Apparatus for fabricating elastic nonwoven material

Abstract

To provide a method for fabricating a more durable elastic nonwoven material in a more cost effective manner.SOLUTION: A method for fabricating an elastic nonwoven material comprises a step of positioning a first bonding module in close proximity to a second bonding module. At least one of the first bonding module and the second bonding module includes a face having a width dimension in a width direction and a circumferential axis extending in a circumferential direction. The method also includes a step of rotating at least one of the first bonding module and the second bonding module. The method further includes a step of directing an elastic strand between the first bonding module and the second bonding module and along a curve curved along the circumferential direction (circumferential axis). The method also includes a step of bonding the elastic nonwoven material in a first region and a second region. At least a portion of the elastic strand is entrapped in the first region and at least a portion of the elastic strand is entrapped in the second region. The elastic strand extends along the curve between the first region and the second region.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 402,457, filed September 30, 2016, the contents of which are incorporated herein by reference.

[0002] FIELD OF THE INVENTION The present invention relates generally to elastic materials, and more particularly to an apparatus for producing elastic nonwoven materials. [Background technology]

[0003] Elastic nonwoven materials are used in a variety of products, such as personal care products (e.g., adult briefs, infant diapers, children's / adult pull-on pants, form-fitting sanitary napkins, etc.) and medical garments (masks, caps, gowns, footwear, etc.). At least some conventional methods for producing elastic nonwoven materials involve adhesively bonding elastic strands between layers of a nonwoven fabric when the elastic strands are under tension. When the elastic strands are contractible, they aggregate regions of the nonwoven fabric that allow the nonwoven fabric to perform elastically.

[0004] However, the durability of elastic nonwoven materials made by these conventional methods may be less than desired because the adhesives tend to creep, which can result in a decrease in elasticity over time. Furthermore, producing elastic nonwoven materials using these conventional methods can be excessively expensive. Therefore, it would be beneficial to provide a system for producing more durable elastic nonwoven materials in a more cost-effective manner. Summary of the Invention [Means for solving the problem]

[0005] In one embodiment, an apparatus for producing an elastic nonwoven material generally includes a first bonding module and a second bonding module. The second bonding module is positionable adjacent to the first bonding module. At least one of the first bonding module and the second bonding module includes a face having a width dimension in a width direction and a circumferential axis extending in a circumferential direction, and is rotatable about a rotation axis. The face includes a plurality of ridges. The ridges are arranged such that at least two adjacent ridges overlap each other in the circumferential direction (circumferential axis).

[0006] In another embodiment, a method for producing an elastic nonwoven fabric generally includes positioning a first bonding module adjacent to a second bonding module. The method also includes positioning a nonwoven fabric and at least one elastic strand between the first bonding module and the second bonding module. The method further includes bonding the nonwoven fabric at a bonding point to hold the at least one elastic strand to the nonwoven fabric. The method further includes cutting the at least one elastic strand to form a first cut portion and a second cut portion. The bonding point (bond) is located between the first cut portion and the second cut portion so that the at least one elastic strand has free ends extending on both sides of the bond portion.

[0007] In yet another embodiment, a method for manufacturing an elastic nonwoven material generally includes the steps of: positioning a first coupling module adjacent to a second coupling module; at least one of the first coupling module and the second coupling module includes a face having a width dimension in a width direction and a circumferential axis extending in a circumferential direction; the method also includes the step of rotating at least one of the first coupling module and the second coupling module; the method further includes the step of guiding elastic strands along a curve that curves in the circumferential direction (circumferential axis) between the first coupling module and the second coupling module; the method also includes the step of bonding the elastic nonwoven material at a first region and a second region; at least a portion of the elastic strands are captured in the first region and at least a portion of the elastic strands are captured in the second region; the elastic strands extend along the curve between the first region and the second region.

[0008] In yet another embodiment, an apparatus for producing an elastic nonwoven material including at least one elastic strand generally includes a first bonding module and a second bonding module positionable adjacent to the first bonding module. At least one of the first bonding module and the second bonding module includes a face having a width dimension in the width direction and a circumferential axis extending in the circumferential direction, and is rotatable about a rotation axis. The face has a plurality of ridges. The first bonding module and the second bonding module are positioned to receive the at least one elastic strand and the nonwoven material. The apparatus further includes a supply station configured to provide the at least one elastic strand. The at least one elastic strand is guided across the width direction (width dimension) along a curve that curves along the circumferential direction (circumferential axis) when at least one of the first bonding module and the second bonding module rotates. [Brief explanation of the drawings]

[0009] [Figure 1] Schematic of a system for producing an elastic nonwoven material [Figure 2]FIG. 2 is a perspective view of one embodiment of a rotary ultrasonic coupling device for use in the system of FIG. 1; [Figure 3] FIG. 2 is a perspective view of another embodiment of a rotary ultrasonic coupling device for use in the system of FIG. 1; [Figure 4] FIG. 4 is a partial cross-sectional view of the device of FIG. [Figure 5] FIG. 2 is a perspective view of another embodiment of a rotary ultrasonic coupling device for use in the system of FIG. 1; [Figure 6] 6 is an enlarged side view of the pinching device of the apparatus of FIG. [Figure 7] FIG. 2 is a perspective view of yet another embodiment of a rotary ultrasonic coupling device for use in the system of FIG. 1; [Figure 8] FIG. 8 is a laid-flat illustration of an annular face of one embodiment of an anvil for use with the apparatus of FIGS. 2-7. [Figure 9] 9 is a cross-sectional view of one embodiment of a ridge defined on the anvil face of FIG. 8, taken along section 9-9 of FIG. 8; [Figure 10] 10 is a cross-sectional view of another embodiment of the ridges defined on the anvil face of FIG. 8, taken along section 10-10 of FIG. 8; [Figure 11] 11 is a cross-sectional view of yet another embodiment of a ridge defined on the anvil face of FIG. 8, taken along section 11-11 of FIG. 8; [Figure 12] FIG. 8 is an exploded view of a portion of the annular face of another embodiment of an anvil for use with the apparatus of FIGS. 2-7; [Figure 13] FIG. 13 is a perspective view of a portion of the annular face of FIG. [Figure 14] 14 is a partial enlarged perspective view of FIG. 13 showing the range of the reference numeral 14 in FIG. 13; [Figure 15] Schematic diagram of an elastic nonwoven material produced using one embodiment of the system of FIG. 1. [Figure 16] FIG. 8 is an exploded view of a portion of an annular face including discontinuous ridges of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7; [Figure 17] FIG. 8 is an exploded view of a portion of an annular face including ridges extending along an oblique axis of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7; [Figure 18]FIG. 8 is an exploded view of a portion of the annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, including discrete ridges of different shapes; [Figure 19] FIG. 8 is an exploded view of a portion of the annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, including a different pattern of ridges; [Figure 20] FIG. 8 is an exploded view of a portion of the annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, including a symmetrical pattern of ridges; [Figure 21] FIG. 8 is an exploded view of a portion of an annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, including ridges oriented at substantially perpendicular angles to one another; [Figure 22] FIG. 8 is an exploded view of a portion of the annular face, including ridges, of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7; [Figure 23] FIG. 8 is an exploded view showing a portion of the annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, with elastic strands extending across the width of the anvil face along a curve; [Figure 24] FIG. 8 is an exploded view of a portion of the annular face of yet another embodiment of an anvil for use with the apparatus of FIGS. 2-7, showing elastic strands received and guided along curves based on ridges on the annular face; [Figure 25] 2 is a schematic diagram of an elastic nonwoven material produced using one embodiment of the system of FIG. 1 and an intermittent acquisition process.

[0010] Like numbers refer to corresponding parts throughout the figures. DETAILED DESCRIPTION OF THE INVENTION

[0011] Referring to the drawings, and particularly to Figure 1, a system for producing elastic nonwoven material is generally designated by the numeral 100. The illustrated system 100 (a system for producing elastic nonwoven material) includes a supply station generally designated by the numeral 102, a processing station generally designated by the numeral 104, and a collection station generally designated by the numeral 106. Other suitable stations are also contemplated without departing from the scope of the present invention.

[0012] In the illustrated embodiment, the supply station 102 includes multiple supply rolls containing nonwoven fabrics. That is, a first supply roll 110 contains a first nonwoven fabric 112, and a second supply roll 114 contains a second nonwoven fabric 116. The supply station 102 also includes supply spools containing elastic strands. That is, a first supply spool 118 contains a first elastic strand 120, a second supply spool 122 contains a second elastic strand 124, a third supply spool 126 contains a third elastic strand 128, and a fourth supply spool 130 contains a fourth elastic strand 132. The elastic strands 120, 124, 128, and 132 may have any suitable cross-sectional shape (e.g., circular, (e.g., relatively flat) rectangular, square, etc.) that enables them to function as described herein.

[0013] The illustrated processing station 104 includes a rotary ultrasonic bonding apparatus (generally designated with the numeral 200) that bonds elastic strands 120, 124, 128, and 132 between nonwovens 112 and 116 to create an elastic nonwoven material 134, which will be described in more detail below. The collection station 106 may include any suitable device (e.g., take-up roll 136) for collecting the elastic nonwoven material 134. In other embodiments, the supply station 102 may include any suitable number of supply rolls and supply spools having any suitable configuration that enables the apparatus 200 (rotary ultrasonic bonding apparatus 200) to function as described herein.

[0014] 2-7 illustrate various embodiments of a rotary ultrasonic bonding device 200. In the illustrated embodiment, the device 200 (rotary ultrasonic bonding device 200) includes bonding modules, such as anvil module 202 and horn module 204, that cooperate to perform bonding operations for bonding elastic strands 120, 124, 128, and 132 between nonwoven fabrics 112 and 116, as described in more detail below.

[0015] In the illustrated embodiment, the horn module 204 includes a frame 206 (horn module frame 206) on which a disk-shaped rotary horn 208 is disposed, a motor 210 for driving the rotating horn 208 (disk-shaped rotary horn 208) via a suitable power transmission 212, and a housing 214 that contains at least a portion of a vibration control unit (not shown) that induces vibration in the horn 208. The horn 208 has a face 216 with a substantially continuous contour (i.e., the horn face 216 (face 216 of the disk-shaped rotary horn 208) has a substantially smooth (i.e., uninterrupted) contour across its entire surface area). In other embodiments, the horn face 216 may have any suitable contour that enables the horn 208 to function as described herein.

[0016] In one embodiment, the vibration control unit (not shown) includes at least one booster (e.g., a drive booster and an integral booster) mechanically connected to a converter. The converter can also be electrically connected to a generator. The converter can convert high-frequency power provided by the generator into mechanical energy (i.e., vibration) that is selectively transmitted through the booster to the horn 208. The booster functions to modify (i.e., increase or decrease) the vibration transmitted from the converter to the horn 208 so that the horn 208 (and in particular the face 216 of the horn 208) vibrates while the horn 208 is rotating during a mating operation, as described in more detail below. It is also contemplated that the horn module 204 can include any suitable operational components arranged in any suitable manner to enable the horn 208 to function as described herein.

[0017] In the illustrated embodiment, the anvil module 202 has a frame 218 (anvil module frame 218) on which a disk-shaped rotating anvil 220 and a motor 222 that drives the rotation of the anvil 220 (disk-shaped rotating anvil 220) are disposed. The anvil 220 has an annular face 226, the outer contour of which is discontinuous (i.e., interrupted), as described in more detail below. The anvil module 202 is positioned relative to the horn module 204 such that the anvil face 226 (annular face 226, face 226 of the disk-shaped rotating anvil 220) is rotatable adjacent to the horn face 216, or such that the horn face 216 is rotatable adjacent to the anvil face 226. This allows elastic strands 120, 124, 128, and 132 to be ultrasonically bonded between nonwoven fabrics 112 and 116 as they pass through apparatus 200 (rotary ultrasonic bonding apparatus 200) and are held under tension, as described in more detail below. As used herein, the term "close proximity" refers to anvil face 226 either contacting or slightly spaced from horn face 216 when horn 208 is not generating ultrasonic vibrations.

[0018] In one embodiment, the apparatus 200 may be configured such that at least one of the anvil module 202 and the horn module 204 can be displaced relative to the other via a suitable displacement mechanism operable either (A) when the elastic nonwoven material manufacturing system 100 is offline and the horn 208 is stopped (i.e., when the horn 208 is not rotating and vibrating), or (B) when the elastic nonwoven material manufacturing system 100 is online and the horn 208 is operating (i.e., when the horn 208 is rotating and vibrating).

[0019] 2 , the apparatus 200 can be configured as a continuous-nip apparatus in which the horn module 204 (A) remains fixed in position relative to the anvil module 202 when the elastic nonwoven manufacturing system 100 is online and the horn 208 is running, and (B) is displaceable relative to the anvil module 202 when the elastic nonwoven manufacturing system 100 is offline and the horn 208 is stationary. Such displacement is facilitated by a selectively actuable pneumatic cylinder 228 (or other suitable linear actuator) connecting the frame 206 and the frame 218 to each other. In this embodiment, the spacing between the horn face 216 and the anvil face 226 is adjustable, primarily for servicing the apparatus 200 when the system 100 is offline.

[0020] 3 and 4, the apparatus 200 can also be configured as an intermittent-nip apparatus, whereby when the system 100 is online and the horn 208 is operating, the horn module 204 is displaceable relative to the anvil module 202 via a rotating cam device 230. The rotating cam device 230 includes a follower 232 disposed on the horn module frame 206 and a cam wheel 234 disposed on the anvil module frame 218 and rotatable via a servo motor 236. The cam wheel 234 has an irregular cam surface 238 such that as the follower 232 rotates via the servo motor 236, the cam wheel 234 rides along the irregular cam surface 238, thereby cyclically displacing the horn module frame 206 relative to the anvil module frame 218 at a predetermined frequency. In this embodiment, the spacing between the horn face 216 and the anvil face 226 and / or the frequency with which the horn face 216 contacts the anvil face 226 can be selectively adjusted. Other displaceable arrangements of the horn module 204 and the anvil module 202 are also contemplated without departing from the scope of the present invention.

[0021] 5 and 6, the rotary ultrasonic coupling apparatus 200 may also include a pinching device 260. In the illustrated embodiment, the pinching device 260 includes a base 262 and a roller 264 that is floatingly positioned relative to the base 262 via at least one biasing element 266. The pinching device 260 also includes a bracket assembly 265 that is positioned on at least one of the horn module frame 206 and the anvil module frame 218. The base 262 and the roller 264 are adjustable with at least two degrees of freedom relative to the anvil 220 (as described in more detail below) to enable the pinching device 260 to be used with anvils 220 of different sizes.

[0022] The illustrated bracket assembly 265 includes a first bracket 267 and a second bracket 268. The first bracket 267 includes at least one linear slot 269 through which a bolt 271 (secured to either the frame 206 of the horn module 204 or the frame 218 of the anvil module 202) can extend and slide along the linear slot 269. The linear slot 269 therefore allows the first bracket 267 to translate relative to the frame 206 and / or the frame 218. The second bracket 268 includes at least one generally arcuate slot 272 through which a bolt 270 (secured to the first bracket 267) can extend and slide along the arcuate slot 272. Thus, the arcuate slot 272 allows the second bracket 268 to rotate relative to the first bracket 267. The base 262 is positioned on the second bracket 268 such that the base 262 (and, therefore, the roller 264) is rotationally adjustable with a first degree of freedom via the rotation of the second bracket 268, and translationally adjustable with a second degree of freedom via the translation of the first bracket 267.

[0023] The position of the base 262, and therefore the roller 264, can be fixed via bolts 270 and 271 to achieve a desired pinching contact between the roller 264 and the anvil face 226. For example, in the illustrated embodiment, the base 262 and roller 264 are oriented such that the biasing element 266 applies a biasing force generally perpendicular to the axis of rotation of the anvil 220 (see FIG. 6). In other embodiments, the pinching device 260 can be arranged in any suitable manner and assembled to perform the pinching operations described herein, and can have any suitable movable (e.g., translatable and / or rotatable) components (e.g., any suitable bracket assembly in which the base 262 and roller 264 are adjustable with at least two degrees of freedom, such as two degrees of translation, or one degree of translation and one degree of rotation).

[0024] In this embodiment, the pinching device 260 limits rebound of the elastic strands 120, 124, 128, and 132 that are broken (severed) between the horn 208 and the anvil 220 during the bonding operation. More specifically, the pinching device 260 has the effect of trapping the broken elastic strands 120, 124, 128, and 132 between the roller 264 and the anvil 220 to prevent them from rebounding back to their respective supply spools 118, 122, 126, and 130. Moreover, because the roller 264 rotates in contact with the anvil 220, any broken elastic strands 120, 124, 128, and 132 are trapped at the interface between the roller 264 and the anvil 220 and automatically returned to the interface between the horn 208 and the anvil 220. Thus, the pinching device 260 acts as a self-threading device for the broken elastic strands 120 , 124 , 128 , and 132 .

[0025] Notably, the apparatus 200 may have any suitable number of anvil modules 202 and / or horn modules 204 cooperating with one another to perform the functions described herein. For example, as shown in the embodiment of FIG. 7, the apparatus 200 may be configured with an anvil drum 274 on which a pair of anvils 220 are disposed. The anvil drum 274 has a pair of predefined annular faces 226 spaced apart from one another. In this embodiment, the horns 208 of the spaced apart horn modules 204 are dedicated to each of the anvil faces 226. This facilitates limited bonding operations on larger nonwoven fabrics where only a portion of the fabric requires elasticity (e.g., a segment of the larger nonwoven fabric that does not require elasticity can be moved along a non-contact region 277 of the anvil drum 274 to interact with the associated horns 208).

[0026] It is desirable to hold the elastic strands 120, 124, 128, and 132 in place within the notches in the anvil face 226 while the nonwoven fabrics 112 and 116 are being bonded together between the horn 208 and the anvil 220 so as to minimize the occurrence of the elastic strands 120, 124, 128, and 132 being severed between the horn 208 and the anvil 220 during the bonding operation. At least the following operational parameters contribute to minimizing the occurrence of elastic strands 120, 124, 128, and 132 breaking during the bonding operation: (A) the inherent energy source (e.g., the amplitude of vibration of horn 208 and its pressure when contacting anvil 220), (B) the energy director (e.g., the shape of anvil face 226), and (C) the material system (e.g., the decitex (thickness) and tension of elastic strands 120, 124, 128, and 132 and the basis weight of nonwovens 112 and 116).

[0027] With respect to one such parameter (i.e., the shape of the anvil face 226), FIG. 8 is a laid-flat illustration of one embodiment of the anvil face 226 of the present apparatus 200. In the illustrated embodiment, the anvil face 226 has a circumferential axis 276 extending in a circumferential direction and a width dimension 278 perpendicular to the circumferential axis 276. The contour of the anvil face 226 is irregular (i.e., discontinuous) along the circumferential axis 276 because the anvil face 226 defines a plurality of circumferentially spaced ridges 280. For example, in one embodiment, each adjacent pair of ridges 280 may have a spacing (i.e., pitch) along the circumferential axis 276 of about 0.10 inches to about 1.00 inches (e.g., about 0.20 inches to about 0.50 inches). Although in the illustrated embodiment, all adjacent pairs of ridges 280 are spaced approximately equally apart on the anvil face 226, it is contemplated that the spacing between adjacent pairs of ridges 280 may vary along the circumferential axis 276 in other embodiments.

[0028] In the illustrated embodiment, the ridges 280 extend substantially linearly across the circumferential axis 276 to span substantially the entire width of the anvil face 226. The ridges 280 have an extension axis 282 that is oblique to the circumferential axis 276. As shown in FIG. 9 , the ridges 280 have a plurality of lands 284 spaced apart along the extension axis 282. Each adjacent pair of lands 284 is spaced apart relative to (i.e., laterally of) a notch 286. While FIG. 8 shows the lands 284 and notches 286 on only select ridges 280, it should be understood that all of the ridges 280 on the anvil face 226 similarly have sets of lands 284 and notches 286 along their respective extension axes 282. In particular, each adjacent land 284 on the ridge 280 is formed such that the corresponding notch 286 defined therebetween is oriented generally parallel to the circumferential axis 276 (i.e., the ridge 280 and notch 286 have a length dimension 298 in the illustrated embodiment that is generally parallel to the circumferential axis 276).

[0029] In some embodiments, the anvil face 226 can be configured for a continuous entrapment bonding operation. More specifically, in such embodiments, the ridges 280 have at least one notch 286 that is aligned with a corresponding notch 286 on each ridge 280 in the width dimension 278. The lands 284 on either side of the aligned notch 286 are spaced apart from one another to form laterally adjacent bonds in the nonwoven fabrics 112 and 116. The laterally adjacent bonds are sufficiently close together in the width dimension 278 to permanently hold the bonded elastic strands 120, 124, 128, and 132 in tension. As a result, after the bonding operation is completed and the nonwovens 112 and 116 are removed from the system 100, at least one of the elastic strands 120, 124, 128, and 132 will thereafter contract between the rows of circumferentially adjacent bonds rather than between the laterally adjacent bonds through which the elastic strands 120, 124, 128, and 132 extend. Thus, the capture bonding operation is continuous in the sense that at least one of the elastic strands 120, 124, 128, and 132 will be permanently held in tension between each pair of laterally adjacent bonds through which it extends.

[0030] In one embodiment of the continuous capture configuration of the anvil face 226, the lands 284 and notches 286 of the ridges 280 have approximately the same dimensions (and therefore spacing) relative to each other as all other ridges 280 on the anvil face 226. The notches 286 are generally U-shaped or generally V-shaped. The sidewalls of the lands 284 flanking the notches 286 may form a wedge angle between them of about 1° to about 140° (e.g., about 60° to about 100°) when viewed from the cross-sectional shape of the notch 286 as shown in FIG. 9 . Other shapes of the notch 286 are also contemplated. For example, in some embodiments, the sidewalls may be formed at an angle of about 0° (i.e., the sidewalls may be generally parallel to each other).

[0031] In one particular embodiment, the elastic strands 120, 124, 128, and 132 have a dtex of about 300 to about 1240, and the nonwoven fabrics 112 and 116 have a dtex of about 8 to about 30 g / m 2 (gsm), the lands 284 may have a length at their peak of about 0.01 inch to about 0.25 inch (e.g., about 0.03 inch to about 0.06 inch) and a width at their peak of about 0.008 inch to about 0.05 inch (e.g., about 0.01 inch to about 0.03 inch). Also, in this example, the notches 286 have a depth of about 0.002 inches to about 0.04 inches (e.g., about 0.004 inches to about 0.02 inches) measured from the peak of the lands 284 flanking them, and a width of about 0.006 inches (e.g., about 0.152 mm) measured from the peak of the lands 284 flanking them. The periphery may have a width of from about 0.002 inches to about 0.02 inches (e.g., from about 0.004 inches to about 0.015 inches) measured from their base.

[0032] By providing the lands 284 and notches 286 with the exemplary dimensions described above, the anvil face 226 is able to better grip the elastic strands 120, 124, 128, and 132 in the notches 286, thereby preventing them from slipping out of the notches 286 and reducing the occurrence of severing the elastic strands 120, 124, 128, and 132. Other suitable dimensions for the lands 284 and notches 286 are also contemplated without departing from the scope of the present invention.

[0033] In another embodiment, the anvil face 226 is configured for an intermittent entrapment bonding operation, in which the lands 284 flanking at least one notch 286 are spaced apart to form laterally adjacent bonds in the nonwoven fabrics 112 and 116. The laterally adjacent bonds are spaced apart sufficiently in the width dimension 278 so as not to permanently hold the bonded elastic strands 120, 124, 128, and 132 under tension. As a result, after the bonding operation is completed and the nonwoven fabrics 112 and 116 are removed from the system 100, the corresponding elastic strands 120, 124, 128, and 132 will thereafter contract between the laterally adjacent bonds through which they extend such that the tension therebetween is generally released. Thus, this capture bonding operation is said to be intermittent in the sense that at least one of the elastic strands 120, 124, 128, and 132 does not permanently hold tension between every pair of laterally adjacent bonds through which it extends.

[0034] In one embodiment of the anvil face 226's intermittent capture configuration, the anvil face 226 may have multiple different circumferential regions 288 in which the dimensions of the notches 286 (and therefore the lands 284 located on either side thereof) of the ridge 280 in at least one circumferential region 288 are different compared to the dimensions of the notches 286 (and therefore the lands 284 located on either side thereof) arranged in the width direction of the ridge 280 in at least one other circumferential region 288.

[0035] For example, the ridges 280 in the first plurality of circumferential regions 290 and 296 may have at least one notch 286 that is sized differently than at least one notch 286 (of the ridges 280 in the first circumferential regions 290 and 296) that is aligned widthwise with the notch 286 (of the ridges 280 in the second circumferential regions 292 and 294) on the ridges 280 in the second plurality of circumferential regions 292 and 294 that are spaced apart from each other between the first circumferential regions 290 and 296. In this example, in the first circumferential regions 290 and 296, the notches 286 may be dimensioned to have a larger width so that the elastic strands 120, 124, 128, and 132 are not subsequently entrapped across (i.e., can slip between) the laterally adjacent bonds provided at the laterally adjacent lands 284 of the ridges 280 in the first circumferential regions 290 and 296. Meanwhile, in the second circumferential regions 292 and 294, the notches 286 may be dimensioned to have a smaller width so that the elastic strands 120, 124, 128, and 132 are subsequently entrapped across (i.e., cannot subsequently release between) the laterally adjacent bonds provided at the laterally adjacent lands 284 of the ridges 280 in the second circumferential regions 292 and 294.

[0036] More specifically, in this example, at least one ridge 280 in second circumferential regions 292 and 294 has a notch 286 dimensioned in the manner described above to illustrate continuous capture, while at least one ridge 280 in first circumferential regions 290 and 296 has a notch 286 dimensioned to have a width (as measured from the peak of the land 284 flanking the notch 286) of about 0.01 inches to about 0.25 inches (e.g., about 0.03 inches to about 0.06 inches in some embodiments, or about 0.035 inches in one particular embodiment). Accordingly, proper releasability of elastic strands 120, 124, 128, and 132 across at least one ridge 280 in first circumferential regions 290 and 296 is facilitated. In particular, the elastic strands 120, 124, 128, and 132 are about 300 to about 1240 decitex, and the nonwoven fabrics 112 and 116 are about 8 g / m 2 (gms) ~ approx. 30g / m 2 It becomes easier to make it properly releasable when you have (gms).

[0037] In both the continuous and intermittent acquisition configurations, the anvil face 226 can have a plurality of different widthwise segments 281. Each of the widthwise segments 281 has a land 284 and / or notch 286 of a comparatively different size. For example, in one particular embodiment shown in FIG. 11 , the anvil face 226 can have a first widthwise segment 283 having a land 284 defining a notch 286 of a first width to accommodate the elastic strands 120, 124, 128, and 132 of a first decitex, and a second widthwise segment 285 having a land 284 defining a notch 286 of a second width narrower than the first width to accommodate the elastic strands 120, 124, 128, and 132 of a second decitex less than the first decitex. Thus, the widthwise segments 281, whether configured for continuous or intermittent capture, can be sized to accommodate different sized elastic strands 120, 124, 128, and 132.

[0038] In still other embodiments, the anvil face 226 can have ridges 280 that extend non-linearly across the circumferential axis 276. For example, in one particular embodiment shown in FIGS. 12-14 , the anvil face 226 defines a plurality of ridges 280 having a curvilinear axis (e.g., a generally arcuate curvilinear axis 287). Notably, these embodiments having non-linear ridges 280 can have similar dimensions to the lands 284 and notches 286 associated with the generally linear ridges 280 described above, including similar dimensional variations common to the circumferential regions 288 and widthwise regions 281 (widthwise segments 281) described above for the generally linear ridges 280.

[0039] 15 illustrates an elastic nonwoven material 300 produced using the present system 100 (a system for producing elastic nonwoven materials). In the illustrated embodiment, an intermittent capture bonding process is performed on the nonwoven fabrics 112 and 116 (and the elastic strands 120 and 124 sandwiched therebetween) using one embodiment of the present apparatus 200 (the rotary ultrasonic bonding apparatus 200) described above. One embodiment of the anvil 220 used to produce the elastic nonwoven material 300 has an anvil face 226 with notches 286 that vary in size across a circumferential region 288 as described in certain embodiments above. In this aspect, the nonwoven fabrics 112 and 116 and the elastic strands 120 and 124 are passed through the present apparatus 200 and held in tension while the horn face 216 and the anvil face 226 create bonds 302 where the lands 284 of the anvil face 226 coincide with the horn face 216 and the anvil face 226.

[0040] When the bonded nonwovens 112 and 116 (and the elastic strands 120 and 124 sandwiched therebetween) are then removed from the system 100, the tension in the elastic strands 120 and 124 is partially released, allowing the segments of the elastic strands 120 and 124 to contract, resulting in the creation of the elastic nonwoven material 300. More specifically, a first segment 304 of the elastic strands 120 and 124 becomes entrapped between adjacent rows of bonds 302 corresponding to the narrower ridges 280 having the notches 286 defined therein, while a second segment 306 of the elastic strands 120 and 124 is allowed to slip across the laterally adjacent bonds 302 in the row corresponding to the wider ridges 280 having the notches 286 defined therein. In this embodiment, nonwovens 112 and 116 gather areas 308 of elastic nonwoven material 300 having closely spaced laterally adjacent bonds 302 (but not areas 310 having widely spaced laterally adjacent bonds 302) to effectively provide elastic material 300 (elastic nonwoven material 300). Notably, if a continuous acquisition operation were used instead of an intermittent acquisition operation, elastic nonwoven material 300 would not have releasable second segment 306, but instead would have only first segment 304 such that nonwovens 112 and 116 gather throughout elastic nonwoven material 300.

[0041] 16-24 are exploded views of a portion of the anvil face 226 of an embodiment of the anvil 220 for use in the rotary ultrasonic coupling device 200 shown in FIGS. 2-7. The anvil face 226 shown in FIGS. 16-24 includes ridges 280 arranged in a pattern that provides continuous running contact between the anvil 220 and the horn 208 during operation of the device 200. As used herein, the term "continuous running contact" means that the anvil face 226 is configured to receive a generally continuous force from the horn 208 throughout operation of the device 200. In an exemplary embodiment, the continuous running contact ensures that the anvil 220 and the horn 208 receive a generally uniform force throughout operation. This reduces the energy required to operate the device 200. Additionally, the provision of the horn 208 and anvil 220 reduces (energy consumption required for operation) compared to known systems, as well as reducing vibrations and / or noise associated with operation of the device 200.

[0042] The annular face 226 embodiment allows for increased spacing between elastic strand bond points in the elastic nonwoven material, allowing for more independent movement of each of the elastic strands 120, 124, 128, and 132 associated with the elastic nonwoven. Thus, the elastic strands 120, 124, 128, and 132 have increased elastic properties and can function similarly to unbonded elastic strands. For example, the annular face 226 may allow elastic strand bond points to be spaced apart from one another by up to about 150 mm, i.e., between about 100 mm and about 150 mm. In alternative embodiments, the elastic strands 120, 124, 128, and 132 can have any elastic strand bond points that allow them to function as described herein. In some embodiments, nonwoven bond points may be used between the elastic strand bond points to guide the elastic strands 120, 124, 128, and 132 without bonding them together. Additionally, bond points between nonwovens can be used to provide continuous running contact.

[0043] FIG. 16 is an exploded view of one embodiment of an anvil face 226 having ridges 280 and gaps 279. In the illustrated embodiment, the ridges 280 extend generally linearly across the circumferential axis 276 and span a portion of the width dimension 278 of the anvil face 226. Furthermore, the ridges 280 are discontinuous such that gaps 279 are defined between adjacent ridges 280. The gaps 279 extend generally linearly across the circumferential axis 276 between adjacent ridges 280 and span a portion of the width dimension 278 of the anvil face 226. Thus, the gaps 279 reduce the surface area of the anvil face 226 that receives force from the horn 208 (see FIGS. 2-7). As a result, the force required to form bonds in the nonwoven fabric during operation of the apparatus 200 is reduced. Additionally, the elastic strands 120 , 124 , 128 , and 132 (see FIG. 1) are able to move more independently relative to one another than if they were uniformly bonded in the width dimension 278 .

[0044] The ridges 280 have extension axes 282 that are oblique to the circumferential axis 276. Furthermore, the ridges 280 are positioned such that the ridges 280 overlap with adjacent ridges 280 along the circumferential axis 276. As a result, the ridges 280 are configured to provide continuous running contact between the horn 208 and the anvil 220 (see FIGS. 2-7) during operation of the device 200 (see FIGS. 2-7). Additionally, the oblique extension axes 282 allow for increased spacing between the ridges 280. Furthermore, because the ridges 280 provide continuous running contact without requiring additional contact points, the portion of the anvil 220 that receives force from the horn 208 may be reduced.

[0045] Further, in the illustrated embodiment, the ridges 280 are aligned along the extension axis 282, with an alternating pattern of ridges 280 and gaps 279 extending along the extension axis 282. In alternative embodiments, the ridges 280 are arranged in any pattern that enables the anvil face 226 to function as described herein. For example, in some embodiments, at least some adjacent ridges 280 may be disposed at a predetermined angle relative to one another.

[0046] In some embodiments, ridges 280 may extend along their respective extension axes 282 a distance ranging from about 1.5 mm to about 10 mm. Gaps 279 may extend along their respective extension axes 282 a distance ranging from about 0.5 mm to about 20 mm. In alternative embodiments, ridges 280 and gaps 279 may extend any distance that enables anvil face 226 to perform the functions described herein.

[0047] FIG. 17 is an exploded view of another embodiment of the anvil face 226 of the apparatus 200 (shown in FIGS. 1-7). The anvil face 226 has a first ridge 311 in a first region 312 and a second ridge 313 in a second region 314. In the first region 312, the first ridge 311 extends along an extension axis 316 (first oblique axis). The extension axis 316 is obliquely oriented relative to the circumferential axis 276 such that the extension axis 316 and the circumferential axis 276 define an angle 318. In the second region 314, the ridge 313 extends along an extension axis 320 (second oblique axis). The extension axis 320 is obliquely oriented relative to the circumferential axis 276 such that the extension axis 316 and the circumferential axis 276 define an angle 322. The extension axis 320 is oblique to the extension axis 316. Furthermore, the ridges 311 in the first region 312 are offset from the ridges 313 in the second region 314. As a result, the spacing between the first ridges 311 and the second ridges 313 can be increased, and the first ridges 311 and the second ridges 313 can be configured to be in continuous running contact.

[0048] FIG. 18 is an exploded view of yet another embodiment of the anvil face 226 of the apparatus 200 (shown in FIGS. 1-7 ). The anvil face 226 has first ridges 311 and second ridges 313. In the illustrated embodiment, the first ridges 311 have extension axes 316 that are oblique to the circumferential axis 276 and the width dimension 278. Each first ridge 311 is spaced apart from adjacent first ridges 311 in the width dimension 278 and from adjacent first ridges 311 along the circumferential axis 276. The second ridges 313 have extension axes 320 that are oblique to the circumferential axis 276 and the width dimension 278. Each second ridge 313 is spaced apart from adjacent second ridges 313 in the width dimension 278 and from adjacent second ridges 313 along the circumferential axis 276. Additionally, the first extension axis 316 is oblique to the second extension axis 320. In alternative embodiments, the anvil face 226 can have any first ridge 311 and second ridge 313 that enables it to function as described herein.

[0049] The first ridges 311 and the second ridges 313 are interspersed across the entire anvil face 226. For example, the second ridges 313 extend through the gaps 279 defined between the first ridges 311. The first ridges 311 also extend through the gaps 279 defined between the second ridges 313. Thus, the first ridges 311 overlap with adjacent second ridges 313 along the circumferential axis 276 and the width dimension 278. The second ridges 313 overlap with adjacent first ridges 311 along the circumferential axis 276 and the width dimension 278.

[0050] The first ridges 311 and second ridges 313 define a pattern on the anvil face 226. In some embodiments, the pattern of the first ridges 311 and second ridges 313 is configured to provide desired properties of the elastic nonwoven material. For example, the pattern of overlapping first ridges 311 and second ridges 313 can be configured to form ruffling having desired properties (e.g., size, spacing, tension, etc.). As a result, the ruffling can provide (1) aesthetic qualities (e.g., appearance, softness) and / or (2) functional properties (e.g., for use in waistbands, panels, leg cuffs, etc.) in one or more sections of the elastic nonwoven material. In alternative embodiments, the first ridges 311 and second ridges 313 can be arranged in any pattern that enables the anvil face 226 to function as described herein.

[0051] Additionally, in some embodiments, the first ridges 311 and / or second ridges 313 can have at least one of a circular, polygonal, rectangular, sinusoidal, and oval shape. In further embodiments, the first ridges 311 and / or second ridges 313 can be configured to define graphics and / or alphanumeric characters (characters) in the elastic nonwoven material. In such embodiments, some of the first ridges 311 and / or second ridges 313 can have substantially continuous faces to create a desired appearance in the elastic nonwoven material.

[0052] FIG. 19 is an exploded view of another embodiment of the anvil face 226 of the present apparatus 200 (shown in FIGS. 1-7) including ridges 280 arranged in multiple patterns. As shown in FIG. 19, the anvil face 226 has a first region 402, a second region 404, and a third region 406. In the first region 402 and the third region 406, the ridges 280 are arranged in a first pattern. In the first pattern, the ridges 280 have extension axes 282 that are oblique to the circumferential axis 276 and the width dimension 278. In the second region 404, the ridges 280 are arranged in a second pattern. In the second pattern, the ridges 280 have extension axes 316 and 320 that are oblique to the circumferential axis 276 and the width dimension 278. The extension axis 316 is oblique to the extension axis 320. Additionally, in second region 404, ridges 280 define gaps 279 between them, and adjacent ridges 280 are interspersed such that they overlap along circumferential axis 276 and in width dimension 278. Thus, the first and second patterns increase the portion of anvil face 226 that is utilized during operation of apparatus 200.

[0053] FIG. 20 is an exploded view of another embodiment of the anvil face 226 of the present apparatus 200 (shown in FIGS. 1-7 ) having a symmetrical pattern of ridges 280. The anvil face 226 has a first region 410 having ridges 280 and a second region 412 having ridges 280. In the first region 410, the ridges 280 have elongation axes 282 that are oblique to the circumferential axis 276 and width dimension 278. In the second region 412, the ridges 280 have elongation axes 282 that are oblique to the circumferential axis 276 and width dimension 278. An axis of symmetry 408 extends between the first region 410 and the second region 412. The ridges 280 in the first region 410 are symmetrical to the ridges 280 in the second region 412 about the axis of symmetry 408. Additionally, the anvil face 226 has multiple axes of symmetry 408 such that the ridges 280 form a repeating symmetrical pattern. In the illustrated embodiment, the axes of symmetry 408 are oblique to the circumferential axis 276. In alternative embodiments, the anvil face 226 can have any axis of symmetry 408 that enables it to function as described herein.

[0054] 21 is an exploded view of another embodiment of an anvil face 226 having first and second ridges 414 and 416 that are generally perpendicular to each other. The anvil face 226 includes the first and second ridges 414 and 416. The first ridges 414 have an elongation axis 413 that is oblique to the circumferential axis 276 and width dimension 278. The second ridges 416 have an elongation axis 415 that is oblique to the circumferential axis 276 and width dimension 278. The elongation axis 413 of the first ridges 414 is perpendicular to the elongation axis 415 of the second ridges 416. Thus, the first and second ridges 414 and 416 form a pattern that (1) provides continuous running contact, (2) reduces the contact area between the horn 208 and the anvil 220, and (3) distributes loads across the anvil 220.

[0055] FIG. 22 is an exploded view of another embodiment of the anvil face 226 of the present apparatus 200, including first ridges 417 and second ridges 418. The first ridges 417 include a plurality of lands 419 and a plurality of notches 421. The second ridges 418 have a generally continuous contour and provide bond points between the nonwoven fabrics. The first ridges 417 and second ridges 418 are intermixed throughout the anvil face 226. Specifically, each first ridge 417 extends between adjacent second ridges 418, and each second ridge 418 extends between adjacent first ridges 417. The second ridges 418 can increase the spacing between the first ridges 417, providing increased bonding and / or continuous running contact of the elastic nonwoven material.

[0056] The first ridges 417 and the second ridges 418 may have any suitable shape. For example, the first ridges 417 and the second ridges 418 may have orthogonal lines, dots, ellipses, polygons, broken lines, letters, and / or any other suitable shape. In the illustrated embodiment, the first ridges 417 and the second ridges 418 are rectangular.

[0057] Additionally, first ridges 417 extend obliquely relative to circumferential axis 276 and width dimension 278. Second ridges 418 extend parallel to circumferential axis 276. Thus, first ridges 417 are oblique relative to second ridges 418. In alternative embodiments, first ridges 417 and second ridges 418 may extend in any direction that enables device 200 to operate as described herein. For example, in some embodiments, at least some of second ridges 418 may extend obliquely relative to circumferential axis 276 and / or width dimension 278.

[0058] FIG. 23 is an exploded view of another embodiment of the anvil face 226 of the present apparatus 200. The elastic strands 420 extend across the width dimension 278 of the anvil face 226 along a curve 422 that is curved along the circumferential axis 276. The elastic strands 420 may be guided along the curve 422 by the supply station 102 (shown in FIG. 1). For example, with reference to FIGS. 1, 2, and 23, the supply station 102 may be configured to reciprocate (swing) the elastic strands 420 so that the elastic strands 420 are received by the ridges 280 on the anvil face 226 as the anvil 220 rotates. Following this reciprocating motion, the elastic strands 420 may be received at various positions on the ridges 280 so that they are guided along the curve 422. In alternative embodiments, the elastic strands 420 may be guided in any manner that enables the elastic nonwoven material to function as described herein.

[0059] 24 is an exploded view of another embodiment of the anvil face 226 of the present apparatus 200. The anvil face 226 has ridges 280 extending across a portion of its width dimension 278. The arrangement of the ridges 280 corresponds to a curve 424 that curves along the circumferential axis 276. The ridges 280 are configured to guide the elastic strands 420 along the curve 424 across the width of the anvil face 226 as the anvil 220 rotates (as shown in FIG. 2). In alternative embodiments, the elastic strands 420 can be guided in any manner that enables the elastic nonwoven material to function as described herein.

[0060] In some embodiments, the elastic strand 420 may be guided, at least in part, by the feeding station 102 (shown in FIG. 1). For example, the ridge 280 is configured to receive the elastic strand 420 and guide the elastic strand 420 along a curve 424 that corresponds to the reciprocating motion. In other embodiments, the feeding station 102 may feed the elastic strand 420 from a stationary position and guide the elastic strand 420 along the curve 424 by any suitable means.

[0061] The elastic strands 420 can be guided along the curve 424 during a continuous acquisition process and / or an intermittent acquisition process. Additionally, the elastic strands 420 can be guided along the curve 424 in a portion of the elastic nonwoven material, and not necessarily throughout the entire elastic nonwoven material.

[0062] 25 is a schematic diagram of an elastic nonwoven material 500 produced using the present system 100 and intermittent elastic acquisition process. The elastic nonwoven material 500 includes at least one elastic strand 504 and a nonwoven fabric 506. The elastic nonwoven material 500 further includes a first region 508, a second region 510, and a third region 512. The elastic strand 504 is held in the nonwoven fabric 506 in at least the first region 508 and the third region 512. For example, the elastic strand 504 can be acquired within the nonwoven fabric 506 using the present systems and methods described herein.

[0063] In the illustrated embodiment, the elastic strands 504 may be severed or cut (separated) by a cutting device 514 between the first region 508 and the second region 510, and between the second region 510 and the third region 512. As a result, the elastic strands 504 remain at least somewhat free in the second region 510. In some embodiments, the elastic strands 504 may be cut along lines that are generally perpendicular to the longitudinal direction of the elastic nonwoven material 500. In other embodiments, the elastic strands 504 may be cut along lines that extend at least somewhat obliquely and / or parallel to the longitudinal direction. In further embodiments, the elastic strands 504 may be cut along a curved line. In alternative embodiments, the elastic strands 504 may be severed in any manner that enables the elastic nonwoven material 500 to perform the functions described herein.

[0064] The elastic nonwoven material 500 may have different elastic properties and appearances in the first region 508, the second region 510, and the third region 512. For example, in the first region 508 and the third region 512, the elastic strands 504 may be under tension and gather the nonwoven 506. In the second region 510, the elastic strands 504 are loose and the nonwoven 506 is not gathered by the elastic strands 504.

[0065] The nonwoven fabric 506 has at least one bond 516 in the second region 510 configured to hold the elastic strands 504 to the nonwoven fabric 506 when the elastic strands 504 are severed by the cutting device 514. Specifically, the nonwoven fabric 506 is bonded between the first cut region 518 and the second cut region 520 such that the free ends 522 of the elastic strands 504 extend on either side of the bond 516. Furthermore, the bond 516 prevents the free elastic strands 504 (the elastic strands 504) from breaking apart into pieces that could damage or clutter the elastic nonwoven material 500 and the device 200 (shown in FIG. 1 ). As a result, the bond 516 reduces the cost of manufacturing the elastic nonwoven material 500.

[0066] The rotary ultrasonic bonding system and method described herein are utilized to directly capture tensioned elastic materials onto nonwoven fabrics without the use of adhesives, thereby providing various functional and commercial advantages. The system and method eliminate the complex adhesive delivery systems and costly adhesive materials associated with adhesive bonding processes. The system and method also provide a simpler, cleaner, and safer (e.g., cooler) manufacturing environment with lower power consumption and material costs. Additionally, various functional defects of adhesively bonded materials, such as adhesive bleed-through, overspray, curing, and creep, common in conventional adhesively bonded materials, are eliminated. Therefore, lower-cost nonwoven / film substrates and elastic materials can be utilized.

[0067] Additionally, the systems and methods described herein facilitate a more continuous production sequence (i.e., increased process uptime) by eliminating at least some of the following: adhesive-related cleaning operations, adhesive system deliverability / reliability issues, time to cool heated equipment prior to a maintenance event, cool-down start times, and reheat or purge-calibrate events. Moreover, a more continuous production sequence is further facilitated by automatic threading (i.e., self-threading) of severable elastic strands while the system is online, and by using continuously running over-the-end elastic spools.

[0068] Additionally, the systems and methods described herein can be used to bond (e.g., capture) elastic strands while simultaneously performing other elastic processing steps such as cutting / slitting processes, seaming processes, edge trimming processes, etc. The systems and methods can also be applied to existing capital asset bases, thereby providing retrofit capability (with customizable configurations as needed) and the ability to change grades more quickly when changing the length of the bond zone using a software interface.

[0069] The present systems and methods can also maximize elastic performance. For example, the present systems and methods can reduce tension when stretched compared to other bonding methods (e.g., the present systems and methods can provide a nearly purely elastic response to tension and stress when at least some substrates are in use). The present systems and methods can also minimize creep (i.e., performance degradation) due, at least in part, to the fact that the elastic strands can be captured in a thermoplastic substrate, as opposed to being bonded to a substrate with a susceptible intermediate binder material (e.g., the present systems and methods produce a more robust elastic material regardless of temperature, time, and end-user solvents (e.g., softeners)).

[0070] The present system and method also allow for customization of aesthetic and functional benefits. For example, gathers can be created based on bond patterns and / or strand feed rates arranged to allow selectable size, shape, and frequency. Also, tension can be controlled by the elastic segments based on the desired fabric configuration (e.g., based on the desired widthwise direction (between lanes) and / or the desired lengthwise direction (within lanes) within the fabric), allowing for segmented tensioning. Bonds can also be curved as needed. Furthermore, controlled release / creep of elastic strands for an adjustable fit is facilitated by using intermittent or continuous bonding of elastic material to selectable substrates, thereby allowing for placement / compartmentalization of existing elastic and inelastic segments. The present system and method also allows for more precise adjacent placement of elastic strands compared to conventional systems. For example, the present system does not include an adhesive dispenser that can limit the placement of elastic strands relative to one another. As a result, the described system and method offers a greater range of elastic strand placement compared to known systems.

[0071] The present systems and methods also allow for the placement of bond points between nonwoven fabrics and between elastic strands at various locations in the machine direction (circumferential direction) and cross-machine direction (cross-machine direction). As a result, the present systems and methods provide the ability to control nonwoven fabric folding in both directions in response to forces from the elastic strands. Furthermore, the present systems and methods increase control over the functional and aesthetic properties of elastic nonwoven fabrics. Embodiments also provide the ability to impart functional and aesthetic graphic and / or textual characteristics to elastic nonwoven materials. Furthermore, the described systems and methods may provide the ability to control wearability of bonded modules by reducing zones of uneven engagement.

[0072] In addition to the system and method embodiments described above, other embodiments are also contemplated. For example, non-rotational bonding systems (e.g., stationary (i.e., blade-type) ultrasonic horns, heat, pressure, etc.) are contemplated. Also, in alternative embodiments, the above-described rotational embodiments can be combined with adhesive systems. Furthermore, latent elastics can be used in place of the tensioned elastics of some embodiments. Furthermore, the system and method can bend (i.e., displace) the elastic strands with reduced breakage. Furthermore, the system and method can also create matrix tensions (e.g., checkerboard effects), different wave patterns, dead zones, and / or simultaneous entrapment of elastic strands of different decitexes.

[0073] In particular, the systems and methods described herein enable the production of a variety of elastic nonwoven materials that can be used in a variety of products, such as personal care items (adult briefs, infant diapers, child / adult pull-on pants, form-fitting sanitary napkins, etc.) or medical garments (masks, caps, gowns, footwear, etc.). Additionally, individual components of products (e.g., scrims / nets, diaper ears, discrete panels, etc.) can be manufactured using the elastic nonwoven materials made by the above systems and methods. Other possible products that can use the nonwoven materials of the present invention include insulation or filters (e.g., associated with wavy or blousing patterns), as well as elastic-topped garbage bags, non-adhesive wrappers, hair nets, house wraps, etc.

[0074] When introducing elements of the invention or preferred embodiments thereof, the words "a / an," "the," and "said" are intended to mean the presence of one or more elements. The terms "comprising / including / having" are inclusive and mean that there may be additional elements other than the listed elements.

[0075] It is intended that all matter contained in the above description or illustrated in the accompanying drawings should be interpreted as illustrative and not in a limiting sense, as various changes may be made to the above construction without departing from the scope of the present invention.

Claims

1. 1. A method for making an elastic nonwoven material comprising a nonwoven fabric and at least one elastic strand, comprising: placing a first coupling module adjacent to a second coupling module; disposing the nonwoven fabric between the first bonding module and the second bonding module; disposing the at least one elastic strand between the first and second coupling modules; ultrasonically bonding the nonwoven fabric at a bond point using the first bonding module and the second bonding module to hold the at least one elastic strand to the nonwoven fabric; cutting the at least one elastic strand to form a first cut; and cutting the at least one elastic strand to form a second cut; the elastic nonwoven material includes a first region, a second region adjacent to the first region in a longitudinal direction of the elastic nonwoven material, and a third region adjacent to the second region on the opposite side of the longitudinal direction of the elastic nonwoven material from the first region, In the longitudinal direction of the elastic nonwoven material, the length of the second region is shorter than the length of the first region and the length of the third region; the first region, the second region, and the third region each include the bonding point; the at least one elastic strand in the second region is separated from the at least one elastic strand in the first region by the first cutting portion and separated from the at least one elastic strand in the third region by the second cutting portion; The bond point in the second region is located between the first cut portion and the second cut portion such that the at least one elastic strand has free ends extending on either side of the bond point.

2. The method of claim 1 , wherein at least one of the first coupling module and the second coupling module includes a face having a plurality of ridges defining alternating lands and notches.

3. The method of claim 1 , further comprising directing the at least one elastic strand across a width dimension of the second link module along a curve that curves along a circumferential axis.

4. 4. The method of claim 3, wherein directing the elastic strand along the curve comprises feeding the elastic strand from a feeding station in a swaying manner along the width dimension of the face of the second coupling module.

5. The method of claim 4 , wherein directing the elastic strands along the curve includes directing the elastic strands between notches defined in ridges of the face.

6. Each of the protrusions has a plurality of alternating lands and a plurality of the notches, The method of claim 5 , wherein each of the lands and each of the notches are oriented parallel to the circumferential axis and obliquely relative to the direction of extension of at least one of the ridges.

7. 10. The method of claim 1, wherein cutting the at least one elastic strand to form the first cut comprises cutting the at least one elastic strand along a line perpendicular to the longitudinal direction of the elastic nonwoven material.

8. 10. The method of claim 1, wherein cutting the at least one elastic strand to form the first cut comprises cutting the at least one elastic strand along a line oblique to the longitudinal direction of the elastic nonwoven material.

9. 10. The method of claim 1, wherein cutting the at least one elastic strand to form the first cut comprises cutting the at least one elastic strand along a line parallel to the longitudinal direction of the elastic nonwoven material.

10. The method of claim 1 , wherein cutting the at least one elastic strand to form the first cut comprises cutting the at least one elastic strand along a curve.

11. 10. The method of claim 1, wherein cutting the at least one elastic strand to form the first cut comprises cutting the at least one elastic strand with a cutting device.

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