certain embodiments, the excess material may also be recycled.

[0091] In some embodiments, the secondary material or materials may be coated onto the raised features of the rotary ultrasonic generator. Such secondary materials may include, but are not limited to, adhesives, polymers, and inks. Incorporating these materials into the raised features of the rotary ultrasonic generator may allow patterns to be printed or compressed onto the ultrasonic generator side of the substrate during the ultrasonic formation of the fastener element. As disclosed herein, there is a significant amount of heat and pressure associated with the ultrasonic formation method of the fastener element. In some embodiments, the heat and pressure may be used to assist in drying, curing, or transforming the secondary material to aid in the production of the fastener element. For example, a thermoplastic secondary material may be used to at least partially penetrate a non-thermoplastic substrate material (such as cotton or paper) to allow for the formation of the secondary material with the substrate material. Such embodiments would allow for the use of more environmentally friendly substrate materials. Although the use of secondary materials has been disclosed with reference to a rotary ultrasonic generator, the inventors have recognized that secondary materials may also be used with a blade ultrasonic generator, as discussed in more detail below.

[0092] In some embodiments, the functional surface of the rotary ultrasonic generator may include curved surfaces in the form of grooves or dikes. The inventors have found that these features may be implemented to enhance the filling of the fastener cavity when using an ultrasonic formation method to form the fastener element from the substrate material. The benefits of providing grooves or dikes in the functional surface of the rotary ultrasonic generator include, but are not limited to: increasing the production speed during the process, reducing the incidence of holes or damage in the processed substrate, and making the distribution of the substrate material more uniform during the process. The inventors have recognized that the use of grooves or dikes may also be incorporated into a blade ultrasonic generator device, as further disclosed below.

[0093] Figure 5The illustrative embodiment shows an implementation of the linear grooves 19 and raised dikes 20 in the functional surface of the rotary ultrasonic generator device 1. The illustrative embodiment also includes a molded roller 3 having an outer periphery 5 that includes an area of the fastener cavity 4. One or more grooves and dikes may be configured in a transverse direction and may be adjacent to each other, as Figure 5 shown. The raised dike 20 may allow for an application such that ultrasonic energy is locally concentrated in a manner similar to an energy director used in insert ultrasonic welding of molded thermoplastic parts. However, different from these conventional energy directors described above, when used in combination with the adjacent grooves 19, the raised dike 20 forms a series of storage portions in the functional surface of the rotary ultrasonic generator, and the storage portions may contain an aggregated substrate. The density or mass of the substrate material (including but not limited to nonwoven materials) typically varies throughout the material. Since a portion of the mass of the substrate is used to form the fastener element, any change in the mass of the incoming substrate may result in holes in the final product or missed or partially filled fastener cavities during processing. The aggregated substrate in the storage portions formed by the grooves 19 and dikes 20 may be used to supplement the low-mass portions of the substrate material during processing. As disclosed herein, the surface speed of the rotary ultrasonic generator may be varied to induce shear forces that may help distribute the aggregated substrate to provide a more uniform substrate material during processing.

[0094] The inventors have found that, in some embodiments, using certain surface finishes or textures in rotary and / or vane ultrasonic generators can be used to reduce the friction applied to the substrate material. For example, some or all of the functional surfaces of the rotary and / or vane ultrasonic generators can have a satin finish or a polished finish. In some embodiments, the functional surfaces of the rotary ultrasonic generator or the raised features on the rotary ultrasonic generator can be textured to assist in the ultrasonic formation of the fastener elements. The inventors have found that a textured surface finish in the range from 0.7 microns Ra to 1 micron Ra, where Ra is the average roughness of a given surface, can be beneficial in reducing the adhesion of the substrate material to the functional surface of the rotary ultrasonic generator. Although this range of Ra values is disclosed, a textured surface finish with any suitable average roughness can be used, including greater than or equal to 0.001 microns Ra, 0.01 microns Ra, 0.1 microns Ra, 0.5 microns Ra, 0.6 microns Ra, 0.7 microns Ra, 0.8 microns Ra, 0.9 microns Ra, 1 micron Ra, 1.1 microns Ra, 1.2 microns Ra, 1.3 microns Ra, 1.5 microns Ra, 2 microns Ra, 3 microns Ra, 5 microns Ra, 7 microns Ra, 10 microns Ra, 12 microns Ra, or greater. The use of a textured surface on the rotary ultrasonic generator can also allow for cooling of the functional surface. Without wishing to be bound by theory, this may be due to the textured surface providing a channel for the hot, stagnant air to escape from the compression area between the rotary ultrasonic generator, the molding roller, and the substrate before or during the ultrasonic formation process. It will be apparent to those skilled in the art that any suitable method can be used to apply the texture to the rotary ultrasonic generator, including but not limited to electrical discharge machining, electrochemical machining, chemical or mechanical etching, sandblasting, electroplating, laser engraving, and spraying. The inventors have recognized that the use of a textured surface with any suitable average roughness can also be incorporated into vane ultrasonic generators.

[0095] In another example, one or more slots can be provided on the rotary and / or vane ultrasonic generators, and only the slots can have a similar satin finish or polished finish. Such a configuration can be used to reduce the friction applied to multiple portions of the substrate during processing due to the reduced surface roughness on the portions of the functional surface that contact the substrate.

[0096] In some embodiments, various methods known to those skilled in the art can be used to cool the rotary ultrasonic generator device to avoid adhesion of the substrate material to the functional surface of the rotary ultrasonic generator or to avoid damage to the substrate. Such cooling methods include, but are not limited to, using cooling air provided by a blower, compressed air, cooled compressed air, vortex cooling nozzles, or cryogenic techniques. The rotary ultrasonic generator can be cooled from the outside, or the rotary ultrasonic generator can be cooled by flowing a cooling medium (including, but not limited to, compressed air, gas, or other fluids) through cooling channels that can be machined within or on the rotary ultrasonic generator.

[0097] In some embodiments, the incoming substrate material can be preheated prior to being subjected to the ultrasonic energy used to form the fastener element. Preheating the substrate material can soften the substrate material prior to processing, can result in a higher production speed, and provides easier forming of the substrate within the fastener cavity. It will be apparent to those skilled in the art that the incoming substrate material can be preheated by any suitable method, including, but not limited to, hot air, infrared, radio frequency, and contact heating.

[0098] As Figure 6 shown in the illustrative embodiment of, one or more rollers 23 can be positioned around the periphery of the rotary ultrasonic generator 1 to provide contact pressure of the incoming substrate 6 against the rotary ultrasonic generator. The rollers can be positioned to allow contact with the substrate prior to contact with the molding roller 3, which preheats the substrate material prior to fastener element formation. In such an embodiment, the substrate material is preheated or softened prior to being subjected to a high enough amount of ultrasonic energy and pressure from the rotary ultrasonic generator, thereby allowing easier forming of the substrate material within the fastener cavity 4 positioned along the periphery of the molding roller 5.

[0099] In some embodiments, the rotary ultrasonic generator can be cantilevered or supported at both ends. The rotary ultrasonic generator can also be driven using any common ultrasonic frequency range, as the present disclosure is not limited thereto. In some embodiments, suitable ultrasonic operating frequencies of the rotary ultrasonic generator can be greater than or equal to 1 kHz, 2 kHz, 5 kHz, 10 kHz, 15 kHz, 20 kHz, 25 kHz, 30 kHz, 35 kHz, 40 kHz, 45 kHz, 50 kHz, 60 kHz, 70 kHz, 80 kHz, 90 kHz, 100 kHz, 110 kHz, 120 kHz or greater. However, in some embodiments, the preferred range of the operating ultrasonic frequency of the rotary ultrasonic generator is between 5 kHz and 100 kHz. During operation of the rotary ultrasonic generator at a predetermined ultrasonic frequency, the ultrasonic generator may radially expand and contract, thereby generating heat due to friction, which softens the substrate. During operation, the vane ultrasonic generator can also be driven at any suitable ultrasonic frequency such that the vane ultrasonic generator can expand and contract to generate heat to soften the substrate.

[0100] In some embodiments, the rotary ultrasonic generator can have any suitable dimensional parameters to achieve ultrasonic waves of half wavelength, full wavelength, or any multiple thereof during operation of the ultrasonic generator. In some such embodiments, using these wavelength increments can be used to promote resonance of the rotary ultrasonic generator during operation, thereby imparting ultrasonic energy to the substrate. In some embodiments, the diameter of the rotary ultrasonic generator can be greater than or equal to about 20 mm, 50 mm, 75 mm, 100 mm, 150 mm, 200 mm, 250 mm, 300 mm, 350 mm, 400 mm, 450 mm, 500 mm, 600 mm, 700 mm or greater. Combinations of the above reference ranges are also possible. For example, the diameter of the rotary ultrasonic generator can be about 75 mm and the ultrasonic frequency can be 40 kHz. In another example, the diameter of the rotary ultrasonic generator can be about 150 mm and the ultrasonic frequency can be 20 kHz.

[0101] Although the above disclosure has discussed in detail improvements to rotary ultrasonic generators, the improvements can also be applied to vane ultrasonic generators to overcome the above limitations. As previously discussed, vane ultrasonic generators have been used in prior art arrangements to provide a longer dwell time on a substrate under compression to address the limited tangential contact area of a rotary ultrasonic generator with the substrate. Vane ultrasonic generators also have the limitations disclosed above, including but not limited to the possible formation of pseudo-products in the processed substrate and excess heat associated with the functional surfaces of the vane ultrasonic generator. Although the formation of pseudo-products has been discussed herein with reference to vane ultrasonic generators, pseudo-products may also occur in the processed substrate using a rotary ultrasonic generator.

[0102] In some embodiments, a vane ultrasonic generator may include one or more reliefs or channels. These features can be implemented to allow multiple portions of the substrate material to pass through the compression zone between the vane ultrasonic generator and the molding roll while not subjecting those portions of the substrate to the same ultrasonic energy loading as the remainder of the substrate. It may be desirable to preserve these undisturbed portions of the substrate to retain the characteristics of the substrate material prior to processing. For example, if a nonwoven substrate material is used in combination with reliefs or channels in the surface of a vane ultrasonic generator, the soft undisturbed portions can be used to protect the end user from abrasion or discomfort caused by raised pseudo-products that may be present in the processed substrate. The inventors have found that these raised pseudo-products may be present in the processed substrate due to displacement of the substrate material (which may protrude slightly above the substrate surface). The undisturbed portions can be useful in addressing discomfort associated with such pseudo-products in applications including but not limited to adult and infant disposable diapers.

[0103] Figure 7A An illustrative embodiment shows a vane ultrasonic generator 2, a molding roll 3, and a substrate material 6. The molding roll 3 includes a region of fastener cavities 4 located around the perimeter of the molding roll 3. The vane ultrasonic generator includes one or more reliefs or channels 15 that allow multiple portions of the incoming substrate to pass through the compression zone while being subjected to a minimal ultrasonic energy loading, thus resulting in minimal or no disturbance to multiple portions 16 of the substrate material after processing. Figure 7B These portions of the substrate are further shown in the illustrative embodiment, which shows Figure 7ACross-sectional view of the substrate. The number of undisturbed portions after processing can be controlled by adding more bleeding portions or channels to the functional surface of the vane-type ultrasonic generator. The desired size of the undisturbed portions after processing can also be controlled by changing the dimensional parameters related to the bleeding portions or channels. In addition, the one or more bleeding portions or channels can have different or the same profiles. As described above, these undisturbed portions can be used to protect the end user from discomfort caused by raised artifacts in the processed substrate surface, but the benefits of providing undisturbed portions in the substrate surface are not limited to this. When using such a rotary ultrasonic generator (with channels provided on the functional surface of the ultrasonic generator to generate undisturbed portions), the same function can be provided, as described in detail below.

[0104] Figure 7C An illustrative embodiment shows a rotary ultrasonic generator 1, a molding roll 3, and a substrate material 6. The molding roll 3 includes a region of a fastener cavity 4 located around the periphery of the molding roll 3. The rotary ultrasonic generator 1 includes one or more bleeding portions or channels 15 that allow multiple portions of the incoming substrate to pass through the compression region while being subjected to a minimum ultrasonic energy load, thus resulting in a minimum or no disturbance to the multiple portions 16 of the substrate material after processing.

[0105] Figure 7D -I embodiments show various embodiments of the pattern of the undisturbed portions 16 of the substrate 6, which can be formed by changing the functional surface of the rotary ultrasonic generator 1 to include bleeding portions or channels 15 with different profiles. Figure 7D Shows by Figure 7C The formed undisturbed portions 16 of the substrate 6 formed by the profile of the channel 15 depicted in Figure 7C The channel 15 of Figure 7D is formed perpendicular to the direction of the incoming substrate 6, and thus, Figure 7E and 7F The formed undisturbed portions 16 of the substrate 6 are shown as having an angled pattern and a wavy pattern, respectively. In Figure 7G and 7H The formed undisturbed portions 16 are shown as being formed as a crosshatch pattern and a staggered pattern, respectively. In addition, Figure 7I shows an embodiment in which the formed undisturbed portions 16 can be formed as a logo. Although in Figure 7IIn an embodiment, the logo is shown as having multiple features with a "teddy bear" appearance, but any suitable type of logo can be formed from the undisturbed portion of the base material, as the present disclosure is not limited thereto. Although examples of the pattern of the undisturbed portion of the base are disclosed above, any suitable pattern can be formed from the base by varying the functional surfaces of the rotary and / or vane ultrasonic generators.

[0106] In one embodiment, the undisturbed portion 16 of the base material can be used to enhance the permeability of an adhesive applied to the base surface. This configuration can result from the fibrous nature of certain undisturbed base materials (e.g., non-woven or paper materials), which can provide easier adhesion compared to the film-like surface provided by a molded base material. The use of an adhesive can allow the base to be attached to other materials by means including but not limited to adhesive bonding or fiber encapsulation. If the base is composed of materials that are difficult to bond (including but not limited to polyolefins, silicones, and polyamides), the adhesive used to bond the undisturbed portion of the base can be particularly beneficial.

[0107] In a further embodiment, the undisturbed portion of the base can be compressed to reduce the thickness of the base or increase the density of the base in a selected area. For a given base, an increase in density can result in an increase in tensile strength. The size of the undisturbed portion can also be selectively adjusted by varying the height of the bleed portions or channels in the ultrasonic generator surface. In such a configuration, the bleed portions or channels can be used to provide sufficient ultrasonic energy to compress the undisturbed portion while not providing sufficient energy to melt the undisturbed portion.

[0108] As disclosed herein, channels can provide an undisturbed portion on the base. Specifically, in some embodiments, the undisturbed portion of the base can be provided on the same side as the formed fastener element. This can be advantageous for increasing the flexibility of the treated base. However, in such a configuration, the undisturbed portion may interfere with the engagement of the formed fastener element with the corresponding loop materials conventionally used in the fastener application field. Thus, in some embodiments, the treated base can include a fastener element positioned above the undisturbed portion of the base, which can be easily engaged with a mating material (e.g., loop material).

[0109] In some embodiments, the functional surface of the vane ultrasonic generator can include a curved surface in the form of a groove or a dike. As discussed above for the rotary ultrasonic generator, the inventors have also found that the grooves or dikes in the functional surface of the vane ultrasonic generator can be implemented to enhance the filling of the fastener cavity, thereby increasing the production speed during processing, reducing the incidence of holes or damage in the processed substrate, and providing a more uniform substrate distribution after processing.

[0110] In Figure 8A and 8B illustrative embodiments of, the vane ultrasonic generator 2 can include one or more grooves 19 or raised dikes 20 that are incorporated into the functional surface 7 of the vane ultrasonic generator. These grooves and dikes can be applied to both planar and curved vane ultrasonic generator functional surfaces. The included dikes can be used to direct ultrasonic energy over a smaller application area, which can improve the transmission of ultrasonic energy from the vane ultrasonic generator to the substrate. The grooves (which are combined with adjacent dikes) can be used to aggregate multiple portions of the softened substrate and act as a reservoir for supplying material to selected low-density regions of the incoming substrate.

[0111] In Figure 9A and 9B further illustrative embodiments of, the grooves 19 in the functional surface 7 of the vane ultrasonic generator 2 can have symmetric side surfaces (as Figure 9A shown) or asymmetric side surfaces (as Figure 9B shown). It can be beneficial to implement asymmetric grooves on the functional surface of the vane ultrasonic generator to generate a downward force vector on the softened substrate material that can be aggregated in one or more grooves in the functional surface. The downward force vector can be generated by the ramp-like characteristics of the asymmetric grooves leading to adjacent dikes in the functional surface. The applied downward force vector can be used to provide greater pressure on the substrate, which can enhance the filling of the fastener cavity.

[0112] While various embodiments of continuous raised and / or recessed features in rotary and / or vane ultrasonic generators have been disclosed above, in some embodiments, the raised and / or recessed features may be formed in a non - continuous manner in the functional surface of the ultrasonic generator. Such non - continuous features may be formed as non - continuous channels, grooves, ridges, or any other suitable features, as the present disclosure is not limited thereto. As used herein, the term "continuous" is used to describe raised and / or recessed features that extend over the entire extent of the functional surface of the rotary and / or vane ultrasonic generator, while the term "non - continuous" is used to describe raised and / or recessed features that do not extend over the entire extent of the functional surface of the rotary and / or vane ultrasonic generator. Additionally, such continuous or non - continuous features may be formed on the functional surface of the ultrasonic generator in the machine direction, the cross - machine direction, or any other suitable direction, as the present disclosure places no restrictions thereon.

[0113] The inventors have recognized that the use of non - continuous features (such as non - continuous channels, grooves, and / or ridges) in the functional surface of the ultrasonic generator can be used to reduce the contact area between the substrate and the ultrasonic generator, thereby reducing the resistance and the force required to compress the substrate. As disclosed herein, the resistance may cause unwanted deformation and the generation of other artifacts in the processed substrate, and thus, benefits can be achieved by providing non - continuous raised and / or recessed features to create a more uniform processed substrate. Additionally, the inventors have found that forming certain continuous features (such as continuous channels formed in the cross - machine direction) may undesirably cause multiple portions of the substrate to converge within the continuous feature, thereby creating interference in the processed substrate. Therefore, the inventors have recognized that certain configurations of non - continuous features can be used to reduce the tendency of the substrate to converge while reducing the compression on the substrate.

[0114] The non - continuous features disposed on the functional surface of the rotary and / or vane ultrasonic generator may be formed in any suitable manner, as the present disclosure places no restrictions thereon. In some embodiments, the non - continuous features may include non - continuous channels, grooves, and / or ridges as disclosed above. Without wishing to be bound by theory, the non - continuous features may be formed in any suitable pattern. For example, in some embodiments, a plurality of grooves and ridges may be provided in the functional surface of the vane ultrasonic generator, and the plurality of grooves and ridges may be formed in a staggered pattern such that each groove and ridge is offset relative to the others over the entire extent of the functional surface of the ultrasonic generator. In particular, the inventors have found that the staggered pattern can be used to periodically alternate between providing drainage and compression when processing the incoming substrate, while not allowing the substrate to converge within the non - continuous features.

[0115] Figure 9CA schematic perspective view of a functional surface 7 of a vane ultrasonic generator is shown, the functional surface having a plurality of grooves 19 and dikes 20 formed in a staggered pattern along the machine direction such that each row of grooves 19 and dikes 20 is offset from the next row of grooves and dikes. As described above, such a configuration can be used to reduce the tendency of the substrate to bunch up during processing. Additionally, although Figure 9C the embodiments depict a plurality of grooves 19 and dikes 20 formed in a staggered pattern in the machine direction, in other embodiments, such a pattern can be formed along the transverse direction or any other suitable direction, as the present disclosure is not limited thereto.

[0116] In Figure 10 the illustrative embodiment, a vane ultrasonic generator 2 having a functional surface 7 is shown in combination with a molding roll 3, the molding roll having a region of a fastener cavity 4 along the outer periphery 5 of the molding roll. As Figure 10 shown, one or more grooves can be provided in the functional surface of the ultrasonic generator to generate a downward force vector 32. These downward force vectors are shown as applying force from the side surfaces of the grooves to the aggregated substrate in the reservoir. In one embodiment, the radius of the groove or dike can be in the range of 0.125 mm to 30 mm, and the radius of the groove or dike can vary individually. Grooves or dikes can be applied to flat or curved functional surfaces of the vane ultrasonic generator. In such a configuration, grooves or dikes can be employed to selectively apply force and ultrasonic energy to the substrate as it advances through the compression zone.

[0117] In some embodiments, the secondary material or supplementary material can be added to the vane ultrasonic generator device by feeding the secondary material or supplementary material through a passage located within or as part of the vane ultrasonic generator. Supplementary materials can include, but are not limited to, monofilaments, fluids, tapes, and thermoplastic and non-thermoplastic materials. In further embodiments, the supplementary material can include metallic materials, including but not limited to wires, to provide electrical shielding properties or magnetism to the processed substrate.

[0118] In some embodiments, the supplemental material can be used as a filler material to supplement defective portions in the substrate where there are variations in density and mass. In some such embodiments, adding the supplemental material can change the structure of the processed substrate. Additionally or alternatively, adding the supplemental material can be used to change the functional properties of the processed substrate material. For example, a supplemental material can be added to increase or decrease the flexibility of the processed substrate, such as by using a supplemental material such as an elastomer. While this example is disclosed, any suitable functional property of the substrate material can be changed by adding a supplemental material, including but not limited to thermal, electrical, magnetic, chemical, optical, and / or physical properties (e.g., the amount of mechanical stress that can be applied to the substrate by bending, stretching, folding, indentation, etc.).

[0119] In Figure 11A and 11B illustrative embodiments of, one or more such supplemental materials 29 can be directed to locations within the vane ultrasonic generator device 2 through one or more corresponding passageways 30. These passageways can be used to enhance the filling of the fastener cavities in conjunction with the contained supplemental material. This can be beneficial because the incoming substrate 6 can have variations in density and mass, and thus, the provided supplemental material can help fill selected fastener cavities to achieve a more uniform substrate material and fastener elements 13 after processing. These passageways can be used to precisely position the supplemental material in the compression regions where the vane ultrasonic generator applies ultrasonic energy to the incoming substrate, as Figure 11B illustrated in the illustrative embodiments of Figure 11B which shows a cross-section of an example channel within the vane ultrasonic generator. The supplemental material can be positioned on the side 14B of the substrate facing the ultrasonic generator, while the fastener elements are formed by the side 14A of the substrate facing the molding roller. While in Figure 11A and 11B the embodiments of, the passageways 30 are depicted as holes passing through the vane ultrasonic generator 2, in some embodiments, the passageways can alternatively take the form of channels that are used to assist in directing the supplemental material to the desired location, as Figure 11C illustrated in the embodiments of Figure 11C where the passageway is shown to include a channel 15 in the vane ultrasonic generator device 2 at which the supplemental material 29 can be directed to the desired location.

[0120] As disclosed herein, during the processing of a substrate material, the functional surface of a vane-type ultrasonic generator may become overheated. This heat is typically caused by friction associated with the substrate material when the substrate material contacts the functional surface of the vane-type ultrasonic generator due to ultrasonic energy being applied. The overheated functional surface may limit the quality of the processed substrate because the substrate may become damaged or adhere to the functional surface of the vane-type ultrasonic generator. Excessive heat may also limit the production speed of ultrasonic forming of fastener elements.

[0121] In some embodiments, an additional material having good heat transfer properties can be positioned between the functional surface of the vane-type ultrasonic generator and the substrate to allow enhanced cooling of the functional surface during processing of the substrate. These materials can be of any suitable type as the present disclosure is not limited in this regard. These materials can be attached to the functional surface of the vane-type ultrasonic generator by methods including but not limited to brazing, welding, spraying, or mechanical fastening. In some embodiments, suitable additional materials can include but are not limited to titanium carbide, aluminum, diamond, and / or copper coatings, or any other suitable material, and the present disclosure is not limited thereto. The inventors have recognized that the use of certain materials can provide advantages during processing of the substrate. For example, when an ultrasonic generator surface with increased thermal conductivity is desired, a titanium carbide coating or a diamond coating can be implemented to facilitate softening of the substrate material during processing. In another example, when an ultrasonic generator surface with reduced wear resistance is desired, a copper coating can be implemented to reduce the resistance and friction associated with processing of the substrate. Embodiments of the additional materials disclosed herein can also be incorporated into the functional surface of a rotary ultrasonic generator.

[0122] In another embodiment, an additional material having good heat transfer properties may lack the hardness or wear resistance of typical materials used in the functional surface of a vane-type ultrasonic generator, and thus these materials may experience wear and need to be replaced periodically. In another embodiment, the material may not be attached to the functional surface of the vane-type ultrasonic generator but instead can be alternatively positioned between the functional surface of the vane-type ultrasonic generator and the substrate material without being fixed. The material can be intermittently positioned within a compression zone and then temporarily removed to allow intermittent cooling of the material. Additionally, the additional material can be in the form of a belt, a flat disk, a tapered disk, or any other suitable shape configuration, which will be apparent to those skilled in the art.

[0123] Aspects disclosed herein relate to the use of a rotary or vane ultrasonic generator to apply ultrasonic energy to a substrate to form fastener elements in a continuous ultrasonic method. In a continuous ultrasonic method, ultrasonic energy from the ultrasonic generator is continuously present. However, in the field of ultrasonics, there is a discontinuous ultrasonic forming method that is commonly used to join materials, where the materials need to be cooled during processing. For example, a person skilled in the art can adopt a discontinuous method (such as insert welding of plastic parts) for applications such as toys or automotive components to keep the welded components in a compressed state without applying ultrasonic energy for a given time span to allow the welded material to cool. A person skilled in the field of ultrasonics generally refers to this method as "hold time".

[0124] Although the aspects disclosed herein relate to a continuous ultrasonic method, the inventors have recognized that modifying the trailing edge of the functional surface of a vane ultrasonic generator can allow cooling by reducing the contact area and the ultrasonic energy applied to the substrate. In Figure 12 an illustrative embodiment, a relief area 21 can be provided in the functional surface 7 of the vane ultrasonic generator 2. As Figure 12 shown, a molding roll 3 can also be included that has a fastener cavity 4 along the outer periphery 5 to create a compression area using the ultrasonic generator to ultrasonically form the incoming substrate material 6. By reducing the amount of ultrasonic energy applied to the substrate in a selected area, the relief area of the functional surface of the ultrasonic generator can provide sufficient cooling time for the incoming substrate material. Thus, the relief area can reduce the heat associated with the functional surface of the vane ultrasonic generator and reduce the likelihood of the substrate material adhering to or being damaged by the functional surface.

[0125] In one embodiment, the functional surface of the vane ultrasonic generator can also be cooled using a variety of methods, including but not limited to using cooling air provided by a blower, compressed air, cooled compressed air, vortex cooling nozzles, or cryogenic techniques. The vane ultrasonic generator can be cooled from the outside or can be cooled by flowing a cooling medium (including but not limited to compressed air, gas, or other fluids) through cooling channels that can be machined inside or on the vane ultrasonic generator.

[0126] Additional features can be employed in the functional surface of the vane ultrasonic generator to assist in cooling the ultrasonic generator surface. These features can include but are not limited to raised heat sinks, grooves, slits, or channels that can be machined into the functional surface of the ultrasonic generator. Specifically, as Figure 13A shown in the illustrative embodiment of Figure 13AAs shown, it may also include a molding roll 3 having a fastener cavity 4 along an outer periphery 5 to assist in the formation of fastener elements. As shown, an extension 22 of the functional surface is used to increase the size of the surface area exposed to the surrounding environment, which would otherwise be the hottest part of the ultrasonic generator. Thus, the extension 22 is used to locally cool the surface of the ultrasonic generator. The cooling associated with the extension 22 can be used to reduce the adhesion of the substrate to the functional surface and can reduce or eliminate possible damage to the substrate during processing. In some embodiments, the ultrasonic generator can be formed at least in part from a material with relatively poor thermal conductivity (such as titanium). In some such embodiments, the surface of the ultrasonic generator can include an extension as detailed above, and the exposed portion of the extension can allow for more local cooling to be applied using compressed air, cooled compressed air, or other means known to those skilled in the art and / or detailed herein.

[0127] In some embodiments, the inventors have recognized that adding an extension to the surface of the ultrasonic generator may not be suitable for certain applications. For example, using an extension may not allow the ultrasonic generator to obtain the desired acoustic response during the application of ultrasonic energy. Using an extension may also result in artifacts that are formed in the processed substrate due to the extension affecting the amount of energy applied to a given location on the substrate. In view of the above, the inventors have found that benefits can be achieved by implementing a recessed portion located within the boundary of the functional surface of the ultrasonic generator, rather than implementing an extension that protrudes beyond the boundary of the functional surface as detailed in Figure 13A In some embodiments, the recessed portion can be provided along the side of the ultrasonic generator, as shown in Figure 13A Although only one recessed portion is shown in Figure 13A , multiple recessed portions can also be provided within the boundary of the functional surface of the ultrasonic generator (for example, two recessed portions opposite each other on both sides of the ultrasonic generator surface). Compared to using the extension detailed above, these recessed portions can be used to provide a smaller variation in the amount of energy applied to the substrate. In Figure 13B , a vane-type ultrasonic generator 2 having a functional surface 7 with a recessed portion 35 is shown. The recessed portion 35 is formed in the functional surface 7 such that a tail portion 36 is provided. Since the tail portion 36 is formed within the boundary of the functional surface 7, the tail portion 36 can be used to apply consistent energy to the substrate 6 to reduce the number of artifacts formed in the processed substrate 6, while also allowing for local cooling of the ultrasonic generator surface through the recessed portion 35. Also as shown in Figure 13BAs shown, in combination with a blade ultrasonic generator 2, a molding roller 3 can be provided that has a fastener cavity 4 along its outer periphery 5 for forming fastener elements from a substrate 6. The recessed portion 35 and the corresponding tail portion 36 can have any suitable size and / or shape such that the functional surface of the ultrasonic generator applies consistent energy to the substrate while also allowing for sufficient local cooling of the ultrasonic generator surface through the exposed recessed portion.

[0128] In some embodiments, combinations of the features disclosed above can be implemented in the ultrasonic generator, as the present disclosure is not limited thereto. For example, the ultrasonic generator can include one or more recessed portions, one or more tail portions, and / or one or more grooves located in the functional surface. Figure 13C An embodiment shows such an arrangement where the blade ultrasonic generator 2 has a functional surface 7 on which a groove 19 is provided. In Figure 13C , a recessed portion 35 in the side surface of the ultrasonic generator 2 is shown, and a tail portion 22 extending beyond the boundary of the functional surface 7 is shown. The figure shows the combination of the ultrasonic generator 2 with the molding roller 3 and the substrate 6, the molding roller having a region of a fastener cavity 4 along its outer periphery 5, and the substrate being disposed between the functional surface 7 of the ultrasonic generator 2 and the outer periphery of the molding roller 5.

[0129] Figure 13D Shows Figure 13C A dimensional schematic of a portion of the ultrasonic generator 2 in. The inventors have recognized that the groove 19, the recessed portion 35, and / or the tail portion 22 can be selectively configured and arranged to provide different ultrasonic generator features. For example, the size and / or shape of the recessed portion 35 and / or the tail portion 22 may affect the amount of cooling that can be provided on the functional surface 7 of the ultrasonic generator or the structural integrity of the ultrasonic generator 2 itself. The size and / or shape of the tail portion may also affect the magnitude of the pressure applied to the incoming substrate. In another example, the size and / or shape of the one or more grooves can be used to help accumulate different amounts of substrate material for filling the region of the fastener cavity 4 to produce contact fasteners. The inventors have also recognized that the proximity of the recessed portion, the tail portion, and / or the grooves relative to each other may affect the aforementioned features of the ultrasonic generator. Therefore, the inventors have found that certain dimensional parameters associated with these features are beneficial, as Figure 13D Shown.

[0130] In Figure 13DAmong them, dimensions A, B, and C respectively refer to the height of the outer recessed portion, the height of the inner recessed portion, and the depth of the recessed portion. In some embodiments, the suitable size of dimension A is greater than or equal to 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. In some embodiments, the suitable size of dimension B is greater than or equal to 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. In some embodiments, dimension B can also be 0 mm (for example, if the recessed portion tapers from dimension A to dimension B). In a preferred embodiment, dimensions A and B can be 20 mm and 15 mm respectively. The inventors have also recognized that the size of dimension C can depend on the width of the ultrasonic generator itself. In some embodiments, the suitable size of dimension C is greater than or equal to 0.25 mm, 0.50 mm, 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. Figure 13D It further includes dimension I, which depicts the corner of the recessed portion 35. The corner can be rounded, chamfered, or machined in any other suitable way, as the present disclosure does not limit this.

[0131] In Figure 13D Among them, dimensions F and G depict the height and width parameters of the groove 19 provided in the functional surface 7. In some embodiments, the suitable size of dimension F is greater than or equal to 0.01 mm, 0.05 mm, 0.10 mm, 0.50 mm, 1 mm, 3 mm, 5 mm, 10 mm or greater. In some embodiments, the suitable size of dimension G can be greater than or equal to 0.50 mm, 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. In a preferred embodiment, dimensions F and G can be 1 mm and 2 mm respectively. Figure 13D Dimension E is also shown, and dimension E refers to the distance between the recessed portion 35 and the groove 19. In some embodiments, the suitable size of dimension E can be greater than or equal to 0 mm, 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. The size of dimension E can also be less than or equal to 10 mm, 5 mm, 0 mm, -5 mm, -10 mm or smaller, where a negative value indicates that the groove is positioned to pass through the inner height of the recessed portion along the functional surface 7 of the ultrasonic generator 2.

[0132] In addition, dimensions D and J refer to the height and length of the tail portion 22, respectively. In some embodiments, suitable sizes for dimension D are greater than or equal to 0.15 mm, 0.30 mm, 0.50 mm, 0.75 mm, 1 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or greater. In some embodiments, suitable sizes for dimension J are greater than or equal to 5 mm, 10 mm, 15 mm, 20 mm, 25 mm or greater. In a preferred embodiment, dimensions D and J can be 1 mm and 15 mm, respectively. In some embodiments, the tail portion 22 can be curved substantially as Figure 13D shown to match the curvature of the corresponding molding roller. However, in other embodiments, the tail portion 22 can be substantially parallel to the functional surface 7 of the ultrasonic generator 2, as Figure 13D shown by the dashed line in. The inventors have also found that the radius of curvature H of the tail portion 22 can affect the cooling performance of the ultrasonic generator 2 and the amount of ultrasonic energy that can be applied to the substrate during processing. In some embodiments, the inventors have recognized that the radius of curvature H is preferably slightly greater than the radius of the corresponding molding roller, thereby allowing the tail portion 22 to remain in contact with the corresponding substrate to prevent the processed substrate from expanding. In particular, expansion refers to the tendency of the substrate to expand when the compression on the substrate during processing and cooling is not sufficiently maintained. Although these dimensional parameters have been disclosed in the above embodiments, any suitable dimensional parameters can be implemented for each of the recessed portion, the tail portion, and / or the groove. In addition, in some embodiments, not all of these features may be present. For example, a groove and a recessed portion can be provided in the ultrasonic generator, but no tail portion is provided. In Figure 14A the illustrative embodiment of, linear ribs 26 or channels 27 can be provided in the functional surface 7 of the vane-type ultrasonic generator 2. Figure 14B is shown in Figure 14A a cross-sectional view of to show in detail an embodiment in which linear ribs are provided on the functional surface of the vane-type ultrasonic generator. Specifically, the linear ribs and channels can be located along the inlet portion 28 of the vane-type ultrasonic generator, where the ultrasonic generator has not yet generated sufficient ultrasonic energy to soften the substrate. These linear ribs or channels can be directed in the machine direction, i.e., the direction facing the incoming substrate material. The linear channels can be used to reduce the initial surface contact area between the incoming substrate material and the functional surface of the vane-type ultrasonic generator, which can be beneficial for reducing the friction and heat associated with the functional surface. As the incoming substrate material passes through the end of the channel and enters the adjacent region of the functional surface 7, the tapered characteristics of the linear channel can also be used to gradually apply ultrasonic energy to the substrate.

[0133] Another limitation that may occur when using a vane type ultrasonic generator for ultrasonic forming of fastener elements is that it may be difficult to accurately position the vane type ultrasonic generator relative to the molding roller during continuous use. Specifically, when a molding roller of a block with intermittent and raised fastener cavities is used in combination with a vane type ultrasonic generator, it may be particularly difficult to maintain the positioning of the vane type ultrasonic generator. This limitation may occur due to the radial force exerted by the vane type ultrasonic generator on the molding roller as it rotates. Thus, in an embodiment where the molding roller includes a block with intermittent fastener cavities, the block on the molding roller may suddenly contact the functional surface of the vane type ultrasonic generator, resulting in an interruption or displacement of the positioning of the functional surface.

[0134] The inventors have also recognized and understood that it can be beneficial to provide features for the functional surface of the vane type ultrasonic generator that reduce or eliminate the above limitations. In Figure 15 the illustrative embodiment, it is shown that the vane type ultrasonic generator 2 may include a functional surface 7 of the vane type ultrasonic generator that, as it rotates, bridges over the intermittent region 8 of the fastener cavity 4 on the molding roller 3. The region of the fastener cavity may be raised above the outer surface 9 of the molding roller. This illustrative embodiment further details the front portion 24 and the tail portion 25 of the functional surface that remain in contact with at least portions of two or more raised blocks of the fastener cavity. The front and tail portions may have any suitable size, shape, or other characteristics, as the present disclosure is not limited in this regard. These features are beneficial because they can reduce or eliminate interference of the vane type ultrasonic generator in the radial direction.

[0135] The inventors have also recognized that in some embodiments, the use of a vane type ultrasonic generator may result in residual material along the region where the treated substrate material is deposited. Specifically, when using a molding roller with intermittent blocks having fastener cavities (see Figure 2), since the ultrasonic energy applied by the vane type ultrasonic generator drags on portions of the softened substrate, residual material may be deposited near the portion of the substrate where the contact fastener is formed, as shown in Figure 16. The resulting residual material may provide an undesirable profile, an unsightly visual effect, and / or a rough texture to the substrate surface, which may cause discomfort to the end user in applications such as diapers. Due to the presence of the residual material, the treated substrate may also become harder, and / or the substrate material may be damaged (e.g., holes in the substrate) as the residual material melts through the substrate. Although the above disclosure discusses the deposition of residual material due to the use of a vane type ultrasonic generator, the inventors have also found that the use of a rotary ultrasonic generator may also result in the deposition of residual material.

[0136] Figure 16 depicts a prior art arrangement of a vane ultrasonic generator 2, a substrate material 6, and a molding roll 3. The functional surface 7 of the vane ultrasonic generator 2 can apply ultrasonic energy to form a contact fastener 13 from the substrate material 6 using contact fastener cavities 4 formed in intermittent blocks 8 of the molding roll 3. The intermittent blocks 8 can rise above the outer periphery 9 of the molding roll 3 to selectively contact a compression zone formed by the functional surface 7 of the vane ultrasonic generator. In this process, residual material 33 may form on the area of the substrate 6 adjacent to the formed contact fastener 13. Although the residual material 33 shown in this arrangement is positioned on the trailing edge of the formed contact fastener, the residual material can also be deposited along the leading edge, side edge, or any portion of the perimeter of the formed contact fastener.

[0137] In view of the above, the inventors have recognized and understood that the dimensional parameters of the intermittent blocks formed on the molding roll can be modified, and these blocks can include a textured surface to reduce the accumulation of residual material on the substrate surface. For example, the length of the blocks can be increased to provide what is hereinafter referred to as a "runoff zone". The runoff zone can include a textured surface having any suitable size, shape, pattern, or other characteristics to reduce the accumulation of residual material.

[0138] Figure 17 An illustrative embodiment of a vane ultrasonic generator 2 having a functional surface 7, a substrate material 6, and a molding roll 3 is depicted, the molding roll including intermittent blocks 8 of fastener cavities 4 that project above the outer periphery 9. The intermittent blocks 8 include a runoff zone 34 that can be provided with a textured surface. The runoff zone 34 can be used to collect residual material that would otherwise accumulate on the substrate 6 due to the application of ultrasonic energy to form the contact fastener 13. The collected residual material can be deposited in a controlled pattern within the textured surface, thereby reducing the accumulation of residual material on the substrate and improving the flexibility of the treated substrate. Although the runoff zone 34 is shown as being positioned on the trailing edge of the block 8, the runoff zone 34 can also be positioned on the leading edge of the block 8 or on the perimeter of the block 8, as disclosed above.

[0139] Figure 18A depicts Figure 17 A perspective view of the illustrative embodiment shown, without the substrate material, to show the intermittent blocks 8 of the fastener cavities 4 and the runoff zone 34 contained within the blocks 8 adjacent to the cavities 4. Figure 18B shows Figure 18A An enlarged radial view of region 18B of

[0140] Figure 18C - 18E depicts certain embodiments of intermittent blocks 8 having fastener cavities 4 and runoff zones 34. Figure 18C shows a runoff zone having a line pattern, Figure 18DShows a runoff area with a crosshatch pattern, Figure 18E Shows a runoff area with a wave pattern. Although these configurations are disclosed, the runoff area can have any suitable texture, size, shape, and pattern, such as checkerboard, stripes, circles, ovals, rings, polygons (squares or rectangles), or any other suitable pattern or other shape or combinations thereof, as the present disclosure is not limited thereto.

[0141] As disclosed above, the use of a runoff area can extend the circumference of the discontinuous blocks on the molding roll. In some embodiments, a suitable length or overhang of the runoff area can be greater than or equal to 1 mm, 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm or greater.

[0142] In some embodiments, the runoff area can include raised and / or recessed textures. For example, the runoff area can include a texture pattern in a crosshatch configuration, where some textures are recessed into the substrate and other textures are raised relative to the base of the substrate. The textures can be raised to any suitable height, including greater than or equal to 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.7 mm, 1 mm, 1.5 mm, 2 mm or greater. The textures can also be recessed to any suitable depth, including greater than or equal to 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.7 mm, 1 mm, 1.5 mm, 2 mm or greater.

[0143] The inventors have also found that in some embodiments, benefits can be achieved by providing the runoff area with a texture pattern that is substantially similar to the existing pattern of the substrate material. Such a configuration can be used to reduce the appearance of the textured portion on the substrate material itself, which appearance is due to the application of ultrasonic energy to the substrate in the compression area. For example, in embodiments where a nonwoven material is used as the substrate material and the nonwoven material is fibrous, a random texture pattern that blends well with the fibrous appearance of the nonwoven material can improve the aesthetics of the treated substrate.

[0144] The inventors have recognized the benefits associated with mounting a sleeve onto the outer surface of a roller, which can then be used in combination with ultrasonic energy from an ultrasonic generator to produce contact fasteners. These benefits include: the sleeve can provide a cheaper and more easily customizable alternative compared to the area of the fastener cavity formed by a molded ring mounted on the roller; and the mountable sleeve can allow for the easier production of wider dies, which can produce contact fasteners at a higher rate. The types of contact fasteners that can be produced by a sleeve mounted on a roller include, for example, mushroom-shaped fasteners having an hourglass shape. While such fastener types are disclosed, any suitable fastener shape and size can be produced by a sleeve mounted on a roller. Additionally, the sleeve can be constructed and arranged in any suitable manner to allow for mounting onto the roller. In some embodiments, the sleeve can be tubular such that the sleeve can be fixed around the circumference of the roller. However, in other embodiments, the sleeve can be fixed only to a portion of the circumference of the roller, as the present disclosure is not limited thereto.

[0145] U.S. Patent No. 6,287,665B1 discloses an example of a prior art sleeve arrangement configured for manufacturing fastening elements, the disclosure of which is incorporated herein by reference in its entirety. Referring to FIG. 19 shows an example of this prior art arrangement, which shows a sleeve 101 formed by a screen 102 having a molded opening 103. The inventors have found it beneficial to use ultrasonic waves to manufacture contact fasteners using a molded reel formed by such a sleeve 101 mounted on a reel (hereinafter referred to as a sleeve-type molded reel (note: the reel is not shown in FIG. 19)).

[0146] In some embodiments, a rotary ultrasonic generator can be used to apply ultrasonic energy to a sleeve-type molded roller to produce contact fasteners, as shown in the exemplary arrangement of Figure 20A In Figure 20A this arrangement includes a rotary ultrasonic generator device 1, a sleeve-type molded roller 3', and a substrate 6. In the illustrated embodiment, the molded roller 3' is formed by a sleeve 50, which includes a screen 51 having a screen cavity 52 extending around the circumference of the screen 51. The sleeve 50 is also fixed to a reel 53. The cavity can be of any suitable shape and size, but in Figure 20A it is shown as being formed in an hourglass shape. As the substrate 6 is fed through the contact area between the rotary ultrasonic generator 1 and the sleeve-type molded reel 3', the ultrasonic energy applied by the ultrasonic generator presses a portion of the substrate 6 into the cavity 52. This process can result in a contact fastener protruding from the treated substrate surface, which is shown in Figure 20A as an elliptical mushroom-shaped contact fastener 40. Although reference is made to Figure 20AA rotary ultrasonic generator is described, but other suitable ultrasonic generators, including vane ultrasonic generator devices, can also be used, as the present disclosure is not limited thereto.

[0147] Figure 20B Shows a perspective view of a substrate that can be formed by the arrangement of Figure 20A after processing. Figure 20B Shows a row of mushroom-shaped fasteners 40 extending from the substrate 6. It should be noted here that the use of the sleeve-type molding roller can be customized such that the width of the sleeve 50 in the cross machine direction can be changed to increase the number of fasteners produced during the manufacturing process.

[0148] Figure 21 Shows an enlarged view of the contact area between the rotary ultrasonic generator device 1 and the sleeve 50. In this embodiment, the substrate 6 is a film-like material that can be fed into the contact area between the ultrasonic generator and the sleeve 50 to press a portion of the substrate 6 into the screen cavities 52 of the screen 51, thereby forming a plurality of mushroom-shaped fasteners 40 thereon. Due to the nature of the film-like material of the substrate 6, the fasteners 40 and the substrate 6 can provide a substantially homogeneous resulting product, as the substrate is composed of a polymer or a similar film-like material.

[0149] Figure 22A Shows Figure 21 Another embodiment. In this embodiment, the substrate 6 is a fibrous or at least partially fibrous material that can be fed into the contact area between the ultrasonic generator and the sleeve to press a portion of the substrate 6 into the screen cavities 52 of the screen 51, thereby causing a plurality of mushroom-shaped fasteners 40 to be formed thereon. In some embodiments, due to the relatively large and rounded inlet openings of the screen cavities 52, some of the fibers may not melt during the ultrasonic treatment process. In particular, the relatively large openings caused by the hourglass shape of the screen cavities 52 may provide minimal or no support during the local compression of the substrate after the application of ultrasonic energy, which may result in the substrate not being completely melted. The inventors have recognized that this arrangement can provide additional strength to the resulting fasteners 40 to help secure the fasteners 40 to the base of the processed substrate 6. However, in some embodiments, if fibrous and / or incompletely melted fasteners are not desired, the surface speed of the rotary ultrasonic generator device 1 can be set to be different from the surface speed of the sleeve 50 mounted on the molding roller to scrape the remaining molten material from the substrate 6 into the screen cavities 52. Figure 22B Shows Figure 22A An enlarged view of region 22B of Figure 22BAs can be seen, the fibrous elements 42 of the substrate 6 can remain intact after the fasteners 40 are formed.

[0150] Figure 23A An embodiment of a vane ultrasonic generator device 2 is shown, which is configured to be used with a molding roll 3', the molding roll having a sleeve 50 fixed to a reel 53. As described above, the sleeve 50 includes a series of screen cavities 52 arranged circumferentially around a screen 51. During processing, a substrate 6 (which can be any suitable material disclosed herein) can be fed through the contact area between the vane ultrasonic generator 2 and the molding roll 3' to press a portion of the substrate 6 into the screen cavities 52, thereby causing a plurality of fasteners 40 to be formed on and project from the substrate 6.

[0151] Figure 23B A cross-sectional view of the molding roll 3' is shown. In some embodiments, the outer surface of the reel can be smooth. In another embodiment, the reel can be provided with a texture to create channels between portions of the inner surface of the sleeve 50 and portions of the outer surface of the roll 53. This arrangement can allow air to be discharged from the cavities formed in the screen 51 when the cavities are filled with the substrate during ultrasonic processing.

[0152] In some such embodiments, the sleeve 50 can be mounted to the molding roll by stretching the sleeve 50 over the roll 53. The inventors have found that due to this mounting arrangement, a raised area 54 may occur during ultrasonic processing of the substrate, as Figure 23A shown. This raised area 54 may be due to shear forces applied to the sleeve 50 during rotation of the molding roll 3', which in turn separates a portion of the sleeve 50 from the roll 53 on which it is mounted.

[0153] Figure 24 An embodiment of a molding roll 3' with an improved sleeve mounting arrangement is shown. The sleeve 50 can be stretched over the reel 53, and one or more sides of the reel 53 can be tapered so that the sleeve 50 can more easily grip the reel 53 to reduce the likelihood of detachment between the sleeve 50 and the reel 53. The sides of the reel 53 can be chamfered, rounded, or have any other suitable edge design, as the present disclosure is not limited thereto. Thus, the sleeve 50 can be described as having a plurality of sections that engage different portions of the reel 53. In Figure 24In [the figure], the sleeve 50 includes a first section 60, a second section 62, and a third section 64. In this exemplary embodiment, the first section 60 includes a screen cavity into which a portion of the corresponding substrate will be pressed to form a fastener, while the second and third sections (62, 64) are fixed to the tapered sides of the reel 53. The sleeve 50 can be at least partially elastic such that, after the sleeve 50 is installed on the reel 53, a resultant force can be generated along the tapered sides of the reel 53 (represented by arrows 66 and 68 respectively) due to the contraction of the sleeve 50. The inventors have recognized that by including the tapered sides of the reel 53, the corresponding bending of the sleeve 50 and the resulting geometry can reduce the tendency of the sleeve 50 to bulge in response to shear forces during substrate handling.

[0154] Figure 25 Another embodiment is shown in which the sleeve 50 is further fixed to the reel 53 by fastening features 70. The fastening features 70 can be of any suitable type, including but not limited to, a bolted clamp connection as Figure 25 shown. Using the fastening features 70 can provide additional tension to the sleeve 50 to reduce the likelihood of a bulging area (e.g., a section where the sleeve disengages from the reel) occurring during substrate handling.

[0155] Figure 26 Another embodiment is shown of installing the sleeve 50 onto the reel 53 using various suitable arrangements, including but not limited to adhesives, brazing, soldering, or mechanical fastening, as the present disclosure is not limited thereto. The sleeve 50 can also be attached using laser spot welding, electron beam spot welding, or other suitable methods known to those skilled in the art. In some embodiments, the sleeve 50 can also be removed from the reel 53 by using heat, chemicals, or other suitable methods, as the present disclosure is not limited thereto. In Figure 26 the embodiment, the sleeve 50 is shown attached to the reel 53 via an adhesive 72 positioned between the screen 50 and the reel 53. As disclosed above, the outer surface of the reel can be provided with a texture to form channels that allow air to escape from the cavity when the cavity is filled with the processed substrate. In this regard, the position or configuration of the adhesive should not impede air exhaust.

[0156] It should be understood that the foregoing description can employ the improved ultrasonic forming method disclosed herein, as well as improvements to rotary and / or blade ultrasonic generators, for forming fastener elements for various product applications. These product applications include but are not limited to adult and baby disposable diapers, incontinence products, hygiene products, medical products, brush bristles, pins, scrapers, and disposable cleaning products. The foregoing description can also be used for ultrasonic bonding and texturing applications, where the foregoing features can be used to improve quality, throughput, and production efficiency.

[0157] Aspects of the present disclosure may be used alone, in combination, or in a variety of arrangements not specifically discussed in the foregoing embodiments, and thus its application is not limited to the details and arrangements of the components set forth in the foregoing description or shown in the drawings. For example, aspects described in one embodiment may be combined with aspects described in other embodiments in any manner.

[0158] Although the present teachings have been described in conjunction with various embodiments and examples, the present teachings are not intended to be limited to such embodiments or examples. On the contrary, those skilled in the art should understand that the present teachings cover various alternatives, modifications, and equivalents. Accordingly, the foregoing description and drawings are provided by way of example only.

Claims

1. A system for ultrasonically forming contact fasteners, the system comprising: an ultrasonic generator having a functional surface; and a molding roller having a plurality of fastener cavities; wherein the ultrasonic generator has a plurality of raised and / or recessed features disposed on the functional surface of the ultrasonic generator, and wherein the plurality of raised and / or recessed features are configured to apply ultrasonic vibrations to a substrate to gradually form contact fasteners from the substrate, the substrate being disposed between the functional surface and the molding roller.

2. The system according to claim 1, wherein, the ultrasonic generator is a rotary ultrasonic generator.

3. The system according to claim 1, wherein, the ultrasonic generator is a vane ultrasonic generator.

4. The system according to claim 1, wherein, the plurality of raised and / or recessed features are configured to create undisturbed portions in the substrate.

5. The system according to claim 1, further comprising one or more supplementary materials, wherein, the one or more supplementary materials are configured to be disposed between the substrate and the functional surface of the ultrasonic generator and / or between the substrate and the molding roller.

6. The system according to claim 1, wherein, the plurality of raised and / or recessed features include one or more supplementary materials coated thereon.

7. The system according to claim 3, wherein, the vane ultrasonic generator includes one or more passages disposed therein, the passages being configured to receive supplementary materials and direct the supplementary materials to a desired area between the functional surface and the molding roller.

8. The system according to claim 1, wherein, the plurality of raised and / or recessed features are a plurality of raised features, wherein the plurality of raised features are intermittently positioned along the functional surface of the ultrasonic generator.

9. The system according to claim 1, wherein, the plurality of raised and / or recessed features are formed as grooves and / or dams.

10. The system according to claim 9, wherein, the grooves include symmetric side surfaces.

11. The system according to claim 9, wherein, the grooves include asymmetric side surfaces.

12. The system according to claim 1, wherein, the functional surface of the ultrasonic generator includes one or more textured surfaces.

13. The system according to claim 12, wherein, the one or more textured surfaces have a roughness average (Ra) value between 0.7 microns Ra and 1 micron Ra.

14. The system according to claim 12, wherein, the one or more textured surfaces have a polished finish or a satin finish.

15. The system according to claim 2, wherein, the rotary ultrasonic generator and the molding roller are driven at a fixed ratio.

16. The system according to claim 2, wherein, the rotary ultrasonic generator and the molding roller are driven at a varying ratio.

17. The system according to claim 2 further includes one or more rollers positioned around the periphery of the rotary ultrasonic generator, wherein, the one or more rollers are configured to preheat the substrate.

18. The system according to claim 2, wherein, the rotary ultrasonic generator operates at an ultrasonic frequency between 5 kHz and 100 kHz.

19. The system according to claim 1, wherein, the plurality of raised and / or recessed features provided on the functional surface are formed as channels.

20. The system according to claim 19, wherein, the one or more channels include at least one tapered portion.

21. The system according to claim 3, wherein, the plurality of raised and / or recessed features include relief portions in the functional surface.

22. The system according to claim 3, wherein, the functional surface extends in a direction substantially similar to the circumference of the molding roller.

23. The system according to claim 3, wherein, the molding roller includes a plurality of blocks having fastener cavities, and wherein the plurality of raised and / or recessed features include a plurality of raised features configured to span at least a portion of at least two of the plurality of blocks during rotation of the molding roller.

24. The system according to claim 1, wherein, the molding roller includes one or more blocks having a plurality of fastener cavities and adjacent runoff zones.

25. The system according to claim 24, wherein, the runoff zone includes one or more textured surfaces configured to collect excess material during formation of the contact fastener.

26. The system according to claim 25, wherein, the textured surface has a pattern selected from at least one of a crosshatch pattern, a wave pattern, a checkerboard pattern, a stripe pattern, a circular pattern, an oval pattern, an annular pattern, a square pattern, and a rectangular pattern.

27. The system according to claim 25, wherein, at least a portion of the one or more textured surfaces is recessed into the surface of the runoff zone.

28. The system according to claim 25, wherein, at least a portion of the one or more textured surfaces protrudes above the surface of the runoff zone.

29. The system according to claim 3, wherein, the plurality of raised and / or recessed features include recessed portions provided along one side of the functional surface of the ultrasonic generator.

30. A baby diaper having one or more discontinuous contact fasteners integrally formed to the substrate according to the system of claim 27 or 28.

31. A system for ultrasonically forming contact fasteners, the system comprising: a rotary ultrasonic generator having a functional surface; and a molding roller having a plurality of fastener cavities; Wherein, the functional surface of the rotary ultrasonic generator is configured to apply ultrasonic vibration to a substrate to be disposed between the functional surface and the molding roller, so as to form a contact fastener from the substrate, wherein the rotary ultrasonic generator has one or more raised and / or recessed features disposed on the functional surface, and wherein the rotary ultrasonic generator and the molding roller are driven at a varying ratio.

32. The system according to claim 31, wherein, the plurality of raised and / or recessed features are configured to create undisturbed portions in the substrate.

33. The system according to claim 31, further comprising one or more supplementary materials, wherein, the one or more supplementary materials are configured to be disposed between the substrate and the functional surface of the rotary ultrasonic generator and / or between the substrate and the molding roller.

34. The system according to claim 31, wherein, the plurality of raised and / or recessed features include one or more supplementary materials coated thereon.

35. The system according to claim 31, wherein, the plurality of raised and / or recessed features are a plurality of raised features, wherein the plurality of raised features are intermittently positioned along the functional surface of the rotary ultrasonic generator.

36. The system according to claim 31, wherein, the plurality of raised and / or recessed features are formed as grooves and / or dams.

37. The system according to claim 36, wherein, the groove includes symmetric side surfaces.

38. The system according to claim 36, wherein, the groove includes asymmetric side surfaces.

39. The system according to claim 31, wherein, the functional surface of the rotary ultrasonic generator includes one or more textured surfaces.

40. The system according to claim 39, wherein, the one or more textured surfaces have a roughness average (Ra) value between 0.7 micrometers Ra and 1 micrometer Ra.

41. The system according to claim 39, wherein, the one or more textured surfaces have a polished finish or a satin finish.

42. The system according to claim 31, further comprising one or more rollers positioned around the perimeter of the rotary ultrasonic generator, wherein, the one or more rollers are configured to preheat the substrate.

43. The system according to claim 31, wherein, the rotary ultrasonic generator operates at an ultrasonic frequency between 5 kHz and 100 kHz.

44. The system according to claim 31, wherein, the molding roller includes one or more blocks having a plurality of fastener cavities and adjacent runoff regions.

45. The system according to claim 44, wherein, the runoff region includes one or more textured surfaces configured to collect excess material during the formation of the contact fastener.

46. The system according to claim 45, wherein, The textured surface has a pattern selected from at least one of a crosshatch pattern, a wave pattern, a checkerboard pattern, a stripe pattern, a circular pattern, an oval pattern, an annular pattern, a square pattern, and a rectangular pattern.

47. The system according to claim 44, wherein, at least a portion of the one or more textured surfaces is recessed into the surface of the runoff zone.

48. The system according to claim 44, wherein, at least a portion of the one or more textured surfaces protrudes above the surface of the runoff zone.

49. The system according to claim 31, wherein, the spacing between the contact fasteners is changed in the machine direction by accelerating and / or decelerating the surface speed of the rotary ultrasonic generator relative to the surface of the molding roll.

50. The system according to claim 31, wherein, the spacing between the contact fasteners is changed in the cross direction by sliding the rotary ultrasonic generator relative to the molding roll to a desired position in the cross direction.

51. The system according to claim 31, wherein, the plurality of raised and / or recessed features provided on the functional surface are formed as channels.

52. A baby diaper having one or more discontinuous contact fasteners integrally formed to a substrate according to the system of claim 31.

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