Energy mechanism assembly and method for providing energy to an item

Abstract

Energy mechanism assemblies and methods of operating such assemblies are described. One method of providing energy to an item may include positioning the item proximate to an energy mechanism assembly comprising a first energy mechanism, a second energy mechanism, and a translation system configured to move the second mechanism between a first position and a second position along a first axis and a second axis, positioning the item between the first and second mechanisms, moving the second mechanism from the first position to the second position, moving the second mechanism a first length along the second axis while the second mechanism is in contact with the item, and providing energy to the item while the second mechanism is in contact with at least the item.

Description

[Technical Field]

[0001] TECHNICAL FIELD The present disclosure relates to energy mechanism assemblies and methods for providing energy to items. More particularly, the present disclosure relates to ultrasonic bonding devices and methods for utilizing the same. [Background technology]

[0002] Various manufacturing equipment and processes provide various techniques for transferring energy to items, which may be to accomplish different tasks. Energy transfer mechanisms may include devices configured for cutting, sealing, embossing, pressure bonding, ultrasonic bonding, and the like. In the manufacture of some absorbent articles, an ultrasonic bonding device is one energy transfer device that may be utilized to provide ultrasonic bonding to one or more components of the absorbent article. As an example, some absorbent articles include side panels having side seam bonds that may be formed by transferring ultrasonic energy from respective components of the ultrasonic bonding device, commonly referred to as an anvil and an ultrasonic horn, across the web material that forms the side panels.

[0003] While current ultrasonic bonding devices can provide sufficient bonds for some absorbent article configurations and manufacturing process conditions, increases in manufacturing speed and / or absorbent article configurations can result in undesirable bond strength in the materials being bonded. Thus, there is a need for improved energy devices and methods for providing energy to items. More specifically, there is a need for improved ultrasonic bonding devices and methods for providing ultrasonic energy to items. Summary of the Invention

[0004] In one embodiment, a method of providing energy to an item may include positioning the item proximate to an energy mechanism assembly comprising: a first energy mechanism and a second energy mechanism; at least one of the first energy mechanism and the second energy mechanism comprising a plane and a plurality of joint elements extending from the plane; and a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position, the translational motion system further configured to move the second energy mechanism along at least a first axis and a second axis between the first position and the second position. The method may further include positioning the item between the first energy mechanism and the second energy mechanism, with a first axis oriented substantially perpendicular to the item and a second axis oriented substantially perpendicular to the first axis while the item is disposed between the first energy mechanism and the second energy mechanism; moving the second energy mechanism with the translational motion system from the first position to a second position while disposing the item between the first energy mechanism and the second energy mechanism; moving the second energy mechanism with the translational motion system along the second axis by a first length while the second energy mechanism is in contact with the item; and providing energy to at least the item with an energy mechanism assembly while the second energy mechanism is in contact with the item.

[0005] In another embodiment, a method of joining materials may include positioning an item proximate an energy mechanism assembly comprising a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane and a plurality of joining elements extending from the plane, the plurality of joining elements having a combined joining surface area, and a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position. The method may further include positioning the item between the first energy mechanism and the second energy mechanism, moving the second energy mechanism with the translational motion system from the first position to the second position disposing the item between the first energy mechanism and the second energy mechanism, and providing energy to the energy mechanism assembly to the item to form a plurality of bonds, the plurality of bonds having a combined surface area, the combined surface area of ​​the plurality of bonds being at least 10% greater than the combined joining surface area of ​​the plurality of joining elements.

[0006] In yet another embodiment, the joined material may comprise a plurality of bonds, each of the plurality of bonds having a deformed shape, the plurality of bonds being formed by applying energy to the material with an energy mechanism assembly comprising: a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane having a plurality of bond elements extending from the plane, each of the bond elements having a surface feature; and a translation system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position, the translation system further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, the second axis being perpendicular to the first axis. The deformed shape of each of the plurality of bonds may be the deformed shape of the surface feature of one of the bond elements. [Brief explanation of the drawings]

[0007] A full and enabling disclosure of the present specification, directed to one of ordinary skill in the art, makes reference to the accompanying figures below and is more particularly described in the remainder of the specification.

[0008] [Figure 1] FIG. 1 is a perspective view of a preferred embodiment of the energy device of the present disclosure, with some features of the energy device removed for clarity. [Figure 2] FIG. 2 is a schematic diagram of an exemplary energy mechanism assembly and translation system of the energy device of FIG. [Figure 3A] 3A is a schematic diagram of an exemplary energy mechanism assembly and translation system of the energy device of FIG. 1, with the second energy mechanism in a first position. [Figure 3B] 3BA is a schematic diagram of an exemplary energy mechanism assembly and translation system of the energy device of FIG. 1, with the second energy mechanism in a second position. [Figure 4] FIG. 4 is a perspective view of an exemplary second energy mechanism including a coaptation element. [Figure 5] FIG. 5 is a plan view of an exemplary bonding pattern according to an embodiment of the present disclosure. [Figure 6] 6 is a plan view of a further exemplary bonding pattern according to an embodiment of the present disclosure. Repeat use of reference characters in the present specification and drawings is intended to indicate same or analogous features or elements of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] In one embodiment, the present disclosure is generally directed to one or more energy mechanism assemblies for providing energy to items 14. The energy mechanism assemblies may, in some embodiments, be configured to provide ultrasonic energy for ultrasonically bonding items 14. However, it is contemplated that the described energy mechanism assemblies may provide different forms of energy to items 14 to provide energy other than ultrasonic energy, including, but not limited to, thermal energy transfer for heat sealing. In at least one preferred embodiment, one or more energy mechanism assemblies may be implemented as part of an energy device 10. The energy device 10 may be utilized in a variety of manufacturing environments and for a variety of items. In accordance with aspects of the present disclosure, the energy device 10 herein is discussed with respect to providing ultrasonic bonding on components of absorbent articles, such as cross-sectional pants (CD pants). In FIG. 1 and the embodiment of the device 10, the items 14 still represent absorbent articles in the form of an interwoven absorbent article web, which may be referred to as a web 14 throughout this disclosure. It will be appreciated that the energy mechanism assemblies and / or larger energy devices 10 comprising energy mechanism assemblies described herein may be utilized with other manufactured consumer goods, including, but not limited to, other personal care articles, specific portions of personal care articles, consumer goods, and packaging.

[0010] Each example and embodiment is provided for purposes of explanation, not limitation. For example, features illustrated or described as part of one embodiment or illustration may be used with another embodiment or illustration to yield still a further embodiment. Accordingly, aspects of the present disclosure are intended to cover such modifications and variations. When introducing elements of the present disclosure or preferred embodiments thereof, the articles "a," "an," "the," and "said" mean that there are one or more of the elements. The terms "comprise," "include," and "have" are intended to be inclusive and mean that there may be additional elements other than the listed elements. As used herein, terms such as "first," "second," and "third" are used as a means of distinguishing between different features described in the present disclosure, although they do not specify a particular order or indicate that items referring to the use of such terms must be presented sequentially. Many modifications and variations of the present disclosure may be made without departing from the spirit and scope of the present disclosure. Accordingly, the exemplary embodiments described above should not be used to limit the scope of the present invention.

[0011] Definition of Terms The term "absorbent article," as used herein, refers to an article that may be placed in contact with or in close proximity to (i.e., adjacent to) the body of a wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles are intended to be discarded after a limited period of use, rather than being laundered or otherwise restored for reuse. It should be understood that the present disclosure applies to a variety of disposable absorbent articles, including, but not limited to, diapers, diaper pants, training pants, infant pants, swim trunks, feminine hygiene products including, but not limited to, sanitary pads or pants, incontinence products including, but not limited to, adult incontinence garments, medical garments, surgical pads and bandages, other personal care or health care garments, and the like, without departing from the scope of the present disclosure.

[0012] The terms "joined" and "coupled," as used herein, refer to the joining, adhering, connecting, adhering, etc., of two elements. Two elements will be considered to be joined or coupled together when they are joined, adhered, connected, attached, etc., directly to one another, or indirectly to one another, such as when each is directly joined to an intermediate element. The joining or coupling of one element to another element can occur through continuous or intermittent bonding.

[0013] The term "film" as used herein refers to thermoplastic films made using extrusion and / or molding processes, such as cast film extrusion or blown film extrusion processes. The term includes perforated, slit, and other porous films, which constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

[0014] As used herein, the term "meltblown" refers to fibers formed by extruding molten thermoplastic material as molten threads or filaments through multiple, usually circular, narrow die capillaries into a rapidly converging, heated gas (e.g., air) stream, which dilutes the molten thermoplastic filaments and reduces their diameter, in some cases to that of microfibers. The meltblown fibers are then carried by the high-velocity gas stream and deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers that can be continuous or discontinuous, generally smaller than about 0.6 denier, and can be tacky and self-bonded when deposited on a collecting surface.

[0015] The term "nonwoven," as used herein, refers to materials and web materials that are formed without the aid of a textile weaving or braiding process. Materials and web materials may have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") that may be interleaved but not in a distinguishable manner as in knitted fabrics. Nonwoven materials or webs may be formed by many processes, including, but not limited to, meltblown processes, spunbond processes, carded web processes, and the like.

[0016] The term "spunbond," as used herein, refers to a material formed by extruding molten thermoplastic material as filaments from multiple fine capillaries in a spinneret having a circular or other shape, the diameter of the extruded filaments then being rapidly reduced in diameter by conventional processes such as, for example, extraction drawing and processes described in U.S. Pat. No. 4,340,563 (Appel et al.), U.S. Pat. No. 3,692,618 (Dorschner et al.), U.S. Pat. No. 3,802,817 (Matsuki et al.), U.S. Pat. Nos. 3,338,992 and 3,341,394 (Kinney), U.S. Pat. No. 3,502,763 (Hartmann), U.S. Pat. No. 3,502,538 (Peterson), and U.S. Pat. No. 3,542,615 (Dobo et al.), each of which is incorporated herein by reference in its entirety. Spunbond fibers are generally continuous and often have an average denier greater than about 0.3, and in one embodiment have an average denier between about 0.6, 5, and 10 to about 15, 20, and 40. Spunbond fibers are generally not tacky when deposited onto a collecting surface.

[0017] Referring to FIG. 1, an energy device 10 configured to provide energy to an item transported on a rotating drum 12 is shown. In the embodiments described herein, the energy device 10 is configured to provide ultrasonic energy to an item, such as a web 14 transported in a machine direction 16, which is a layered assembly of various nonwoven materials, films, cellulosics, and superabsorbent materials. The material, after being cut, forms individual absorbent articles. In some embodiments, the web 14 can include a laminate of spunbond meltblown spunbond ("SMS") materials and elastic materials (e.g., strands or sheets). The web 14 is transported to the rotating drum 12 and can be removed from the rotating drum 12 with known web handling equipment and processes, including, but not limited to, a conveyor 20 and rollers 22a, 22b. In one embodiment, the energy device 10 can be configured to provide ultrasonic bonding to form side seams 24 on each side of the absorbent article, as shown in FIG. 1. For clarity of the other components of the energy device 10 described herein, the web 14 is not shown in a position on the rotating drum 12 in FIG. 1 ; rather, it is shown in FIG. 1 in an upstream position before engaging the rotating drum 12 and in a downstream position after disengaging from the rotating drum 12. It should be understood that the web 14 engages the drum 12 after passing through roller 22a, moves around the drum 12, and disengages from the drum 12 after passing through roller 22b. Typically, the web 14 may be held under tension as it travels around the drum 12. Some typical tension values ​​may be between 0.5 pounds per linear inch (PLI) (87.5 n / m) and 5 PLI (875 n / m). While in the embodiments described herein, the energy device 10 may form side seams 24 on the web 14 before the web 14 is cut into individual absorbent articles, it is contemplated that the energy device 10 may be configured to provide energy to individual items, such as individual absorbent articles.

[0018] The energy device 10 may include a first energy mechanism 26 and a second energy mechanism 28. Together, a pair of the first energy mechanism 26 and the second energy mechanism 28 may define an energy mechanism assembly in which the first energy mechanism 26 and the second energy mechanism 28 act together to impart energy to an item, such as the web 14. The first energy mechanism 26 may be configured to be mounted inside the rotating drum 12, as shown in FIG. 1. The energy device 10 may include two or more first energy mechanisms 26 and two or more second energy mechanisms 28. In some embodiments, the energy device 10 may include two, three, four, five, six, or more pairs of first and second energy mechanisms 26, 28, providing two, three, four, five, six, or more energy mechanism assemblies. For example, as shown in FIG. 1, the energy device 10 may include six pairs of first energy mechanisms 26 and second energy mechanisms 28. In such an embodiment, the rotating drum 12 may be configured to include a pair of shells 15 for each of the first and second energy mechanisms 26, 28. As described in further detail below, each shell 15 may include a slot 17 that allows the respective first and second energy mechanism 26, 28 to provide energy to the web 14. Throughout, any reference to a single first energy mechanism 26 or a single second energy mechanism 28 is intended to refer to all such energy mechanisms 26, 28 present in the embodiment, unless otherwise stated.

[0019] The first energy mechanism 26 may be fixedly coupled to the rotating drum 12 and configured to rotate with the rotating drum 12. In other words, the first energy mechanism 26 may be configured to rotate with the rotating drum 12 but remain stationary in the axial direction 27 and the radial direction 29. In some examples, the first energy mechanism 26 may be fixedly coupled to the rotating drum 12 but include a damping system to allow some movement in the radial direction 29. As shown in FIG. 1 , the first energy mechanism 26 may be disposed within at least a portion of the shell 15 of the rotating drum 12. The second energy mechanism 28 may be configured to rotate about the circumference 30 or an exterior surface of the rotating drum 12, as described in more detail below. In embodiments described herein in which the energy device 10 is configured to provide ultrasonic energy to the web 14, the first energy mechanism 26 may be an ultrasonic horn and the second energy mechanism 28 may be configured to be an anvil. Of course, in alternative embodiments, it is contemplated that the energy device 10 may be configured such that the first energy mechanism 26 fixedly coupled to the drum 12 inside the circumference (outer surface) 30 of the rotating drum 12 may be an anvil, and the second energy mechanism 28 configured to rotate around the circumference 30 of the drum 12 may be an ultrasonic horn.

[0020] While the energy mechanism assembly is described herein in connection with an apparatus 10 including a rotating drum 12, it should be understood that this is only one intended implementation of the described energy mechanism assembly. Such an apparatus 10 may be particularly suited to certain high-speed manufacturing processes for forming absorbent articles or other similar articles. However, it is contemplated that the energy mechanism assembly described herein, including the specific coordination described between the first energy mechanism 26 and the second energy mechanism 28, may be implemented in a separate manner, separate from the apparatus 10, or even in an apparatus different from the described apparatus 10. Thus, any particular implementation of the energy mechanism assembly described herein should not be construed as limiting the scope of the present disclosure with respect to the described energy mechanism assembly.

[0021] FIG. 2 is a schematic diagram of an energy mechanism assembly including a first energy mechanism 26 and a second energy mechanism 28. According to aspects of the present disclosure, the second energy mechanism 28 can be coupled to a translational motion system 32 operable to move the second energy mechanism 28 between a first position, as shown in FIG. 3A, for example, and a second position, as shown in FIG. 3B, for example. As described in more detail below, the translational motion system 32 can be configured to move the second energy mechanism 28 between the first and second positions both vertically along a vertical axis and horizontally along a horizontal axis, the horizontal axis being perpendicular to the vertical axis. As used herein, the vertical axis can be considered the first axis, and the horizontal axis can be considered the second axis. When describing the embodiment of FIG. 1 in which the energy mechanism assembly is part of the apparatus 10, the horizontal direction is equivalent to an axial direction 27 extending parallel to the axis of rotation of the drum 12, and the vertical direction is equivalent to a radial direction 29 extending radially from the axis of rotation of the drum 12.

[0022] When in the first position, the second energy mechanism 28 may be generally spaced apart from the first energy mechanism 26, as shown in FIG. 3A. When in the second position, the second energy mechanism 28 may be generally proximate to the first energy mechanism 26, as shown in FIG. 3B. According to some embodiments, the second energy mechanism 28 may be configured to remain stationary at the first and second positions for a period of time. However, in other embodiments, the second energy mechanism 28 may not be configured to spend any significant time at the first and / or second positions. Generally, the first and second positions may define a translational movement of the second energy mechanism 28. For example, from the first position, the second energy mechanism 28 may begin to move toward the second position. That is, the second energy mechanism 28 may begin to move from the first position along the first axis and from the first position along the second axis to the second position along the first axis and toward the second position along the second axis. Conversely, from the second position, the second energy mechanism 28 may begin to move toward the first position. That is, the second energy mechanism 28 can begin to move from the second position along the first axis and from the second position along the second axis to the first position along the first axis and toward the first position along the second axis.

[0023] In some contemplated embodiments, movement of the second energy mechanism 28 along the first axis and the second axis may occur at separate times. For example, the translational motion system 32 may be configured to first move the second energy mechanism 28 from a first position along the second axis to a second position along the second axis. Then, once the second energy mechanism 28 is in the second position along the second axis, the translational motion system 32 may move the second energy mechanism 28 from the first position along the first axis to the second position along the first axis. Conversely, when the second energy mechanism 28 moves from the second position to the first position, the translational motion system 32 may be configured to first move the second energy mechanism 28 from the second position along the first axis to the first position along the first axis. Then, once the second energy mechanism 28 is in the first position along the first axis, the translational motion system 32 may move the second energy mechanism 28 from the second position along the second axis to the first position along the second axis.

[0024] In other contemplated embodiments, movement of the second energy mechanism 28 between the first position and the second position may occur at least partially simultaneously. For example, the translation system 32 may be configured to at least partially simultaneously move the second energy mechanism 28 between the first position along a first axis and the second position along the first axis, and between the first position along a second axis and the second position along the second axis.

[0025] In some contemplated embodiments, the translational motion system 32 may be configured to move the second energy mechanism 28 from a first position along a first axis and from the first position along a second axis to a second position along the first axis and toward the second position along the second axis, such that portions of the movements occur simultaneously. In some of these contemplated embodiments, the second energy mechanism 28 may arrive at the second position along the first axis before the second energy mechanism 28 arrives at the second position along the second axis. However, in other of these contemplated embodiments, the second energy mechanism 28 may arrive at the second position along the second axis before the second energy mechanism 28 arrives at the second position along the first axis.

[0026] In further contemplated embodiments, the translation system 32 may be configured to move the second energy mechanism 28 from the second position along the first axis, and from the second position along the second axis to the first position along the first axis, and toward the first position along the second axis, such that portions of the movements occur simultaneously. In some of these contemplated embodiments, the second energy mechanism 28 may begin moving from the second position along the second axis toward the first position before beginning to move from the second position along the first axis toward the first position along the first axis. However, at least a portion of the movement of the second energy mechanism 28 from the second position to the first position may include simultaneous movement of the second energy mechanism 28 from the second position along the second axis toward the first position along the second axis, and from the second position along the first axis toward the first position along the first axis.

[0027] In these other contemplated embodiments, the second energy mechanism 28 may begin moving along the first axis from the second position along the first axis toward the first position before beginning to move along the second axis from the second position toward the first position along the second axis. In such embodiments, at least a portion of the movement of the second energy mechanism 28 from the second position to the first position may include simultaneous movement of the second energy mechanism 28 along the first axis from the second position along the first axis toward the first position and from the second position along the second axis toward the first position along the second axis.

[0028] In still further embodiments, the translational motion system 32 may be configured to move the second energy mechanism 28 between the first position and the second position such that the movement of the second energy mechanism 28 starts and / or stops simultaneously. For example, the translational motion system 32 may be configured to move the second energy mechanism 28 from the first position to the second position such that the second energy mechanism 28 arrives at the second position along the first axis and at the second position along the second axis simultaneously. In other contemplated embodiments, the translational motion system 32 may be configured to move the second energy mechanism 28 from the second position to the first position such that the second energy mechanism 28 begins movement along both the first axis and the second axis simultaneously.

[0029] When in the second position, the second energy mechanism 28 and the first energy mechanism 26 are generally configured to provide energy to the web 14, thereby forming a bond pattern on the web 14. When in the second position, the second energy mechanism 28 may be configured to have an interference fit with the first energy mechanism 26. However, in other embodiments, the second energy mechanism 28 may be configured to apply pressure against the first energy mechanism 26. In still further embodiments, the second energy mechanism 28 may be configured such that there is a gap 56 between the second energy mechanism 28 and the first energy mechanism 26 when the second energy mechanism 28 is in the second position. The specifications for this spacing between the second energy mechanism 28 and the first energy mechanism 26 may be set according to several factors, such as the amount of energy provided to the first energy mechanism 26, the desired energy transfer to the web 14, the characteristics of the web 14, and many other factors.

[0030] According to some embodiments, the energy mechanism assembly of the present disclosure may be configured to provide energy to the first energy mechanism 26 continuously, such that energy may be provided to the web 14 during the entire movement of the second energy mechanism 28 relative to the first energy mechanism 26 while the second energy mechanism 28 is in proximity to the first energy mechanism 26. However, in other embodiments, the energy mechanism assembly of the present disclosure may be configured to provide energy to the first energy mechanism 26 intermittently, such that energy is provided to the first energy mechanism 26 while the second energy mechanism 28 is in proximity to the first energy mechanism 26, but while the second energy mechanism 28 is not positioned away from the first energy mechanism 26.

[0031] In any embodiment, the energy mechanism assembly and translation system 32 may be configured to move along the second axis a first length 58 while the second energy mechanism 28 is in contact with the web 14, sometimes referred to herein as the bond length 58. Such movement along the second axis during bond formation has been found to result in increased bond strength of the formed bond pattern. As discussed above, there are several different ways in which the translation system 32 may be configured to achieve such movement, either moving from a first position to a second position or moving from a second position to a first position along the second axis while simultaneously moving along the first axis or moving before or after movement along the first axis begins or stops. While the second energy mechanism 28 is described herein as moving a bond length 58, it should be understood that in other embodiments, the first energy mechanism 26 may be configured to move a bond length 58. For example, when the second energy mechanism 28 is in the second position, or at least near the second position, the first energy mechanism 26 may be configured to move a certain length along the second axis, and the length of movement of the first energy mechanism 26 may be considered the bond length 58.

[0032] It has been found that providing such movement of the second energy mechanism 28 along the second axis while in contact with the web 14 can produce a bond pattern having a relatively increased bond strength compared to both a) a bond pattern formed when the second energy mechanism 28 does not move along the second axis while in contact with the web 14, and b) a bond pattern formed when the second energy mechanism 28 does not move along the second axis while in contact with the web 14 and the area of ​​the bond formed is equivalent. That is, forming a bond in which the second energy mechanism 28 moves along the second axis while in contact with the web 14 has been found to produce a bond pattern having a comparable bonded area but superior bond strength compared to a bond pattern formed when the second energy mechanism 28 does not move along the second axis while in contact with the web 14. Without being bound by theory, it is believed that movement along the second axis while in contact with the web 14 can better entangle some of the fibers of the material comprising the web 14, thereby improving its overall bond strength.

[0033] If the energy mechanism assembly of the present disclosure includes an ultrasonic energy assembly, such assembly may be configured to bring the first energy mechanism 26 and the second energy mechanism 28 together to achieve a target force metric and form a bond while energy is being delivered to the first energy mechanism 26. Such an energy mechanism assembly may additionally include one or more sensors, for example, positioned between the first energy mechanism 26 and the second energy mechanism 28 and / or coupled to a portion of the mechanism bringing the first energy mechanism 26 and the second energy mechanism 28 together. Information from these one or more sensors may be used to determine a force metric, and this determined force may be compared to a target force value. A particular target force value may be set differently under different circumstances depending on several factors, such as the particular energy mechanism assembly setup, the particular materials comprising the web 14, and the particular bond pattern being formed. Without being bound by theory, it is believed that bond formation begins at some point after the determined force value begins to increase. However, it is believed that bond formation begins before the determined force value reaches 100% of the target force value.

[0034] Based on this understanding and theory, it may be desirable for movement of the second energy mechanism 28 along the second axis by a bond length 58 during bond formation, for example, at least after the determined force value exceeds zero. According to some embodiments of the present disclosure, the bond length 58 may be determined as the length of movement of the energy mechanism 28 along the second axis while the determined force value is equal to or greater than 50% of the target force value. In embodiments in which the second energy mechanism 28 moves along the second axis both toward and away from the second position on the second axis while the determined force value is equal to or greater than 50% of the target force value, the bond length 58 may be the sum of the lengths of movement of the second energy mechanism 28 along the second axis both toward and away from the second position along the second axis at which the determined force value is equal to or greater than 50% of the target force value.

[0035] In embodiments in which the entire movement along the second axis occurs while the determined force value increases from 50% to 100% of the target force value, or the entire movement along the second axis occurs while the determined force value decreases from 100% to 50% of the target force value, bond length 58 may be 0.75 mm to 5 mm, or more preferably 1.5 mm to 4 mm. It is important that bond length 58 not be too large or the bonding method may create an opening in web 14 instead of a bond. It is contemplated that bond length 58 in these embodiments may generally be less than 8 mm to prevent opening formation rather than bond formation, and may be less than 7 mm in other embodiments.

[0036] In embodiments in which the second energy mechanism 28 moves along the second axis while the determined force value increases from 50% to 100% of the target force value (e.g., when moving along the second axis toward the second position) and while the determined force value decreases from 100% to 50% of the target force value (e.g., when moving along the second axis away from the second position), the bond length 58 can be between 1 mm and 8 mm, or more preferably between 2 mm and 6 mm. It is important that the bond length 58 is not too large or the bonding method may create an opening in the web 14 instead of a bond. It is contemplated that the bond length 58 in these embodiments may generally be less than 12 mm, or less than 10 mm in other embodiments, to prevent opening formation rather than bond formation.

[0037] However, in still further embodiments, bond length 58 may be the total amount of movement of energy mechanism 28 along the second axis while the determined force value is approximately equal to 100% of the target force value. In such embodiments, a useful bond length 58 may be between 0.5 mm and 4 mm, or more preferably between 1 mm and 3 mm. It is contemplated that bond length 58 in these embodiments may generally be less than 6 mm to prevent aperture formation rather than bond formation. In one particular example according to these embodiments, a bond length 58 of approximately 2.3 mm was used. Bond patterns such as pattern 65b shown in FIG. 6 created by this method and using the exemplary bond element 62 of FIG. 4 were found to have approximately 7.4% greater bond strength than bond pattern 65a created by the exemplary bond element 62 of FIG. 4 where bond length 58 was zero.

[0038] FIG. 4 illustrates an exemplary second energy mechanism 28. Typically, the second energy mechanism 28 may comprise a relatively flat surface with a plurality of bonding elements 62 protruding from the surface, as shown in FIG. 4. Each of the bonding elements 62 generally has a surface 61 configured to face the first energy mechanism 26 during operation, and the surface 61 of each of the bonding elements 62 generally defines a surface shape 63, for example, formed by the perimeter of the surface 61. In the example of FIG. 4, the bonding elements 62 are shown as pins whose surfaces 61 each define a generally circular surface shape 63. Collectively, the surface shapes 63 of the bonding elements 62 define a pattern 64. The bonding elements 62 interact with the first energy mechanism 26 and, in conjunction with the energy provided by the first energy mechanism 26, form one or more bonds 66. The one or more bonds 66 collectively form a bonding pattern, one exemplary bonding pattern being pattern 65 shown in FIG. 5, which corresponds to the pattern 64 of the bonding elements 62.

[0039] According to an embodiment of the present disclosure, the second energy mechanism 28 moves along the second axis by a bond length 58 during bond formation. The movement of the second energy mechanism 28 produces a bond 66 having a distorted shape 68. FIG. 5 shows an exemplary bond pattern 65a including a bond 66 formed by a portion of the second energy mechanism 28 shown in FIG. 4 used in a bonding process where the bond length was zero. As can be seen, the shape of the bond 66 closely corresponds to the surface shape 63 of the bonding element 62. In contrast, FIG. 6 shows an exemplary bond pattern 65b including a bond 66. Such a bond pattern 65b may be formed by a portion of the second energy mechanism 28 of FIG. 4 used in a bonding process where the bond length 58 was greater than zero.

[0040] As can be seen, the bonds 66 of the bonding pattern 65b include distorted shapes 68. These distorted shapes 68 generally correspond to, but are different from, the surface shapes 63 of the bonding elements 62. In the example of FIG. 4, the bonding elements 62 have circular surface shapes 63, and the resulting distorted shapes 68 of the pattern 65b may be approximately elliptical. However, the formed bonds 66 may not necessarily have a clearly identifiable shape. It should be understood that the particular distorted shapes 68 of the formed bonds 66 may vary depending on the particular surface shapes 63 of the bonding elements 62, as well as how exactly the bonds 66 are formed during the bonding process. Many of these distorted shapes 68 may defy description by any type of well-known shape term, but are generally achieved by translating the planar surface shape 63 of the web 14, for example, along at least a second axis.

[0041] It should be appreciated that the bonds 66 of bond pattern 65b have a greater bond area than the corresponding surface features 63 of the bond elements 62 used to form the bonds 66. For example, the bond 66 shown in FIG. 6 has a bond length of approximately 2.3 mm, and can be seen to have a greater area than the surface area of ​​the corresponding bond element 62 (FIG. 4), representing a bond 66 formed during a bonding process utilizing the second energy mechanism shown in FIG. 4. The greater bond area of ​​the bond 66 relative to the area of ​​the surface features 63 of the bond elements 62 used to form the bond 66 provides bond pattern 65b with greater strength than bond pattern 65a formed when bond length 58 is zero, e.g., when there is no movement of the second energy mechanism 28 along the second axis after the second energy mechanism 28 contacts the web 14. As discussed above, the bond strength of the bonds 66 of pattern 65b may be stronger than a bond having an area equivalent to that of the bond 66 formed by a process in which bond length 58 is zero. The methods described herein are further advantageous when larger areas of the surface features 63 of the joining elements 62 require relatively more energy to be supplied to the first energy mechanism 26 to be able to form the bond 66. Thus, the methods of the present disclosure allow for the formation of relatively larger bonds 66 with relatively less energy supplied to the first energy mechanism 26 as well as with improved bond strength.

[0042] The distorted shapes 68 of the joint 66 may be considered to have a combined bonded area, while the surface shapes 63 of the joint elements 62 used to form the joint may be considered to have the surface areas of the combined joint elements. As is evident in FIG. 6 , the combined bonded area of ​​the distorted shapes 68 is greater than the surface areas of the combined joint elements of the joint elements 62. According to some aspects of the present disclosure, the described techniques can achieve instances where the combined bonded area of ​​the distorted shapes 68 is at least 10% greater than the surface areas of the combined joint elements of the joint elements 62. According to further aspects of the present disclosure, the described techniques can achieve instances where the combined bonded area of ​​the distorted shapes 68 is at least 15% greater than the surface areas of the combined joint elements of the joint elements 62. According to still further aspects of the present disclosure, the described techniques can achieve instances where the combined bonded area of ​​distorted shape 68 is at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, or at least 60% larger than the combined bonded element surface area of ​​bonded element 62.

[0043] Of course, any suitable mechanism may be used to move the second energy mechanism 28 from the first position along both the first axis and the second axis to the second position, and to further move the second energy mechanism 28 the first length 58 after contacting the web 14. In this disclosure, FIGS. 1-3 illustrate one exemplary mechanism, a translational motion system 32, for providing this particular movement of the second energy mechanism 28, which may be suitable for use in an apparatus such as the apparatus 10 including the rotating drum 12. However, this exemplary embodiment of the movement mechanism should not be construed as limiting the disclosure in any way with respect to how the specifically described movement of the second energy mechanism 28 is achieved. Further details of the exemplary translational motion system 32 are provided below.

[0044] 2 and 3A-3B, the translation system 32 can be configured to move the second energy mechanism 28 between a first position and a second position, for example, in both an axial direction 27 and a radial direction 29. While the translation system 32 can be configured in a variety of ways to move the second energy mechanism 28 in the axial direction 27 and the radial direction 29, one preferred embodiment is intended to be shown in the figures herein and described below.

[0045] In one preferred embodiment, the translation system 32 may include a first drive cam having ribs 35 and at least one cam follower 36, as illustrated schematically in FIG. 2. The cam follower 36 may be configured to travel in a path 38 provided by the ribs 35 of the first drive cam. As shown, in the preferred embodiment, the first drive cam is a rib cam, and thus the path 38 is provided by the ribs 35 surrounding the first drive cam. However, it is contemplated that the first drive cam may be in the form of other types of cams, such as, but not limited to, a barrel cam.

[0046] The translational motion system 32 may also include a sled 40. As shown schematically in FIG. 2, the sled 40 may be coupled to the cam follower 36 through a connector frame 37 and may also be coupled to the second energy mechanism 28. The ribs 35 provide a path 38 whose axial position varies depending on its circumferential position, and thus may help provide axial movement of the second energy mechanism 28. As shown in FIG. 2, the sled 40 may be configured to move axially along rails 41 mounted on a housing (not shown in the schematic view of FIG. 2).

[0047] The translational motion system 32 may further include a second drive-side cam 44 (shown schematically in FIG. 2 ). The translational motion system 32 may also include a first connecting link 42 that may be coupled to a second cam follower 45 and the sled 40. The second cam follower 45 may follow along a path provided by the second drive-side cam 44. The translational motion system 32 may also include a second connecting link 46 that may be coupled to the first connecting link 42. The translational motion system 32 may further include a third connecting link 48 that may be coupled to a frame 50, thereby coupling the second connecting link 46 and the second energy mechanism 28. As described further below, the second connecting link 46 may be configured to pivot about a first pivot point P1, and the third connecting link 48 may be configured to pivot about a second pivot point P2. The frame 50 may be configured to slide rails 52 attached to the sled 40 to provide radial movement of the second energy mechanism 28.

[0048] The translational motion system 32 can also include an actuator 54. As shown in FIG. 2 , the actuator 54 is coupled to the first connecting link 42 and the second connecting link 46 and can be selectively extendable and retractable to move the second energy mechanism 28 between a first position (shown in FIG. 3A ) and a second position (shown in FIG. 3B ). When the second energy mechanism 28 is in the second position, the actuator 54 can be extended to maintain a desired angle α between the first connecting link 42 and the second connecting link 46. During movement from the second position to the first position, the actuator 54 can contract in length to pivot the second connecting link 46 about a first pivot point P1 and pivot the third connecting link 48 about a second pivot point P2 between the second connecting link 46 and the third connecting link 48, assisting in lifting the second energy mechanism 28 in the radial direction 29 to move the second energy mechanism 28 from the second position to the first position (shown in FIG. 3A ). While in the first position, the actuator 54 is retracted to maintain an angle β between the first connecting link 42 and the second connecting link 46, where angle β is less than angle α.

[0049] Embodiment Embodiment 1: In a first embodiment, a method of providing energy to an item may include positioning the item proximate to an energy mechanism assembly, the energy mechanism assembly comprising at least one of a first energy mechanism and a second energy mechanism, the second energy mechanism comprising the first energy mechanism and a plane and a plurality of joint elements extending from the plane, and a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position, the translational motion system further configured to move the second energy mechanism along at least a first axis and a second axis between the first position and the second position. The method may further include positioning the item between the first energy mechanism and the second energy mechanism, with a first axis oriented substantially perpendicular to the item and a second axis oriented substantially perpendicular to the first axis while the item is disposed between the first energy mechanism and the second energy mechanism; moving the second energy mechanism with the translational motion system from the first position to a second position while disposing the item between the first energy mechanism and the second energy mechanism; moving the second energy mechanism with the translational motion system along the second axis by a first length while the second energy mechanism is in contact with the item; and providing energy to at least the item with an energy mechanism assembly while the second energy mechanism is in contact with the item. Embodiment 2: 2. The method of embodiment 1, wherein the second axis may be substantially parallel to a plane of the item. Embodiment 3: 3. The method of embodiment 1 or 2, wherein the second energy mechanism has a first position along the first axis and a first position along the second axis when in the first position, and a second position along the first axis and a second position along the second axis when in the second position, and wherein movement of the second energy mechanism along the second axis by the first length can occur after the second energy mechanism is at the second position along the first axis.

[0050] Embodiment 4: 4. The method of any one of embodiments 1 to 3, wherein the second energy mechanism, when in the first position, has a first position along the first axis and a first position along the second axis, and when in the second position, has a second position along the first axis and a second position along the second axis, and at least a portion of the movement of the second energy mechanism along the second axis by a first length can occur while the second energy mechanism is moving from the first position along the first axis to the second position along the second axis.

[0051] Embodiment 5: 5. The method of any one of embodiments 1 to 4, wherein the second energy mechanism, when in the first position, has a first position along the first axis and a first position along the second axis, and when in the second position, has a second position along the first axis and a second position along the second axis, and at least a portion of the movement of the second energy mechanism along the second axis by a first length can occur while the second energy mechanism is moving from the second position along the first axis to the first position along the first axis. Embodiment 6: 6. The method of any one of embodiments 1 to 5, wherein the movement of the second energy mechanism by the first length can occur in a direction extending away from the first location along a second axis. Embodiment 7: 7. The method of any one of embodiments 1 to 6, wherein the movement of the second energy mechanism by the first length can occur in a direction extending from the first location along a second axis. Embodiment 8: The method of any one of embodiments 1 to 7 may further include measuring a force applied to the item by the energy mechanism assembly, and the first length may be determined as the sum of the lengths of movement of the second energy mechanism along the second axis while the measured applied force is between 50% and 100% of the target force value. Embodiment 9: 9. The method of embodiment 8, wherein the first length can be between 0.75 mm and 5 mm. Embodiment 10: The method of any one of embodiments 1 to 7 may further include measuring a force applied to the item by the energy mechanism assembly, and the first length may be determined as the sum of the lengths of movement of the second energy mechanism along the second axis while the measured applied force is approximately 100% of the target force value. Embodiment 11: 11. The method of embodiment 10, wherein the first length can be between 0.5 mm and 4 mm. Embodiment 12: A method of joining materials may include positioning an item proximate an energy mechanism assembly, the energy mechanism assembly including a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane and a plurality of joining elements extending from the plane, the plurality of joining elements having a combined joining surface area, and a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position. The method may further include positioning the item between the first energy mechanism and the second energy mechanism, moving the second energy mechanism with the translational motion system from the first position to the second position disposing the item between the first energy mechanism and the second energy mechanism, and providing energy to the energy mechanism assembly to the item to form a plurality of bonds, the plurality of bonds having a combined surface area, the combined surface area of ​​the plurality of bonds being at least 10% greater than the combined joining surface area of ​​the plurality of joining elements. Embodiment 13: 13. The method of embodiment 12, wherein the combined surface area of ​​the plurality of joints may be at least 30% greater than the combined joint surface area of ​​the plurality of joint elements. Embodiment 14: 13. The method of embodiment 12, wherein the combined surface area of ​​the plurality of joints may be at least 40% greater than the combined joint surface area of ​​the plurality of joint elements. Embodiment 15: The method of any one of embodiments 12 to 14, wherein the translational motion system may be further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, and at least a portion of the movement along the second axis may occur while the joint element is in contact with the item. Embodiment 16: The method of any one of embodiments 12 to 15 further includes measuring a force applied to the item by the energy mechanism assembly, wherein the translational motion system is further configured to move the second energy mechanism axis from the first position and the second position along at least a first axis and a second axis, and at least a portion of the movement along the second axis can occur when the measured applied force is between 50% and 100% of the target force value. Embodiment 17: 17. The method of any one of embodiments 12-16, wherein the item comprises at least two layers of nonwoven material, and wherein the bonding bonds the at least two layers of nonwoven material together. Embodiment 18: The bonded material may comprise a plurality of bonds, each of the plurality of bonds having a distorted shape, formed by applying energy to the material with an energy mechanism assembly comprising: a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane having a plurality of bond elements extending from the plane, each of the bond elements having a surface feature; and a translation system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position, the translation system further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, the second axis being perpendicular to the first axis. The distorted shape of each of the plurality of bonds may be the distorted shape of the surface feature of one of the bond elements. Embodiment 19: 19. The method of embodiment 18, wherein the distorted shape can be formed by moving the second energy mechanism along a second axis during formation of the bond in the joined materials. Embodiment 20: 19. The method of embodiment 17 or 18, wherein the distorted shape of the plurality of junctions may be generally elliptical. All documents cited in the detailed description are, in relevant part, incorporated herein by reference. The citation of any document should not be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term set forth in this document conflicts with a meaning or definition in any of the documents incorporated herein by reference, the meaning or definition assigned to the term in this document shall apply. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A method of providing energy to an item, comprising: positioning the item in proximity to an energy mechanism assembly, the energy mechanism assembly comprising: at least one of a first energy mechanism and a second energy mechanism, the first energy mechanism and the second energy mechanism comprising a plane and a plurality of joint elements extending from the plane; positioning the second energy mechanism adjacent to an energy mechanism assembly comprising: a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position, the translational motion system further configured to move the second energy mechanism along at least a first axis and a second axis between the first position and the second position; positioning the item between the first energy mechanism and the second energy mechanism, wherein the first axis is oriented substantially perpendicular to the item and the second axis is oriented substantially perpendicular to the first axis while the item is disposed between the first energy mechanism and the second energy mechanism; moving, by the translational motion system, the second energy mechanism from the first location to the second location with the item positioned between the first energy mechanism and the second energy mechanism; moving, with the translation system, the second energy mechanism a first length along the second axis while the second energy mechanism is in contact with the item; providing energy to the energy mechanism assembly to at least the item while the second energy mechanism is in contact with the item.

2. The method of claim 1 , wherein the second axis is substantially parallel to a plane of the item.

3. 10. The method of claim 1, wherein the second energy mechanism has a first position along the first axis and a first position along the second axis when in the first position, and a second position along the first axis and a second position along the second axis when in the second position, and wherein the movement of the second energy mechanism along the second axis by the first length occurs after the second energy mechanism is at the second position along the first axis.

4. 10. The method of claim 1, wherein the second energy mechanism has a first position along the first axis and a first position along the second axis when in the first position, and a second position along the first axis and a second position along the second axis when in the second position, and wherein at least a portion of the movement of the second energy mechanism along the second axis by the first length occurs while the second energy mechanism is moving from the first position along the first axis to the second position along the second axis.

5. 10. The method of claim 1, wherein the second energy mechanism has a first position along the first axis and a first position along the second axis when in the first position, and a second position along the first axis and a second position along the second axis when in the second position, and wherein at least a portion of the movement of the second energy mechanism along the second axis by the first length occurs while the second energy mechanism is moving from the second position along the first axis to the first position along the first axis.

6. 10. The method of claim 1, wherein the movement of the second energy mechanism by the first length occurs in a direction extending away from the first location along the second axis.

7. 10. The method of claim 1, wherein the movement of the second energy mechanism by the first length occurs in a direction extending from the first location along the second axis.

8. 10. The method of claim 1, further comprising measuring a force applied to the item by the energy mechanism assembly, wherein the first length is determined as a sum of lengths of movement of the second energy mechanism along the second axis while the measured applied force is between 50% and 100% of a target force value.

9. The method of claim 8, wherein the first length is between 0.75 mm and 5 mm.

10. 10. The method of claim 1, further comprising measuring a force applied to the item by the energy mechanism assembly, wherein the first length is determined as a sum of lengths of movement of the second energy mechanism along the second axis while the measured applied force is approximately 100% of a target force value.

11. The method of claim 10, wherein the first length is between 0.5 mm and 4 mm.

12. positioning the item in proximity to an energy mechanism assembly, the energy mechanism assembly comprising: a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane and a plurality of interface elements extending from the plane, the plurality of interface elements having a combined interface surface area; a translation system coupled to the second energy mechanism and configured to move the second energy mechanism between a first position and a second position; positioning the item between the first energy mechanism and the second energy mechanism; moving, by the translational motion system, the second energy mechanism from the first location to the second location with the item positioned between the first energy mechanism and the second energy mechanism; and providing energy to the items to form a plurality of bonds with the energy mechanism assembly; 10. A method of joining materials, wherein the plurality of joints have a combined surface area, the combined surface area of ​​the plurality of joints being at least 10% greater than the combined joining surface area of ​​the plurality of joining elements.

13. The method of claim 12 , wherein the combined surface area of ​​the plurality of joints is at least 30% greater than the combined joint surface area of ​​the plurality of joint elements.

14. The method of claim 12 , wherein the combined surface area of ​​the plurality of joints is at least 40% greater than the combined joint surface area of ​​the plurality of joint elements.

15. 13. The method of claim 12, wherein the translation system is further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, and at least a portion of the movement along the second axis occurs while the joint element is in contact with the item.

16. 13. The method of claim 12, further comprising measuring a force applied to the item by the energy mechanism assembly, wherein the translation system is further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, and wherein at least a portion of the movement along the second axis occurs when the measured applied force is between 50% and 100% of a target force value.

17. 13. The method of claim 12, wherein the item comprises at least two layers of nonwoven material, and the bonding bonds the at least two layers of nonwoven material together.

18. a plurality of junctions, each of the plurality of junctions having a distorted shape; The plurality of bonds are formed by applying energy to the material with the energy mechanism assembly, the energy mechanism assembly comprising: a first energy mechanism and a second energy mechanism, at least one of the first energy mechanism and the second energy mechanism comprising a plane having a plurality of interface elements extending from the plane, each of the interface elements having a surface feature; a translational motion system coupled to the second energy mechanism and configured to move the second energy mechanism between the first position and a second position, the translational motion system further configured to move the second energy mechanism from the first position and the second position along at least a first axis and a second axis, the second axis being perpendicular to the first axis; The bonded material, wherein the distorted shape of each of the plurality of bonds is a distorted shape of a surface feature of one of the bond elements.

19. 20. The bonded material of claim 18, wherein the distorted shape is formed by moving the second energy mechanism along the second axis during formation of the bond in the bonded material.

20. 20. The bonded material of claim 18, wherein the distorted shape of the plurality of bonds is generally elliptical.