Elastic composite structure for absorbent sanitary product and apparatus and method for making said elastic composite structure

Abstract

To provide a machine and method for manufacturing an elastic composite structure for disposable sanitary products.SOLUTION: A machine and method for manufacturing an elastic composite structure for disposable sanitary products involves manufacturing the elastic composite structure with an elasticized leg and leg cuff region in a manner that minimizes or eliminates the use of consumable adhesives. The elastic composite structure includes pairs of leg bonds and cuff bonds that are formed without adhesive and anchor respective leg and cuff elastic threads in position relative to facing web layers. The leg bonds and cuff bonds are formed using one or more anvils that include discrete raised projections.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 977,438, filed February 17, 2020, and U.S. Provisional Patent Application No. 62 / 977,453, filed February 17, 2020, the disclosures of which are incorporated herein in their entireties.

[0002] Embodiments of the present invention relate generally to absorbent sanitary products, and more particularly to improved apparatus and methods for manufacturing elastic composite structures for use in absorbent sanitary products, including forming elastic leg regions and / or leg cuff regions that minimize or eliminate the use of consumable adhesives such as glue. [Background technology]

[0003] Absorbent hygienic products, such as disposable diapers or light incontinence products, typically include elastic composite structures that include one or more elastic yarns. These elastic composite structures are located in various locations throughout the product, including the waistband, leg cuff regions, and all or part of the front or back panels of the product. Figures 1A-1D show a method for forming the leg region of a hygienic product having leg cuff regions 2 and leg elastic regions 4, according to one embodiment of the known technology.

[0004] Figure 1A shows multiple cuff elastics 6 attached to a cuff web 8 via adhesive 10. In Figure 1B, the cuff web 8 is attached to the topsheet 12 via adhesive 10 at a distal end 14 of the cuff web 8, providing the leg cuff region 2 with freedom of movement independent of the topsheet 12. As shown by the dashed lines, in one embodiment, the cuff web 8 can wrap around the cuff elastics 6 to encapsulate the cuff elastics 6 within the cuff web 8 and protect the elastics 6 and adhesive 10 from external exposure.

[0005] As shown in Figure 1C, a plurality of leg elastics 16 are adhesively attached to the distal end 18 of the backsheet 20. The leg cuff / topsheet assembly of Figure 1B is adhesively attached to the leg elastic / backsheet assembly of Figure 1C, as shown in Figure 1D. An absorbent core 22 may be positioned between the sheets 12, 20 before the topsheet 12 and backsheet 20 are secured together, so that the absorbent core 22 is located within the space between the sheets 12, 20.

[0006] 1A-1D, the cuff elastics 6 are attached in a separate step from the attachment of the leg elastics 16. In some cases, these elastic attachment steps may be significantly spaced upstream / downstream from each other during the manufacturing process.

[0007] Additionally, in typical products, the elastic regions formed by the cuff elastics 6 and the plurality of leg elastics 16 do not extend in the machine direction to the edges of the waist of each product. That is, the elastic regions along the machine direction formed by the leg elastics and cuff elastics may not extend to the edges of the waist web portion of the product. Instead, a portion of the waist web may remain ungathered in the machine direction, with the elastic regions extending sufficiently to wrap around the legs of the end user of the product. In this case, it may be desirable to leave a region of the waist free of elastic while maintaining the connection between the topsheet and backsheet.

[0008] The use of adhesives to attach elastic introduces several disadvantages to both the final product and the manufacturing process, including the cost associated with consumable materials, the spacing of the elastic attachment step, and undesirable tactile characteristics (e.g., stiffness) of the final product caused by the adhesive. Accordingly, there is a need for improved apparatus and methods for manufacturing elastic leg regions of products. Summary of the Invention

[0009] SUMMARY OF THE INVENTION Embodiments of the present invention relate to a method of attaching elastic strands to leg webs and / or cuff webs that minimizes or eliminates the use of adhesives, a machine for carrying out the method, and the resulting product.

[0010] According to one aspect of the present invention, an elastic composite structure includes a first web including leg elastics, leg cuffs, cuff elastics, and cuff cuffs. Leg elastic yarns are disposed between the leg elastics and the leg cuffs. A plurality of leg joins form respective joins between the leg elastics and the leg cuffs, securing the leg elastic yarns therebetween. A cuff elastic yarn is disposed between the cuff elastics and the cuff cuffs. A plurality of cuff joins form respective joins between the cuff elastics and the cuff cuffs, securing the cuff elastic yarns therebetween. The plurality of leg joins and the plurality of cuff joins are formed without the use of adhesive.

[0011] According to another aspect of the present invention, a method for manufacturing an elastic composite structure includes disposing leg elastic yarns between leg elastics of a first web and leg folds of the first web, forming a plurality of leg joins that adhesively join the leg elastics to the leg folds, disposing cuff elastic yarns between cuff elastics of the first web and cuff folds of the first web, and forming a plurality of cuff joins that adhesively join the cuff elastics to the cuff folds.

[0012] According to another aspect of the present invention, an apparatus for forming an elastic composite structure includes a plurality of rollers configured to guide a composite web assembly in a machine direction, the composite web assembly including a first web layer including leg elastics, leg folds, cuff elastics, and cuff folds, at least one leg elastic disposed between the leg elastics and the leg folds, and at least one cuff elastic disposed between the cuff elastic and the cuff folds. A joining device having a horn and an anvil is configured to adhesively join the leg elastics to the leg folds via a plurality of leg joins and adhesively join the cuff elastics to the cuff folds via a plurality of cuff joins.

[0013] According to another aspect of the present invention, an elastic composite structure includes a first web having leg elastics, cuff elastics, and cuff folds. A cuff elastic yarn is disposed between the cuff elastics and the cuff folds. A plurality of cuff joints join the cuff elastics and the cuff folds and secure the cuff elastic yarn therebetween. A second web includes leg elastic regions, leg elastic yarns disposed between the leg elastics of the first web and the leg elastics of the second web, and a plurality of leg joints joining the leg elastics of the first web and the leg elastics of the second web and secure the leg elastic yarn therebetween. The plurality of leg joints and the plurality of cuff joints are formed without the use of adhesive.

[0014] According to another aspect of the present invention, a method for manufacturing an elastic composite structure includes: disposing a cuff elastic yarn between a cuff elastic of a first web and a cuff fold of the first web; forming a plurality of cuff joins that adhesively join the cuff elastic to the cuff fold; disposing a leg elastic yarn between a leg elastic of the first web and a leg elastic of a second web; and forming a plurality of leg joins that adhesively join the leg elastic of the first web and the leg elastic of the second web.

[0015] According to another aspect of the present invention, an apparatus for forming an elastic composite structure includes a first plurality of rollers configured to guide a first portion of a composite web assembly in a machine direction, the first portion of the composite web assembly including a first web layer including a cuff elastic, a cuff fold, and a plurality of cuff elastics disposed between the cuff elastic and the cuff fold. A first joining device having at least one horn and an anvil is configured to adhesively join the cuff fold to the cuff elastic via a plurality of cuff joins that constrain the plurality of cuff elastics to the first web layer. A second plurality of rollers is configured to guide a second portion of the composite web assembly in the machine direction, the second portion of the composite web assembly including a first web layer including leg elastics, a second web layer including leg elastics, and a plurality of leg elastics disposed between the leg elastics of the first web layer and the leg elastics of the second web layer. A second joining device having at least one horn and anvil is configured to join the leg elastic portions of the first web layer and the leg elastic portions of the second web layer via a plurality of leg joints that restrain the plurality of leg elastics to the first web layer and the second web layer without using adhesive.

[0016] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention, which is provided in connection with the accompanying drawings. [Brief explanation of the drawings]

[0017] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0018] In the drawings:

[0019] [Figure 1A] 1 shows a method for forming the leg region of a hygiene product according to one embodiment of the known art; [Figure 1B] 1 shows a method for forming the leg region of a hygiene product according to one embodiment of the known art; [Figure 1C]1 shows a method for forming the leg region of a hygiene product according to one embodiment of the known art; [Figure 1D] 1 shows a method for forming the leg region of a hygiene product according to one embodiment of the known art;

[0020] [Figure 2] 1 is a plan view of a hygiene product according to an embodiment of the present invention; FIG.

[0021] [Figure 3] 1 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to one embodiment of the present invention.

[0022] [Figure 4] FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3.

[0023] [Figure 5] FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 3.

[0024] [Figure 6] FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 3.

[0025] [Figure 7] FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. 3.

[0026] [Figure 8] FIG. 10 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to another embodiment of the present invention.

[0027] [Figure 9] FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 8.

[0028] [Figure 10] FIG. 10 is a cross-sectional view taken along line 10-10 in FIG. 8.

[0029] [Figure 11]FIG. 11 is a cross-sectional view taken along line 11-11 in FIG. 8.

[0030] [Figure 12] FIG. 12 is a cross-sectional view taken along line 12-12 of FIG. 8.

[0031] [Figure 13] FIG. 13 is a cross-sectional view taken along line 13-13 in FIG. 8.

[0032] [Figure 14] FIG. 14 is a cross-sectional view taken along line 14-14 in FIG. 8.

[0033] [Figure 15] FIG. 15 is a cross-sectional view taken along line 15-15 in FIG. 8.

[0034] [Figure 16] FIG. 10 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to another embodiment of the present invention.

[0035] [Figure 17] FIG. 17 is a cross-sectional view taken along line 17-17 of FIG. 16.

[0036] [Figure 18] FIG. 18 is a cross-sectional view taken along line 18-18 of FIG. 16.

[0037] [Figure 19] FIG. 19 is a cross-sectional view taken along line 19-19 of FIG. 16.

[0038] [Figure 20] 17 is a schematic cross-sectional view of a bonding device that can be used in the manufacturing line of FIG. 3, FIG. 8, or FIG. 16, according to one embodiment of the present invention.

[0039] [Figure 21] FIG. 21 is a detailed view of a portion of the joining apparatus of FIG. 20 showing the horn aligned with the protrusion on the rotating anvil, according to one embodiment of the present invention.

[0040] [Figure 22] 17 is a flattened representation of an exemplary anvil pattern that can be used in the manufacturing line of FIG. 3, FIG. 8, or FIG. 16, according to one embodiment of the present invention.

[0041] [Figure 23] FIG. 23 is a detailed view of a portion of the rotary anvil of FIG. 22.

[0042] [Figure 24] 17 is a flattened representation of an exemplary anvil pattern that can be used in the manufacturing line of FIG. 3, FIG. 8, or FIG. 16, in accordance with another embodiment of the present invention.

[0043] [Figure 25] 17 is a flattened representation of an exemplary anvil pattern showing a constrained bond zone and / or a laminate bond zone that can be used in the manufacturing line of FIG. 3, FIG. 8, or FIG. 16, in accordance with one embodiment of the present invention.

[0044] [Figure 26] 26 illustrates an exemplary elastic leg and leg cuff web assembly that can be produced using the rotary anvil of FIG. 25.

[0045] [Figure 27] FIG. 27 is a detailed view taken along line 27-27 of FIG. 26.

[0046] [Figure 28A] FIG. 28 is a cross-sectional view taken along line 28-28 of FIG. 27. [Figure 28B] FIG. 28 is a cross-sectional view taken along line 28-28 of FIG. 27.

[0047] [Figure 29] FIG. 10 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to another embodiment of the present invention.

[0048] [Figure 30] FIG. 30 is a cross-sectional view taken along line 30-30 of FIGS. 29 and 34.

[0049] [Figure 31] FIG. 31 is a cross-sectional view taken along line 31-31 of FIGS. 29 and 34.

[0050] [Figure 32] FIG. 32 is a cross-sectional view taken along line 32-32 of FIGS. 29 and 34.

[0051] [Figure 33A] FIG. 33 is a cross-sectional view taken along line 33-33 of FIG. 29. [Figure 33B] FIG. 33 is a cross-sectional view taken along line 33-33 of FIG. 29.

[0052] [Figure 34] FIG. 10 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to another embodiment of the present invention.

[0053] [Figure 35] FIG. 35 is a cross-sectional view taken along line 35-35 of FIG. 34.

[0054] [Figure 36] FIG. 36 is a cross-sectional view taken along line 36-36 of FIG. 34.

[0055] [Figure 37] FIG. 10 is a schematic diagram of a portion of a manufacturing line for forming an elastic leg and leg cuff web assembly according to another embodiment of the present invention.

[0056] [Figure 38A] FIG. 38 is a cross-sectional view taken along line 38-38 of FIG. 37. [Figure 38B] FIG. 38 is a cross-sectional view taken along line 38-38 of FIG. 37.

[0057] [Figure 39] 37 according to one embodiment of the present invention. FIG. 37 is a schematic cross-sectional view of a bonding device that can be used in the manufacturing line of FIG.

[0058] [Figure 40] FIG. 40 is a detailed view of a portion of the joining apparatus of FIG. 39 showing the horn aligned with the protrusion on the rotating anvil, according to one embodiment of the present invention.

[0059] [Figure 41] 37 according to one embodiment of the present invention.

[0060] [Figure 42] FIG. 42 is a detailed view of a portion of the rotary anvil of FIG. 41.

[0061] [Figure 43] 37. FIG. 38 is a flattened representation of an exemplary anvil pattern that can be used in the manufacturing line of FIG. 29, FIG. 34, or FIG. 37, in accordance with another embodiment of the present invention.

[0062] [Figure 44] 37. FIG. 38 is a flattened representation of an exemplary anvil pattern showing constrained and / or laminated bond zones that can be used in the manufacturing line of FIG. 29, FIG. 34, or FIG. 37, in accordance with one embodiment of the present invention.

[0063] [Figure 45] 45 illustrates an exemplary elastic leg and leg cuff web assembly that can be produced using the rotary anvil of FIG. 44.

[0064] [Figure 46] FIG. 46 is a detailed view taken along line 46-46 of FIG. 45.

[0065] [Figure 47A] FIG. 47 is a cross-sectional view taken along line 47-47 of FIG. 46. [Figure 47B] FIG. 47 is a cross-sectional view taken along line 47-47 of FIG. 46.

[0066] [Figure 48]FIG. 37 is a schematic diagram of a flattened representation of an exemplary anvil pattern showing constrained bonding zones and / or stacked bonding zones that can be used in the manufacturing line of FIG. 29, FIG. 34, or FIG. 37, in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0067] Embodiments of the present invention provide an apparatus and method for forming elastic cuff and leg regions of disposable products such as diapers or absorbent products such as light incontinence products that minimize or eliminate the use of adhesives such as glue.

[0068] 2 is a plan view of a disposable product 24 according to one exemplary embodiment. The disposable product 24 has a front waist region 26, a crotch region 28, and a rear waist region 30. The front waist region 26 is the portion that contacts the wearer's front waist region (abdomen). The rear waist region 30 is the portion that contacts the wearer's rear waist region (back). The crotch region 28 is located between the front waist region 26 and the rear waist region 30. In the illustrated embodiment, the direction from the front waist region 26 toward the rear waist region 30 is referred to as the front-to-back direction L, and the direction perpendicular to the front-to-back direction L is referred to as the width direction W.

[0069] The disposable product 24 includes an absorbent body 32. The absorbent body 32 spans the crotch region 28 and extends toward at least one of the front waist region 26 and the rear waist region 30. The illustrated absorbent body 32 is positioned across the front waist region 26, the crotch region 28, and the rear waist region 30. The absorbent body 32 has an absorbent core 32a and a core wrap 32b. The absorbent body 32 may have its own liquid-impermeable backsheet (not shown).

[0070] A liquid-permeable topsheet 34 is provided and forms the skin-facing side of the disposable article 24, which contacts the wearer. The topsheet 34 is disposed across the front waist region 26, the crotch region 28, and the rear waist region 30. In some embodiments, the topsheet 34 comprises fibers and may be formed from a nonwoven. Alternatively, the topsheet 34 may comprise a nonwoven material, a woven material, a film, a foam, and / or a composite or laminate of any of these material types.

[0071] On the non-skin-facing side of the disposable article 24, opposite the topsheet 34, is a backsheet 36, which is similarly disposed generally across the front waist region 26, crotch region 28, and rear waist region 30. In some embodiments, the backsheet 36 comprises fibers and may be formed from a nonwoven. Alternatively, the backsheet 36 may comprise a nonwoven material, a woven material, a film, a foam, and / or a composite or laminate of any of these material types.

[0072] A pair of side sheets 38 are arranged at least partially along the outer widthwise sides of the disposable product 24 and substantially symmetrically with respect to an axis of symmetry 40 extending along the center of the disposable product 24 in the widthwise direction. Three-dimensional gathers or leg cuffs 42 are formed in the elastic regions of the side sheets 38, forming upstanding gathers that can rise toward the wearer. The leg cuffs 42 are composed of a portion of the side sheet 38 and one or more side elastic members 44 joined thereto. The side elastic members 44 are configured to be stretchable in the front-to-back direction L and are arranged on the inner edge side of the side sheet 38. The leg cuffs 42 further have an upstanding portion 46 that can rise toward the wearer, a first fixed portion 48 that serves as the starting edge for the upstanding portion 46, and a second fixed portion 50 that is located outside the upstanding portion 46 in the front-to-back direction L and has a first end 52 that serves as the starting end for the upstanding portion 46. The front end edge of the standing portion 46 coincides with the rear end edge of the second fixed portion 50 arranged in the front waist region, and the rear end edge of the standing portion 46 coincides with the front end edge of the first fixed portion 48 arranged in the rear waist region.

[0073] The side sheet 38 is joined to the top sheet 34 at first and second fastening portions 48 and 50. The fastening portions 48, 50 can be joined to the top sheet 34 using joining techniques known in the art, such as ultrasonic, thermal, or pressure bonding techniques for fusing web layers together, adhesive bonding, or various other forms of welding / bonding processes. The upstanding portions 46 are provided between the second fastening portions 50 in the front-to-back direction L and are not joined to the top sheet 34, and therefore can rise from the top sheet 34. The upstanding portions 46 rise toward the wearer when the side elastic members are contracted. The upstanding portions 46 rise toward the wearer when the disposable product is worn. Each of the upstanding portions 46 has a contraction region C in which the side elastic members 44 are contractibly arranged. The contraction region C is the region where the side elastic members 44 are joined to the side sheet 38 to form an elastic region. The leg cuffs 42 form walls that rise along the outer edges of the absorbent body 32 on the skin-facing side, preventing side leakage of exudates.

[0074] Leg openings 54 that are positioned around the legs of a wearer are formed at the outer edge of the disposable product 24. The disposable product 24 is provided with one or more leg elastics 56 that are stretchable in the front-to-back direction L and are positioned inside the leg openings 54 in the width direction.

[0075] In the rear waist region 30, a pair of selvedge portions 58 extend outward in the width direction W from the side sheets 38. The selvedge portions 58 may be formed from the top sheet 34, the back sheet 36, the side sheets 38, or a separate sheet attached to the disposable product 24. In the rear waist region 30, a pair of fastening tapes 60 extend outward in the width direction W from the selvedge portions 58. The fastening tapes 60 have fastening portions 62 that are attached to target portions 64 in the front waist region 26. The fastening portions 62 are provided with, for example, engagement hooks. The fastening tapes 60 are attached to the target portions 64 in the front waist region 26 to hold the disposable product 24 to the wearer's body. The target portions 64 are provided on the surface of the outer sheet of the front waist region 26 that faces away from the skin. The target portions 64 are configured to engage the engagement hooks of the fastening tapes 60 and function as loops for a hook-and-loop fastening system.

[0076] The disposable product 24 has a waist elastic portion 66 that is stretchable in the width direction. The waist elastic portion 66 is located in the rear waist region 30. The waist elastic portion 66 is located between a pair of fastening tapes 60, and causes the portion between the fastening tapes 60 to contract in the width direction.

[0077] Referring now to FIG. 3 , a portion of an exemplary manufacturing line 68 for producing an elastic leg and leg cuff web assembly 70 according to one embodiment of the present invention is illustrated. As shown, a first web layer 72 and a plurality of elastic yarns or strands 74 are fed in a machine direction 76 by a roller assembly 78, which may include one or more rollers. The elastic yarns 74 include one or more cuff elastic yarns 80 and one or more leg elastic yarns 82. The elastic yarns 74 move in the machine direction 76 under tension from a creel assembly (not shown) or similar device. The elastic yarns 74 can have any suitable cross-sectional shape that facilitates the formation of an elastic composite structure having desired elasticity, visual aesthetics, and manufacturability. By way of non-limiting example, the elastic yarns 74 can have a round, rectangular, square, or irregular cross-sectional shape, such as when each elastic yarn 74 is a multifilament product. The elastic yarns 74 may be composed of any suitable elastic material, including, for example, by way of non-limiting example, a thermoplastic elastomer, natural or synthetic rubber, or a sheet, strand, or ribbon of elastic strands. Each elastic yarn 74 may be provided in the form of an individual elastomeric strand, or may be a manufactured multifilament product including many individual elastomeric filaments joined together, such as by a dry spinning manufacturing process, to form a single, united elastic yarn 74.

[0078] Referring to Figure 4, a cross-sectional view taken along line 4-4 in Figure 3 is shown. The first web layer 72 includes cuff elastics 84 configured to receive the cuff elastic yarns 80 and leg elastics 86 configured to receive the leg elastic yarns 82. The first web layer 72 also includes cuff folds 88 configured to be folded over at least the cuff elastic yarns 80 and the cuff elastics 84, and leg folds 90 configured to be folded over at least the leg elastic yarns 82 and the leg elastics 86.

[0079] Referring again to FIG. 3 , the first web layer 72 and elastic yarn 74 travel downstream to a turn assembly 92 having, for example, a pair of plow folders 94, 96, although it should be understood that other types of known turn structures may be used. The plow folder 94 is configured to turn the cuff turn portion 88 of the first web layer 72 over at least the cuff elastic yarn 80. In one embodiment, the length of the cuff turn portion 88 may extend to overlap a portion of the leg elastic 86 as well. During turn-up, the cuff edge 98 of the first web layer 72 is moved away from the outer edge of the first web layer 72 onto the cuff elastic side of the elastic leg and leg cuff web assembly 70. The plow folder 96 is configured to turn the leg turn portion 90 of the first web layer 72 over at least the leg elastic yarn 82 and the leg elastic 86, and may extend to overlap a portion of the cuff elastic 84 as well. During the turn-up, the leg edge 100 of the first web layer 72 is moved away from the outer edge of the first web layer 72 and onto the leg elastic side of the elastic leg and leg cuff web assembly 70 .

[0080] 5, taken along line 5-5 of FIG. 3, the folds 88, 90 overlap the cuff elastics 84 and leg elastics 86, respectively, after folding. As will be described below, multiple leg and cuff attachment areas 102, 104 are available for joining the cuff elastics 84 and leg elastics 86 to the folds 88, 90.

[0081] Referring again to FIG. 3 , downstream of the cuff assembly 92, a joining device 106 is positioned to receive the assembly of the first web layer 72 having its folded portions around the elastic yarns 74 and join the cuff elastics 84 and leg elastics 86 to the cuff portions 88, 90 at the join site 102. The joining device 106 may be any known ultrasonic welding system in alternative embodiments, including, by way of non-limiting example, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, the joining device 106 includes a rotating anvil 108 and an ultrasonic fixed-blade horn 110, also known as a sonotrode, which cooperate to join (i.e., fuse) the cuff elastics 84 and leg elastics 86 to the cuff portions 88, 90. Alternative embodiments may include multiple fixed-blade horns or one or more rotary horns. As shown in the cross-sectional view of FIG. 6 taken along line 6-6 of FIG. 3, during the bonding process, the elastic yarns 80, 82 may be secured in place relative to the first web layer 72 by leg bonds 112 and cuff bonds 114 to form the elastic regions of the elastic leg and leg cuff web assembly 70, while in the non-elastic regions of the elastic leg and leg cuff web assembly 70, they may not be secured by bonds 112, 114 so as to move freely independent of the first web layer 72.

[0082] The ultrasonic emission of energy from the bonding device 106 is focused at specific bond points where frictional heat fuses the layers of the web together without the need for consumable adhesives. Although the bonding device 106 is described herein as an ultrasonic bonding assembly that ultrasonically fuses the layers of the web together, it is contemplated that the techniques described herein can be extended to any other known welding or bonding techniques that fuse two or more layers of material together without the use of adhesives, including ultrasonic, thermal, or compression bonding techniques, and various other forms of welding known in the art.

[0083] 3, after bonding by bonding apparatus 106, an adhesive applicator 116 applies adhesive 118 (FIG. 7) to the leg elastics of elastic leg and leg cuff web assembly 70, and adhesively bonds elastic leg and leg cuff web assembly 70 to second web layer 120, such as a topsheet, using a roller assembly 122 configured to apply pressure to press or bond elastic leg and leg cuff web assembly 70 and second web layer 120 together. As shown in FIG. 7, the adhesively bonded assembly provides elastic leg regions 124 with associated elastic cuff regions 126 when combined into a finished product, such as a disposable diaper or light incontinence product.

[0084] Referring now to FIG. 8 , a portion of an exemplary manufacturing line 128 for producing an elastic leg and leg cuff web assembly 130 according to another embodiment of the present invention is illustrated. As shown, a first web layer 132 and a plurality of elastic yarns or strands 134 are fed in a machine direction 136 by a roller assembly 138, which may include one or more rollers. In the illustrated embodiment, the elastic yarns 134 comprise a group of cuff elastic yarns 140. Alternative embodiments may include a single elastic yarn 134. The elastic yarn 134 travels in the machine direction 136 under tension from a creel assembly (not shown) or similar device. The elastic yarn 134 may have any suitable cross-sectional shape that facilitates the formation of an elastic composite structure having the desired elasticity, visual aesthetics, and manufacturability. By way of non-limiting example, the elastic yarns 134 may have a round, rectangular, square, or irregular cross-sectional shape, such as when each elastic yarn 134 is a multifilament product. The elastic yarns 134 may be constructed from any suitable elastic material, including, for example, by way of non-limiting example, a thermoplastic elastomer, natural or synthetic rubber, or a sheet, strand, or ribbon of elastic strands. Each elastic yarn 134 may be provided in the form of an individual elastomeric strand, or may be a manufactured multifilament product including many individual elastomeric filaments joined together, such as by a dry spinning manufacturing process, to form a single, united elastic yarn 134.

[0085] Referring to Figure 9, a cross-sectional view taken along line 9-9 of Figure 8 is shown. The first web layer 132 has cuff elastics 142 configured to receive the cuff elastic yarns 140. The first web layer 132 also has cuff folds 144 configured to be folded over at least the cuff elastic yarns 140 and the cuff elastics 142.

[0086] 8, the first web layer 132 and elastic yarn 134 travel downstream to a turn assembly 146, which may include a plow folder or other known turn device. The turn assembly 146 is configured to turn the cuff turn portion 144 of the first web layer 132 over at least the cuff elastic yarn 140. During the turn, the cuff edge 148 of the first web layer 132 is moved away from the outer edge of the first web layer 132 and onto the cuff elastic side of the first web layer 132.

[0087] 10, taken along line 10-10 in FIG. 8, the fold portion 144 overlaps the cuff elastics 142 after folding. Multiple cuff attachment sites 150 are available for attaching the cuff elastics 142 to the fold portion 144, as described below.

[0088] 8, downstream of the turn-up assembly 146, a joining device 152 is positioned to receive the assembly of the first web layer 132 having its turned-up portion about the elastic yarn 134 and to join the cuff elastic 142 to the turn-up portion 144 at a joining site 150. The joining device 152 may be similar to the joining device 106 described herein.

[0089] 8, during the bonding process, the elastic yarns 140 may be secured in place relative to the first web layer 132 by cuff bonds 154 to form the elastic regions of the elastic leg and leg cuff web assembly 130, while in the non-elastic regions of the elastic leg and leg cuff web assembly 130, they may not be secured by bonds 154 so as to be free to move independently from the first web layer 132. After bonding by the bonding device 152, the elastic cuff web 156 is fed for further downstream processing.

[0090] 8, in a separate portion of the manufacturing line 128, one or more leg elastic yarns 158 and a second web layer 160, such as a topsheet, are fed in the machine direction 136 by a roller assembly 162, which may include one or more rollers. The leg elastic yarns 158 may be similar to or different from the cuff elastic yarns 140.

[0091] 12, taken along line 12-12 in FIG. 8, the second web layer 160 includes a pair of leg elastic portions 164 configured to receive the leg elastic yarns 158. The second web layer 160 also has leg turn-up portions 166 configured to be turned up over at least the leg elastic yarns 158 and the leg elastic portions 164.

[0092] 8 , the second web layer 160 and elastic yarn 134 travel downstream to a turn assembly 168, which may include a plow folder or other known turn device. The turn assembly 168 is configured to turn the cuff turn portion 166 of the second web layer 160 over at least the leg elastic yarn 158. During the turn, the leg edge 170 of the second web layer 160 is moved away from the outer edge of the second web layer 160 and onto the leg elastic side of the second web layer 160.

[0093] 8, the leg cuffs 166 overlap the leg elastics 164 after folding. As will be described below, multiple leg join regions 172 are available for joining the leg elastics 164 to the leg cuffs 166.

[0094] 8, downstream of the cuff assembly 168, a joining device 174 is positioned to receive the assembly of the second web layer 160 having its folded portion around the leg elastic yarn 158 and to join the leg elastic 164 to the leg cuff 166 at a joining site 172. The joining device 174 may be similar to the joining device 106 described herein.

[0095] 8, during the bonding process, the leg elastic yarns 158 may be secured in place relative to the second web layer 160 by leg bonds 176 to form the elastic regions of the elastic leg and leg cuff web assembly 130, while the non-elastic regions of the elastic leg and leg cuff web assembly 130 may not be secured by bonds 176 so as to be free to move independently from the first web layer 132. After bonding by the bonding device 152, the elastic leg web 178 is fed for further downstream processing.

[0096] 8, after bonding by bonding device 174, adhesive applicator 180 applies adhesive 182 to the leg elastics 164 of elastic leg web 178. A roller assembly 184 then receives and applies pressure to both elastic leg web 178 and elastic cuff web 156 to adhesively bond them together to form elastic leg and leg cuff web assembly 130 that can be used in a finished product such as a disposable diaper or light incontinence product.

[0097] As shown in the cross-sectional view of FIG. 15 taken along line 15-15 of FIG. 8, the elastic leg webs 178 and the elastic cuff webs 156 are adhesively bonded while leaving the cuff elastics 142 with freedom of movement independent of the elastic leg webs 178.

[0098] Figure 16 shows a portion of an exemplary manufacturing line 186 for producing elastic cuff webs 156 and elastic leg webs 178 according to another embodiment of the present invention. A first portion of the manufacturing line 186 is similar to that described in Figures 8-11, and like portions that are numbered identically and are not described or referenced below are as described above and will not be repeated for purposes of brevity.

[0099] Downstream of the bonding device 152, the elastic cuff web 156 is bonded integrally to the topsheet 188 using a roller assembly 190. An adhesive applicator 192 applies adhesive 194 near the edges of the topsheet 188, bonding the elastic cuff web 156 to the topsheet 188 in response to pressure applied by the roller assembly 190. The adhesively bonded web / topsheet assembly is fed for further processing downstream. Figure 17 is a cross-sectional view taken along line 17-17 in Figure 16, showing the elastic cuff web 156 adhesively bonded to the topsheet 188.

[0100] 16 and 18 show that a backsheet film 196, which serves to provide an impermeable layer adjacent to the second web layer 160, is adhesively attached to the second web layer 160. The adhesive 182 in the manufacturing line 186 is applied to the elastic leg web 178 in greater quantities than described with respect to FIG. 8. In one embodiment, multiple absorbent cores 198 are shown schematically, with each absorbent core 198 inserted between the elastic cuff web 156 and the elastic leg web 178 before being adhesively bonded by the roller assembly 184 as the webs move in the machine direction 136.

[0101] As shown in the cross-sectional view of Figure 19 taken along line 19-19 of Figure 16, the elastic leg web 178 and the elastic cuff web 156 are adhesively bonded together with the absorbent core 198 sandwiched therebetween, while leaving the cuff elastics 142 free to move independently of the elastic leg web 178.

[0102] 20 , an anvil 108 according to one embodiment of the present invention is shown. As shown, the anvil 108 includes an array of discrete projections 200 extending outward from an anvil face 202. These projections 200 are configured to (A) fuse the first web layer 72 to the cuff cuff folds 88 and the first web layer 72 to the leg cuff folds 90 together, and (B) restrain or hold the elastic yarn 74 in place relative to the bonded layer of the resulting elastic composite structure 70. As will be explained in more detail below, the restraining projections 200 are designed so that an elastic yarn 74 passing between two adjacent restraining projections 200 on the face 202 of the anvil 108 is restrained in place relative to the bonded layer by frictional resistance that prevents the elastic yarn 74 from sliding through the resulting bonded pair.

[0103] The particular size, shape, and general arrangement of the constraining projections 200, as well as the total number of projections 200, shown in FIG. 20 are intended to represent a representative, non-limiting example of the overall pattern of projections 200 on the anvil 108. Alternate embodiments may include any number of projections 200 arranged in any number of alternative configurations to achieve a desired pattern of bonds on the final product. The working surface of each of the constraining projections 200 may be configured to form similarly sized and shaped bonds, or differently sized and / or shaped bonds, in alternative embodiments. By way of non-limiting example, the land surface of each of the constraining projections 200 may be circular, rectangular, crescent-shaped, or may have an irregular shape that can be selected to form a desired overall pattern on the final product. The resulting pattern of bonds includes one or more constraining regions that secure or lock one or more elastic threads 74 under tension in place relative to the bonding layer.

[0104] In a preferred embodiment, the captive projections 200 are formed on the anvil 108 using a machining process that removes bulk material from the anvil 108 to form the desired raised pattern of the projections 200 relative to the face 202 of the anvil 108. Alternatively, the captive projections 200 may be provided on one or more inserts that are mechanically coupled to the face 202 of the anvil 108.

[0105] 20, the working surface 204 of the horn 110, in one non-limiting embodiment, has a smooth or substantially smooth surface contour. Alternatively, the working surface 204 can include an array of protrusions 200 and / or grooves that mate or align with a pattern of protrusions 200 on the anvil 108 to further facilitate fusing one web layer to another and securing the elastic yarn 74 in place relative to the fused layers.

[0106] During the manufacturing process, the layers to be fused are positioned between the surface 202 of the anvil 108 and the working surface 204 of the horn 110, as shown in FIG. 20 . An elastic thread 74 is positioned between the fusible layers under tension. As shown schematically in FIG. 20 and in more detail in FIG. 21 , the position of the horn 110 is controlled to maintain a nip gap 206 between the working surface 204 of the horn 110 and the land surface 208 of the restraining projection 200. The size of the nip gap 206 is determined based on the parameters of the manufacturing process to facilitate bonding between the fusible layers. The bonding apparatus 106 can include any known positioning means 210 that applies a force to at least one of the horn 110 and the anvil 108 to maintain the desired nip gap 206 between the horn 110 and the anvil 108. The positioning means 210 can be, by way of non-limiting example, a pneumatic assembly (not shown) or a mechanical camshaft (not shown).

[0107] In alternative embodiments, the constraining projections 200 can have flat work surfaces, flat sides, or some combination of curved and straight work surfaces and sides. In the embodiment shown in FIG. 21 , the land surface 208 of the constraining projections 200 has a flat work surface and sides. In an alternative embodiment in which the land surface 208 has an arcuate or curved surface profile, the curved profile allows the fusible layer to slide against the face 202 of the anvil 108 during the bonding process, thereby allowing the rate at which the composite assembly of tensioned elastic strands 74 and fusible layer advances toward the bonding device 106 to be increased or decreased relative to the rotational speed of the anvil 108. When the composite web / yarn assembly advances at a speed greater than the speed of the anvil 108, the resulting bonds are spaced apart by a distance greater than the radial spacing between adjacent projections 200 on the anvil face 202. Similarly, slowing the feed rate of the composite web / yarn assembly relative to the speed of the anvil 108 results in bonds spaced a distance less than the radial spacing between adjacent projections 200 on the anvil face 202. The speed mismatch or difference between the web speed and the anvil speed can be controlled to accommodate variations in the size of the final product. As a result, bonds of elastic composites for one size diaper may be made with little or no slippage, while bonds of elastic composites for larger or smaller diapers may be made with a greater amount of slippage. Thus, a manufacturing line such as that shown in FIG. 3, FIG. 8, or FIG. 16 equipped with anvils including projections 200 with a curved surface profile can be used to produce multiple sizes of elastic composite structures for use in different size products, allowing for dynamic sizing without the need to change the tooling configuration of the manufacturing line.

[0108] 22 is a flattened representation of the peripheral surface 202 of the anvil 108 according to an embodiment in which the anvil 108 includes a pattern of protrusions 212 that form constraint regions. The protrusion pattern 212 includes a plurality of constraint weld lines 214 that are spaced apart from one another along a circumferential axis 216 of the anvil face 202. The constraint weld lines 214 define one or more constraint regions 218 of the protrusion pattern 212. Similar to the constraint protrusions 200 described above, in a preferred embodiment, the constraint weld lines 214 are formed on the anvil 108 using a machining process that removes bulk material from the anvil 108 to form the desired raised pattern of the constraint weld lines 214 relative to the face 202 of the anvil 108. Alternatively, the constraint weld lines 214 may be provided on one or more inserts that are mechanically coupled to the face 202 of the anvil 108.

[0109] 22 shows a constraint weld line 214 having separate weld line portions 220, 222 on either side of the face 202 along a longitudinal direction 224 of the rotary anvil 108. The longitudinal direction 224 extends generally in the cross-machine direction. The spacing between adjacent constraint weld lines 214, as well as the length and placement of each constraint weld line 214 along the longitudinal direction 224, may be according to the design of the joint pattern desired in the finished product.

[0110] As shown more particularly in the detailed view shown in FIG. 23 , each weld seam 214 includes a pattern of discrete projections 226, 228 extending outward from the face 202 of the anvil 108. The projections 226, 228 are spaced from one another by notches 230 defined by the width of gaps 232 disposed between a given pair of adjacent projections 226, 228. The width or size of the gaps 232 can constrain one or more elastic yarns 74 between adjacent joints formed by the projections 226, 228 such that the elastic yarns 74 are securely held by and between the adjacent joints. In this manner, for example, the adjacent joints constrain the elastic yarns 74 such that the elastic yarns 74 are constrained between the adjacent joints without the use of adhesive to form elastic regions. The elastic regions are formed by the projections of the constrained region portion 218 of the rotary anvil 108.

[0111] The anvil 108 may additionally or alternatively include one or more protrusions, referred to herein as lamination protrusions or non-constraining protrusions 234. As shown in FIG. 22, multiple lamination protrusions 234 are shown within a lamination weld line 238 of one or more lamination sections 236 of the rotary anvil 108. The lamination protrusions 234, similar to the constraining or constraining protrusions 226, 228, fuse the first web layer 72 and the second web layer 120 together. The lamination protrusions 234 differ from the constraining protrusions 226, 228 because they do not constrain the elastic yarns 74 in position relative to the fused web layers due to the spacing of the gaps 240 between adjacent protrusions 226, 228. Thus, if the retraction length is sufficient, a broken elastic yarn 74 can freely retract from the gap between adjacent lamination weld joints. Such lamination protrusions 234 are advantageous, for example, when laminating two web layers in an area designed for elastic deactivation, where the elastic yarns 74 are intentionally broken to form non-elastic portions of the joined web layers. Embodiments of the present invention contemplate the use of any number and arrangement of stacking projections 234, or none.

[0112] 23 , it is contemplated that in alternative embodiments, the contact surfaces 242 of the protrusions 226, 228 may have different geometric shapes. By way of non-limiting example, the protrusions 226, 228 may be circular, rectangular, crescent-shaped, or may have an irregular shape that can be selected to form a desired overall pattern on the final product. In yet another embodiment, corresponding protrusions 226, 228 of adjacent weld lines 214 may be aligned with one another in a line parallel to the circumferential axis 216. Alternatively, the protrusions 226, 228 of successive weld lines 214 may be offset from one another in the cross-machine direction to define a stepped or nonlinear path through the bond line formed on the fused web layer.

[0113] 22 , another weld line 244 is shown as an example to illustrate another embodiment in which the weld line extends across a majority of the width of the anvil 108 in the longitudinal direction 224. As shown, the restraining weld line 244 includes both restraining protrusions 226 and stacking protrusions 234. The combination of protrusions 226, 234 may also be designed as any of the other weld lines 214, 238. Alternatively, in other embodiments, the weld line 244 may include only one of the types of protrusions 226, 234.

[0114] 22 and 23 show in phantom lines elastic yarns (such as cuff elastic yarn 80) in a stretched state extending between adjacent restraining projections 226 and / or 228 of restraining weld line 214 and between adjacent laminate projections 234 of laminate weld line 238. The restraining joints formed by adjacent restraining projections 226, 228 (shown in FIG. 27) may form separate, independent joints spaced apart a distance less than the diameter or width of the unstretched elastic yarn, or may form a single joint across the elastic yarn from one contact surface 242 of the elastic yarn to the other contact surface 242 on the other side of the elastic yarn.

[0115] 24 illustrates a non-linear arrangement of restraining weld lines 214 according to another embodiment of the present invention. A sinusoidal pattern is shown, which, when the elastic yarn 74 and multiple web layers are bonded together, forms a distinctive gathering pattern compared to the gathering pattern formed using the linear arrangement shown in FIG. 22. It is contemplated that the restraining weld lines 214 may form alternating array patterns in other embodiments of the present invention. Such other array patterns may bond the elastic yarn 74 and fusible web layers together in linear or curvilinear arrays, or geometric or other patterns arranged to form logos, photographs, other sequential and repeating patterns, or other designs on the final product.

[0116] FIG. 25 is a schematic diagram illustrating a simplified flattened representation of an exemplary anvil pattern showing the location of constrained bond zones and / or laminated bond zones usable in the manufacturing line of FIG. 3 , according to one embodiment of the present invention. The rotary anvil 108 is shown schematically with constrained regions 218 between laminated regions 236. Discrete protrusions within regions 218 and 236 have been omitted for clarity. While a flattened view is shown, it is understood that in a rotated or cylindrical state, the laminated regions 236 may be adjacent to one another and comprise continuous laminated regions. The constrained regions 218 and 236 adjacent a first side edge of the rotary anvil 108 may correspond to a cuff region, while the constrained regions 218 and 236 at the opposing side edge may correspond to a leg region. The weld lines in the constrained regions 218 include constrained weld lines 214 for forming constrained elastics to form elastic regions. The weld lines in the laminated regions 236 include laminated weld lines 238 for forming unconstrained elastics to form inelastic regions. In an alternative embodiment of the present invention, the anvil patterns shown in FIGS. 25 and 26-28 may be formed by appropriate design of the separate anvils of joining device 152 and joining device 174.

[0117] FIG. 26 illustrates an exemplary elastic leg and leg cuff web assembly 70 that can be produced using the rotary anvil 108 of FIG. 25. The illustrated portion of the running elastic leg cuff web assembly 70 has multiple elastic regions 246 formed via the restraint region 218 of FIG. 25. The laminated portion 236 forms a laminate bond, and then multiple inelastic regions 248 are formed by breaking or deactivating the elastic strands in the laminated region (e.g., along separation lines 250) using methods known in the art. Once broken, the ends of the elastic strands contract back toward their respective elastic regions 246. Furthermore, cutting or separating the elastic leg and leg cuff web assembly 70 along the separation lines 250 separates the web into individual leg cuff portions having elastic regions 246 and inelastic regions 248 available for attachment to an assembly with an absorbent core and other elements to form a disposable product, such as a diaper or light incontinence product.

[0118] FIG. 27 shows a detailed cutaway view of the elastic leg and leg cuff web assembly 70 shown in FIG. 26. A plurality of restraining joints 252 formed by restraining projections 226, 228 (shown in FIG. 23) capture or restrain the elastic yarn 80 disposed between adjacent joints 252. The joints 252 are formed when the elastic yarn 80 is in a stretched or elongated state. Furthermore, the first web layer 72, which does not exhibit elastic properties, is in a smooth or flat state when the elastic yarn 80 is stretched therealong. The separation distance 232 between adjacent restraining projections 226 and / or 228 is sufficient to allow the stretched elastic yarn 80 to be disposed between the restraining projections or their contact surfaces 242 during ultrasonic bonding to form the restraining joints 252. The separation distance is preferably greater than the width of the stretched elastic yarn, but may be less than or equal to the width of the elastic yarn according to embodiments of the present invention.

[0119] The restraining joints 252 secure the elastic yarn 80 in place relative to the bonded web layers affected by the restraining joints 252. Thus, when the tensioned elastic yarn 80 is allowed to return to its untensioned or untensioned state, the elastic yarn 80 gathers against the bonded web layers, causing the elastic web to form gathers 254. The untensioned portions of the elastic yarn 80 between adjacent lines of restraining joints 252 have a width or diameter 256 that is wider than the width 232 between adjacent restraining joints 252.

[0120] As further shown in FIG. 27 , the plurality of lamination bonds 258 in the inelastic regions 248 formed by the lamination projections 234 (shown in FIG. 23 ) bond the affected web layers together (e.g., the first web layer 72 to the second web layer 120) without trapping or constraining the elastic yarn 80 between adjacent bonds 258. The spacing 240 between adjacent restraining projections 234 is sufficient to allow the untensioned elastic yarn 80 to move freely relative to the bonds 258. That is, the spacing 240 is greater than the diameter 256 of the untensioned elastic yarn 80. When the elastic yarn 80 is cut or broken, the elastic yarn is free to contract toward its untensioned state and retract from its position between adjacent separated bonds 258 in the longitudinal direction 224. Thus, the bonds 258 do not constrain the elastic yarn 80 to cause elastic gathering of the web layers.

[0121] Depending on the operating parameters of the ultrasonic bonding apparatus 106 and / or the geometry and configuration of the notches and protrusions on the anvil 108 and / or horn 110, the resulting pair of adjacent bonds 252 may be formed as discrete, discontinuous bonds 260 that fuse together the opposing web layers 84, 88 at the bond site 104, as shown in Figure 28A, or as a continuous fused bond 262 that fuses together one or both of the opposing web layers 84, 88 at the bond site 104, as shown in Figure 28B. As shown in Figure 28A, the untensioned diameter 264 of the restrained bond 252 is larger than the tensioned diameter 266.

[0122] 29, a portion of an exemplary manufacturing line 300 for producing an elastic leg and leg cuff web assembly 302 according to one embodiment of the present invention is illustrated. As shown, a first web layer 304 and a plurality of elastic yarns or strands 306 are fed in a machine direction 308 by a roller assembly 310, which may include one or more rollers. In the illustrated embodiment, the elastic yarns 306 include a group of cuff elastic yarns 312. Alternative embodiments may include a single elastic yarn 306. The elastic yarn 306 moves in the machine direction 308 under tension from a creel assembly (not shown) or similar device. The elastic yarn 306 may have any of the shapes and compositions described above with respect to the elastic yarn 74 and may be provided in the form of individual elastomeric strands or may be a manufactured multifilament product including many individual elastomeric filaments joined together, such as by a dry spinning manufacturing process, to form a single, coalesced elastic yarn 306.

[0123] Referring to Figure 30, a cross-sectional view taken along line 30-30 in Figure 29 is shown. The first web layer 304 has cuff elastics 314 configured to receive the cuff elastic yarns 312. The first web layer 304 also has cuff folds 316 configured to be folded over at least the cuff elastic yarns 312 and the cuff elastics 314.

[0124] 29, the first web layer 304 and elastic yarn 306 travel downstream to a turn assembly 318, which may include a plow folder or other known turn device. The turn assembly 318 is configured to turn the cuff turn portion 316 of the first web layer 304 over at least the cuff elastic yarn 312. During the turn, the cuff edge 320 of the first web layer 304 is moved away from the outer edge of the first web layer 304 and onto the cuff elastic side of the first web layer 304.

[0125] As shown in the cross-sectional view of Figure 31 taken along line 31-31 in Figure 29, the fold portion 316 overlaps the cuff elastics 314 after folding. Multiple cuff attachment sites 322 are available for attaching the cuff elastics 314 to the fold portion 316, as described below.

[0126] 29 , downstream of the turnup assembly 318, a bonding device 324 is positioned to receive the assembly of the first web layer 304 having its turned-up portion about the elastic yarn 306 and bond the cuff elastic 314 to the turnup portion 316 at a bond site 322. The bonding device 324 may be any known ultrasonic welding system in alternative embodiments, including, by way of non-limiting example, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, the bonding device 324 includes a rotating anvil 326 and an ultrasonic fixed-blade horn 328, also known as a sonotrode, which cooperate to bond (i.e., fuse) the cuff elastic 314 to the turnup portion 316. Alternative embodiments may include multiple fixed-blade horns or one or more rotary horns. As shown in the cross-sectional view of Figure 32 taken along line 32-32 in Figure 29, during the bonding process, the elastic yarns 312 may be secured in place relative to the first web layer 304 by cuff bonds 330 to form the elastic regions of the elastic leg and leg cuff web assembly 302, while in the non-elastic regions of the elastic leg and leg cuff web assembly 302, they may not be secured by bonds 330 so as to move freely independent of the first web layer 304.

[0127] The ultrasonic emission of energy from the bonding device 324 is focused at specific bond points where frictional heat fuses the layers of the web together without the need for consumable adhesives. Although the bonding device 324 is described herein as an ultrasonic bonding assembly that ultrasonically fuses the layers of the web together, it is contemplated that the techniques described herein can be extended to any other known welding or bonding techniques that fuse two or more layers of material together without the use of adhesives, including ultrasonic, thermal, or compression bonding techniques, and various other forms of welding known in the art.

[0128] 29 , after joining by the joining device 324, the leg elastic portions 332 of the elastic cuff web 334 produced so far are left unprocessed by the joining device 324 for further downstream processing. One or more leg elastic yarns 336 and a second web layer 338, such as a topsheet, are positioned adjacent to the leg elastic portions 332, and a second joining device 340 joins the second web layer 338 to the leg elastic portions 332 of the elastic cuff web 334 with the leg elastic yarns 336 sandwiched therebetween. The joining device 340 may be similar to the joining device 324 described herein.

[0129] As shown in FIG. 33A along line 33-33 in FIG. 29, positioning the leg elastic yarn 336 and the second web layer 338 adjacent to the elastic cuff web 334 provides a leg join area 342 for joining the leg elastic portion 344 of the second web layer 338 to the leg elastic portion 332 of the elastic cuff web 334.

[0130] 33B of FIG. 29 along line 33-33 shows an elastic leg and leg cuff web assembly 302 including an elastic cuff web 334 joined to a second web layer 338 using a joining device 340. During the joining process, portions of the elastic yarn 336 may be secured in place relative to the first and second web layers 304, 338 by leg joins 346 to form the elastic regions of the elastic leg and leg cuff web assembly 302, while non-elastic regions of the elastic leg and leg cuff web assembly 302 may not be secured by joins so as to move freely independent of the first and second web layers 304, 338.

[0131] Figure 34 shows a portion of an exemplary manufacturing line 348 for manufacturing an elastic leg and leg cuff web assembly 350 according to another embodiment of the present invention. A first portion of the manufacturing line 348 is similar to that described in Figures 29-32, and like portions that are numbered identically and are not described or referenced below are as described above and will not be repeated for purposes of brevity.

[0132] As shown in Figure 34, after bonding by the bonding device 324, the leg elastic yarns 336 and second web layer 338 are positioned adjacent to the elastic cuff web 334 using a roller assembly 352. Referring to Figures 34 and 35, the leg edge 354 of the second web layer 338 is folded using a folding assembly 356 to wrap the leg folding portion 358 around the distal end 360 of the elastic cuff web 334. By positioning the leg elastic yarns 336 and the second web layer 338 adjacent to the elastic cuff web 334, a bonding site 362 is provided for bonding the second web layer 338 to the elastic cuff web 334 to form the elastic leg cuff web assembly 350.

[0133] As shown in FIG. 34 , after the turn-up assembly 356, a joining device 340 joins the second web layer 338 to the elastic cuff web 334 to form the elastic leg and leg cuff web assembly 350. FIG. 36, taken along line 36-36 in FIG. 34 , shows the elastic cuff web 334 joined to the second web layer 338 using the joining device 340. During the joining process, portions of the elastic yarn 336 may be secured in place relative to the first web layer 304 and the second web layer 338 by leg joins 364 to form the elastic regions of the elastic leg and leg cuff web assembly 350, while the non-elastic regions of the elastic leg and leg cuff web assembly 350 may not be secured by joins so as to move freely independent of the first web layer 304 and the second web layer 338.

[0134] Figure 37 shows a portion of an exemplary manufacturing line 366 for manufacturing an elastic leg and leg cuff web assembly 368 according to another embodiment of the present invention. A first portion of the manufacturing line 366 is similar to that described in Figures 29-32 and 34-35, and like portions that are numbered identically and are not described or referenced below are as described above and will not be repeated for purposes of brevity.

[0135] Downstream of the joining device 324, the elastic cuff web 334 is joined integrally with the second web layer 338 after the leg edges 354 are folded back around the leg elastic yarns 336. The joining is performed using a joining device 340. As shown in the cross-sectional view of FIG. 38A along line 38-38 in FIG. 37, a joining site 362 for joining the leg elastics 332 of the elastic cuff web 334 to the second web layer 338 is shown.

[0136] 38B, taken along line 38-38 in FIG. 37, shows the elastic cuff web 334 joined to the second web layer 338 using a joining device 340. During the joining process, portions of the elastic yarn 336 may be secured in place relative to the first web layer 304 and the second web layer 338 by leg joins 364 to form the elastic regions of the elastic leg and leg cuff web assembly 368, while the non-elastic regions of the elastic leg and leg cuff web assembly 368 may not be secured by joins so as to move freely independent of the first web layer 304 and the second web layer 338.

[0137] 39, an anvil 326 according to one embodiment of the present invention is shown. As shown, the anvil 326 includes an array of discrete projections 370 extending outward from an anvil face 372. These projections 370 are configured to (A) fuse two sheets or sheet layers together (e.g., cuff elastic 314 to cuff cuff fold 316, leg elastic 332 to second web layer 338, etc.) and (B) restrain or hold elastic yarn 306, 336 in place relative to layers of the resulting elastic composite structure (e.g., elastic leg and leg cuff web assembly 302, etc.). As explained in more detail below, the restraining projections 370 are designed so that an elastic yarn 306 passing between two adjacent restraining projections 370 on the face 372 of the anvil 326 is restrained in place relative to the web layers 314, 316 by frictional resistance that prevents the elastic yarn 306 from sliding through the resulting bonded pair.

[0138] The particular size, shape, and general arrangement of the restraining projections 370, as well as the total number of projections 370, shown in FIG. 39 are intended to represent a representative, non-limiting example of the overall pattern of projections 370 on the anvil 326. Alternate embodiments may include any number of projections 370 arranged in any number of alternative configurations to achieve a desired pattern of bonds on the final product. The working surface of each of the restraining projections 370 may be configured to form similarly sized and shaped bonds, or differently sized and / or shaped bonds, in alternative embodiments. By way of non-limiting example, the land surface of each of the restraining projections 370 may be circular, rectangular, crescent-shaped, or may have an irregular shape that can be selected to form a desired overall pattern on the final product. The resulting pattern of bonds includes one or more restraining regions that secure or lock one or more elastic threads 306 under tension in place relative to the fused layers.

[0139] In a preferred embodiment, the captive projections 370 are formed on the anvil 326 using a machining process that removes bulk material from the anvil 326 to form the desired raised pattern of the projections 370 relative to the face 372 of the anvil 326. Alternatively, the captive projections 370 may be provided on one or more inserts that are mechanically coupled to the face 372 of the anvil 326.

[0140] 39, the working surface 374 of the horn 328, in one non-limiting embodiment, has a smooth or substantially smooth surface contour. Alternatively, the working surface 374 can include an array of protrusions 370 and / or grooves that mate or align with a pattern of protrusions 370 on the anvil 326 to further facilitate fusing the web layers 314, 316 together and securing the elastic yarn 306 in place relative thereto.

[0141] During the manufacturing process, the web layers 314, 316 are positioned between a surface 372 of the anvil 326 and a working surface 374 of the horn 328, as shown in FIG. 39. The elastic yarn 306 is positioned between the web layers 314, 316 under tension. As shown schematically in FIG. 39 and in more detail in FIG. 40, the position of the horn 328 is controlled to maintain a nip gap 376 between the working surface 374 of the horn 328 and the land surface 378 of the restraining projection 370. The size of the nip gap 376 is determined based on manufacturing process parameters to facilitate bonding between the web layers 314, 316. The bonding device 324 can include any known positioning means 380 that applies a force to at least one of the horn 328 and the anvil 326 to maintain the desired nip gap 376 between the horn 328 and the anvil 326. The positioning means 380 can be, by way of non-limiting example, a pneumatic assembly (not shown) or a mechanical camshaft (not shown).

[0142] In alternative embodiments, the constraining projections 370 can have flat work surfaces, flat sides, or some combination of curved and straight work surfaces and sides. In the embodiment shown in FIG. 40 , the land surfaces 378 of the constraining projections 370 have flat work surfaces and sides. In alternative embodiments in which the land surfaces 378 have an arcuate or curved surface profile, the curved profile allows the web layers 314, 316 to slide against the surface 372 of the anvil 326 during the bonding process, thereby allowing the rate at which the composite assembly of tensioned elastic strands 306 and web layers 314, 316 advances toward the bonding device 324 to be increased or decreased relative to the rotational speed of the anvil 326. When the composite web / yarn assembly advances at a speed greater than the speed of the anvil 326, the resulting bonds are spaced apart by a distance greater than the radial spacing between adjacent projections 370 on the anvil surface 372. Similarly, slowing the feed rate of the composite web / yarn assembly relative to the speed of the anvil 326 results in bonds spaced a distance less than the radial spacing between adjacent projections 370 on the anvil face 372. The speed mismatch or difference between the web speed and the anvil speed can be controlled to accommodate variations in the size of the final product. As a result, bonds of elastic composites for one size diaper may be made with little or no slippage, while bonds of elastic composites for larger or smaller diapers may be made with a greater amount of slippage. Thus, a manufacturing line such as that shown in FIG. 29, 34, or 37 equipped with anvils including projections 370 with a curved surface profile can be used to produce multiple sizes of elastic composite structures for use in different size products using the same anvil, allowing for dynamic sizing without having to change the tooling configuration of the manufacturing line.

[0143] 41 is a flattened representation of the peripheral surface 372 of the anvil 326 according to an embodiment in which the anvil 326 includes a pattern of protrusions 382 that form constraint regions. The protrusion pattern 382 includes a plurality of constraint weld lines 384 that are spaced apart from one another along a circumferential axis 386 of the anvil face 372. The constraint weld lines 384 define one or more constraint regions 388 of the protrusion pattern 382. Similar to the constraint protrusions 370 described above, in a preferred embodiment, the constraint weld lines 384 are formed on the anvil 326 using a machining process that removes bulk material from the anvil 326 to form the desired raised pattern of the constraint weld lines 384 relative to the face 372 of the anvil 326. Alternatively, the constraint weld lines 384 may be provided on one or more inserts that are mechanically coupled to the face 372 of the anvil 326.

[0144] 41 shows a restraint weld line 384 having separate weld line portions 390, 392 on either side of the face 372 along a longitudinal direction 394 of the rotary anvil 326. The longitudinal direction 394 extends generally in the cross-machine direction. The spacing between adjacent restraint weld lines 384, as well as the length and placement of each restraint weld line 384 along the longitudinal direction 394, may be according to the design of the joint pattern desired in the finished product.

[0145] As shown more particularly in the detailed view shown in FIG. 42 , each weld seam 384 includes a pattern of discrete projections 396, 398 extending outward from the face 372 of the anvil 326. The projections 396, 398 are spaced from one another by notches 400 defined by the width of gaps 402 disposed between a given pair of adjacent projections 396, 398. The width or size of the gaps 402 can constrain one or more elastic yarns 306 between adjacent joints formed by the projections 396, 398 such that the elastic yarns 306 are securely held by and between the adjacent joints. In this manner, for example, the adjacent joints constrain the elastic yarns 306 such that the elastic yarns 306 are constrained between the adjacent joints without the use of adhesive to form elastic regions. The elastic regions are formed by the projections of the constrained region portion 388 of the rotary anvil 326.

[0146] The anvil 326 may additionally or alternatively include one or more protrusions, referred to herein as lamination protrusions or non-constraining protrusions 404. As shown in FIG. 41 , multiple lamination protrusions 404 are shown within a lamination weld line 408 of one or more lamination sections 406 of the rotating anvil 326. The lamination protrusions 404, similar to the constraining or constraining protrusions 396, 398, fuse two web layers together. The lamination protrusions 404 differ from the constraining protrusions 396, 398 because they do not constrain the elastic yarns 306, 336 in position relative to the fused web layers due to the spacing of the gaps 410 between adjacent protrusions 396, 398. Thus, if the retraction length is sufficient, broken elastic yarns 306, 336 can freely retract from the gaps between adjacent lamination weld joints. Such lamination protrusions 404 are advantageous, for example, when laminating two web layers in an area designed for elastic deactivation, where the elastic yarns 306, 336 are intentionally broken to form inelastic portions of the joined web layers. Embodiments of the present invention contemplate the use of any number and arrangement of stacked projections 404, or none.

[0147] 42 , it is contemplated that in alternative embodiments, the contact surfaces 412 of the protrusions 396, 398 may have different geometric shapes. By way of non-limiting example, the protrusions 396, 398 may be circular, rectangular, crescent-shaped, or may have an irregular shape that can be selected to form a desired overall pattern on the final product. In yet another embodiment, corresponding protrusions 396, 398 of adjacent weld lines 384 may be aligned with one another in a line parallel to the circumferential axis 386. Alternatively, the protrusions 396, 398 of successive weld lines 384 may be offset from one another in the cross-machine direction to define a stepped or nonlinear path through the bond line formed on the fused web layer.

[0148] 41 , another weld line 414 is shown as an example to illustrate another embodiment in which the weld line extends across a majority of the width of the anvil 326 in the longitudinal direction 394. As shown, the restraining weld line 414 includes both restraining protrusions 396 and stacking protrusions 404. The combination of protrusions 396, 404 may also be designed as any of the other weld lines 384, 408. Alternatively, in other embodiments, the weld line 414 may include only one of the types of protrusions 396, 404.

[0149] 41 and 42 show in phantom lines elastic yarns (such as cuff elastic yarn 312) in a stretched state extending between adjacent restraining protrusions 396 and / or 398 of restraining weld line 384 and between adjacent laminate protrusions 404 of laminate weld line 408. The restraining joints formed by adjacent restraining protrusions 396, 398 (shown in FIG. 46) may form separate, independent joints spaced apart by a distance less than the diameter or width of the unstretched elastic yarn, or may form a single joint across the elastic yarn from one contact surface 412 of the elastic yarn to the other contact surface 412 on the other side of the elastic yarn.

[0150] 43 illustrates a non-linear arrangement of restraining weld lines 384 according to another embodiment of the present invention. A sinusoidal pattern is shown, which, when the elastic yarns 306, 336 and web layers are joined together, forms a distinctive gathering pattern compared to the gathering pattern formed using the linear arrangement shown in FIG. 41. It is contemplated that the restraining weld lines 384 may form alternating array patterns in other embodiments of the present invention. Such other array patterns may join the elastic yarns 306, 336 and web layers together in linear or curvilinear arrays, or geometric or other patterns arranged to form logos, photographs, other sequential and repeating patterns, or other designs on the final product.

[0151] FIG. 44 is a schematic diagram illustrating a simplified flattened representation of an exemplary anvil pattern showing the location of constrained bonding zones and / or laminated bonding zones that can be used in the manufacturing lines of FIGS. 29, 34, or 37, according to one embodiment of the present invention. The rotating anvils of the joining apparatus 324, 340 schematically illustrate the constrained regions 388 between the laminated regions 406. Discrete protrusions within the regions 388 and 406 have been omitted for clarity. While a flattened view is shown, it is understood that in a rotated or cylindrical state, the laminated regions 406 may be adjacent to one another and comprise continuous laminated regions. The constrained regions 388 and laminated regions 406 adjacent a first side edge of the rotating anvil of the joining apparatus 324 may correspond to a cuff region, while the constrained regions 388 and laminated regions 406 on the opposing side edge of the rotating anvil of the joining apparatus 340 may correspond to a leg region. The weld lines in the constrained regions 388 include constrained weld lines 384 for forming constrained elastics to form elastic regions. The weld lines of the laminated portion 406 include a laminated weld line 408 for forming an unconstrained elastic body for forming an inelastic region.

[0152] FIG. 45 illustrates a portion of an exemplary elastic leg and leg cuff web assembly 302 that can be produced using the rotary anvil 326 of FIG. 44. The depicted portion of the running elastic leg cuff web assembly 302 has multiple elastic regions 416 formed through the restraint region 388 of FIG. 44. The laminated portion 406 forms a laminate bond, after which multiple inelastic regions 418 are formed by breaking or deactivating the elastic strands in the laminated regions (e.g., along separation lines 420) using methods known in the art. Once broken, the ends of the elastic strands contract back toward their respective elastic regions 416. Furthermore, cutting or separating the elastic leg and leg cuff web assembly 302 along the separation lines 420 separates the web into individual leg cuff portions having elastic regions 416 and inelastic regions 418 available for attachment to an assembly with an absorbent core and other elements to form a disposable product, such as a diaper.

[0153] Figure 46 shows a detailed cutaway view of the elastic leg and leg cuff web assembly 302 shown in Figure 45. A plurality of restraining joints 422 formed by restraining projections 396, 398 (shown in Figure 42) capture or restrain the elastic yarn 312 disposed between adjacent joints 422. The joints 422 are formed when the elastic yarn 312 is in a stretched or elongated state. Furthermore, the first web layer 304, which does not itself exhibit elastic properties, is in a smooth or flat state when the elastic yarn 312 is stretched therealong. The separation distance 402 between adjacent restraining projections 396 and / or 398 is sufficient to allow the stretched elastic yarn 312 to be disposed between the restraining projections or their contact surfaces 412 during ultrasonic bonding to form the restraining joints 422. The separation distance is preferably greater than the width of the stretched elastic yarn, but may be less than or equal to the width of the elastic yarn according to embodiments of the present invention.

[0154] The restraining joints 422 secure the elastic yarn 312 in place relative to the bonded web layers affected by the restraining joints 422. Thus, when the tensioned elastic yarn 312 is allowed to return to its untensioned (or untensioned) state, the elastic yarn 312 gathers against the bonded web layers, causing the elastic web to form gathers 424. The untensioned portions of the elastic yarn 312 between adjacent lines of restraining joints 422 have a width or diameter 426 that is wider than the width 402 between adjacent restraining joints 422.

[0155] As further shown in FIG. 46 , the plurality of lamination bonds 428 in the inelastic regions 418 formed by the lamination projections 404 (shown in FIG. 42 ) bond the affected web layers together (e.g., the first web layer 304 with the second web layer 338) without trapping or constraining the elastic yarn 312 between adjacent bonds 428. The separation distance 410 between adjacent restraining projections 404 is sufficient to allow the untensioned elastic yarn 312 to move freely relative to the bonds 428. That is, the separation distance 410 is greater than the diameter 426 of the untensioned elastic yarn 312. When the elastic yarn 312 is cut or broken, the elastic yarn is free to contract toward its untensioned state and retract from its position between adjacent bonds 428 separated in the longitudinal direction 394. Thus, the bonds 428 do not constrain the elastic yarn 312 to cause elastic gathering of the web layers.

[0156] Depending on the operating parameters of the ultrasonic bonding apparatus 324 and / or the geometry and configuration of the notches and protrusions on the anvil 326 and / or horn 328, the resulting pair of adjacent joints 422 may be formed as discrete, discontinuous joints 430 that fuse the opposing web layers 304, 338 together at the joint site 322, as shown in FIG. 47A, or as a continuous fused joint 432 that fuses one or both of the opposing web layers 304, 338 together at the joint site 322, as shown in FIG. 47B. As shown in FIG. 47A, the untensioned diameter 434 of the restrained joint 422 is larger than the tensioned diameter 436.

[0157] FIG. 48 is a schematic diagram of a flattened representation of an exemplary anvil pattern showing constrained bonding zones and / or laminated bonding zones that can be used on the manufacturing lines of FIGS. 29, 34, or 37, according to one exemplary but non-limiting embodiment of the present invention. Similar to that shown in FIG. 44, the anvil of the bonding apparatus 324 is designed to include constrained regions 388 between laminated regions 406. The discrete protrusions of each region 388, 406 have been omitted from FIG. 48 for clarity. The constrained regions 388 and laminated regions 406 on the illustrated side of the rotating anvil 326 may correspond to the cuff regions as shown in FIG. 32. Bonding of the elastic cuff web 334 to the second web layer 338 as shown in FIGS. 29, 33, 34, and 36-38 can be achieved using a bonding pattern according to the pattern shown for the anvil of the bonding apparatus 340 shown in FIG. 48. The restraint region 438, together with the laminate region 440 on the side of the anvil of the joining device 340 opposite the anvil regions 388, 406 of the joining device 324, forms a bond for the leg elastic yarn 336 as described above. Additionally, the laminate region 440 includes a laminate bond that extends toward the cuff elastic side as shown, securing the ends of the elastic assembly to the second web layer 338 across its width beyond the cuff elastic. In this manner, a portion of the elastic assembly 302 is free to move relative to the second web layer 338 (as shown in FIGS. 33, 36, and 38) while its ends remain secured to the second web layer 338. The patterned region of the anvil of the joining device 340 is shown with dashed lines on the anvil of the joining device 324 to illustrate the overlap of the laminate regions 406, 440.

[0158] While the present invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Moreover, while various embodiments of the invention have been described, it should be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the present invention should not be deemed limited by the foregoing description, but is limited only by the appended claims.

Claims

1. a first web including leg elastics, leg folds, cuff elastics, and cuff folds; a leg elastic thread disposed between the leg elastic portion and the leg folded-back portion; a plurality of leg joining portions each forming a joining portion between the leg elastic portion and the leg folded portion, and fixing the leg elastic thread therebetween; a cuff elastic thread disposed between the cuff elastic portion and the cuff folded-back portion; a plurality of cuff joining portions that form respective joining portions between the cuff elastic portion and the cuff folded portion, and fix the cuff elastic thread therebetween; An elastic composite structure, wherein the plurality of leg connections and the plurality of cuff connections are formed without the use of adhesives.

2. The elastic composite structure of claim 1 further comprising a second web adhesively attached to said plurality of leg joints.

3. a pair of leg joints among the plurality of leg joints are disposed on both sides of the leg elastic yarn, The elastic composite structure of claim 1 , wherein each pair of cuff bonds of the plurality of cuff bonds is disposed on opposite sides of the cuff elastic yarn.

4. the pair of leg joints of the plurality of leg joints includes restraint joints spaced apart by a restraint distance that is less than a diameter of the leg elastic yarn in an untensioned state; 4. The elastic composite structure of claim 3, wherein the pairs of cuff interfaces of the plurality of cuff interfaces include restraint interfaces spaced apart by a restraint distance less than a diameter of the cuff elastic yarn in an untensioned state.

5. the plurality of leg joints further include lamination joints spaced apart by a lamination distance greater than the diameter of the leg elastic yarn in the untensioned state; 10. The elastic composite structure of claim 1, wherein the plurality of cuff bonds further comprises lamination bonds spaced apart by a lamination distance greater than the diameter of the cuff elastic yarn in the untensioned state.

6. 1. A method of manufacturing an elastic composite structure, comprising: disposing leg elastic yarns between the leg elastic portions of the first web and the leg folded portions of the first web; forming a plurality of leg joining portions by joining the leg elastic portions to the leg folded portions without using adhesive; disposing a cuff elastic yarn between the cuff elastic portion of the first web and the cuff fold portion of the first web; and forming a plurality of cuff bonds that bond the cuff elastics to the cuff cuff folds without the use of adhesive.

7. The method of claim 6 further comprising adhesively attaching a second web to the first web adjacent the plurality of leg joins.

8. the step of disposing the leg elastic yarn between the leg elastic portion and the leg cuff portion includes folding the leg cuff portion over the leg elastic yarn and the leg elastic portion; 7. The method of claim 6, wherein the step of disposing the cuff elastic yarn between the cuff elastic and the cuff fold comprises folding the cuff fold over the cuff elastic yarn and the cuff elastic.

9. the step of forming the plurality of leg joints includes forming a pair of leg joints among the plurality of leg joints on each side of the leg elastic yarn; The method of claim 6 , wherein the step of forming the plurality of cuff junctions includes forming each cuff junction of a pair of the plurality of cuff junctions on each side of the cuff elastic yarn.

10. separating the pairs of leg joints by a restraining distance that is less than a diameter of the leg elastic yarn in an untensioned state; 10. The method of claim 9, further comprising: spacing the pairs of the plurality of cuff bonds apart by a restraining distance that is less than a diameter of the cuff elastic yarn in an untensioned state.

11. forming the plurality of leg bonds includes forming pairs of lamination bonds spaced apart by a lamination distance greater than a diameter of the leg elastic yarn in an untensioned state; 7. The method of claim 6, wherein forming the plurality of cuff bonds comprises forming pairs of laminate bonds spaced apart by a laminate distance greater than the diameter of the cuff elastic yarn in an untensioned state.

12. 1. An apparatus for forming an elastic composite structure, said apparatus comprising: a plurality of rollers configured to guide a composite web assembly in a machine direction, the composite web assembly comprising: a first web layer including leg elastics, leg folds, cuff elastics, and cuff folds; at least one leg elastic disposed between the leg elastic portion and the leg folded portion; a plurality of rollers, each roller including at least one cuff elastic disposed between the cuff elastic and the cuff fold; A joining device having a horn and an anvil, the horn and the anvil comprising: the leg elastic portions are joined to the leg cuff portions via a plurality of leg joining portions without using adhesive; a joining device configured to join the cuff elastics to the cuff cuff via a plurality of cuff joins without the use of adhesive.

13. The leg folded portion is folded over the leg elastic portion; The device of claim 12, further comprising a folding device configured to fold the cuff fold over the cuff elastic.

14. an adhesive applicator configured to apply adhesive to the leg elastics; 13. The apparatus of claim 12, further comprising a roller assembly configured to press the leg elastics and second web layer together to adhesively bond the leg elastics to the second web layer.

15. each elastic of the at least one leg elastic is disposed between each pair of the plurality of leg joints; 13. The device of claim 12, wherein each elastic of the at least one cuff elastic is disposed between each pair of the plurality of cuff interfaces.

16. the distance between each pair of the plurality of leg joints comprises a restraint distance spaced apart at a distance less than a diameter of the untensioned leg elastic yarn; 13. The device of claim 12, wherein the distance between each pair of the plurality of cuff interfaces comprises a restraint distance spaced apart at a distance less than the diameter of the untensioned cuff elastic yarn.

17. 13. The apparatus of claim 12, wherein the joining device configured to adhesively bond the leg elastics to the leg cuffs is further configured to form stacked pairs of the plurality of leg joins, each stacked pair being spaced apart by a distance greater than the diameter of any one of the at least one leg elastics in an untensioned state.

18. 13. The device of claim 12, wherein the bonding device configured to adhesively bond the cuff elastics to the cuff fold is further configured to form stacked pairs of the plurality of cuff bonds, each stacked pair being spaced apart by a distance greater than the diameter of any one of the at least one cuff elastics in an untensioned state.

19. a first web including leg elastics, cuff elastics, and cuff folds; a cuff elastic thread disposed between the cuff elastic portion and the cuff folded-back portion; a plurality of cuff joining portions that join the cuff elastic portions and the cuff folded portions and fix the cuff elastic thread therebetween; a second web including a leg elastic region; a leg elastic yarn disposed between the leg elastic portion of the first web and the leg folded-back portion of the second web; a plurality of leg joining sections that join the leg elastic sections of the first web and the leg folded-back sections of the second web and fix the leg elastic yarns therebetween, An elastic composite structure, wherein the plurality of leg connections and the plurality of cuff connections are formed without the use of adhesives.

20. a pair of the cuff bond portions among the plurality of cuff bond portions are disposed on either side of the cuff elastic yarn; 20. The elastic composite structure of claim 19, wherein each leg joint of a pair of the plurality of leg joints is disposed on either side of the leg elastic yarn.

21. 21. The elastic composite structure of claim 20, wherein the pair of leg joints of the plurality of leg joints includes restrained joints spaced apart by a restraint distance that is less than a diameter of the leg elastic yarn in an untensioned state.

22. 21. The elastic composite structure of claim 20, wherein the pairs of cuff interfaces of the plurality of cuff interfaces include restraint interfaces spaced apart by a restraint distance less than a diameter of the cuff elastic yarn in an untensioned state.

23. 20. The elastic composite structure of claim 19, wherein the plurality of leg bonds further comprises lamination bonds spaced apart by a lamination distance greater than the diameter of the leg elastic yarn in the untensioned state.

24. 20. The elastic composite structure of claim 19, wherein the plurality of cuff bonds further comprises lamination bonds spaced apart by a lamination distance greater than the diameter of the cuff elastic yarn in the untensioned state.

25. 1. A method of manufacturing an elastic composite structure, comprising: disposing a cuff elastic yarn between the cuff elastic portion of the first web and the cuff fold portion of the first web; forming a plurality of cuff joining portions by joining the cuff elastic portions to the cuff folding portions without using adhesive; disposing leg elastic yarns between the leg elastic portions of the first web and the leg elastic portions of the second web; forming a plurality of leg joints joining the leg elastics of the first web and the leg elastics of the second web without the use of adhesive.

26. the step of forming the plurality of leg joints includes forming a pair of leg joints among the plurality of leg joints on each side of the leg elastic yarn; 26. The method of claim 25, wherein forming the plurality of cuff junctions includes forming each cuff junction of a pair of the plurality of cuff junctions on each side of the cuff elastic yarn.

27. forming each leg bond includes separating the pairs of the plurality of leg bonds by a restraining distance that is less than a diameter of the leg elastic yarn in an untensioned state; 27. The method of claim 26, wherein forming each cuff bond includes separating the pair of the plurality of cuff bonds by a restraining distance that is less than a diameter of the cuff elastic yarn in an untensioned state.

28. 26. The method of claim 25, wherein the step of disposing the cuff elastic yarn between the cuff elastic and the cuff fold comprises folding the cuff fold over the cuff elastic yarn and the cuff elastic.

29. 26. The method of claim 25, wherein the step of disposing the leg elastic yarn between the leg elastic of the first web and the leg elastic of the second web includes folding a portion of the leg elastic of the first web over a portion of the leg elastic of the second web.

30. forming the plurality of leg bonds includes forming pairs of lamination bonds spaced apart by a lamination distance greater than a diameter of the leg elastic yarn in an untensioned state; 26. The method of claim 25, wherein forming the plurality of cuff bonds comprises forming pairs of laminate bonds spaced apart by a laminate distance greater than a diameter of the cuff elastic yarn in an untensioned state.

31. 1. An apparatus for forming an elastic composite structure, comprising: a first plurality of rollers configured to guide a first portion of a composite web assembly in a machine direction, the first portion of the composite web assembly comprising: a first web layer including a cuff elastic portion and a cuff fold portion; a first plurality of rollers including a plurality of cuff elastics positioned between the cuff elastic and the cuff fold; a first joining device having at least one horn and anvil configured to join the cuff elastics to the cuff folds without the use of adhesive via a plurality of cuff joins that constrain the plurality of cuff elastics to the first web layer; a second plurality of rollers configured to guide a second portion of the composite web assembly in a machine direction, the second portion of the composite web assembly comprising: the first web layer including leg elastics; a second web layer including leg elastics; a second plurality of rollers including a plurality of leg elastics disposed between the leg elastics of the first web layer and the leg elastics of the second web layer; a second joining device having at least one horn and anvil configured to join the leg elastics of the first web layer and the leg elastics of the second web layer via a plurality of leg joins that restrain the plurality of leg elastics to the first web layer and the second web layer without the use of an adhesive.

32. the anvil of the first joining device includes an array of discrete projections that join the cuff elastics to the cuff folds such that each cuff elastic of the plurality of cuff elastics is disposed between each pair of the plurality of cuff joining portions; 32. The apparatus of claim 31, wherein the anvil of the second joining device includes an array of discrete protrusions that join the leg elastic portions of the first web layer and the leg elastic portions of the second web layer such that each leg elastic of the plurality of leg elastics is disposed between each pair of the plurality of leg join portions.

33. the distance between each pair of the plurality of leg joints comprises a restraint distance spaced apart at a distance less than a diameter of the untensioned leg elastic yarn; 33. The device of claim 32, wherein the distance between each pair of the plurality of cuff interfaces comprises a constrained distance spaced apart at a distance less than the diameter of the untensioned cuff elastic yarn.

34. 32. The device of claim 31, further comprising a folding device configured to fold the cuff fold over the cuff elastic.

35. 32. The apparatus of claim 31, further comprising a folding device configured to fold a portion of the leg elastic of the first web over a portion of the leg elastic of a second web.

36. 32. The apparatus of claim 31, wherein the first bonding device comprises an ultrasonic horn positioned adjacent the anvil.

37. 32. The apparatus of claim 31, wherein the anvil configured to adhesively join the leg elastics of the first web layer and the leg elastics of the second web layer includes an array of discrete projections extending outward from the face of the anvil to form stacked pairs of the plurality of leg joints, each stacked pair being spaced apart by a distance greater than the diameter of any of the plurality of leg elastics in an untensioned state.

38. 32. The device of claim 31, wherein the anvil configured to adhesively bond the cuff elastics to the cuff folds includes an array of discrete projections extending outward from the face of the anvil to form stacked pairs of the plurality of cuff bonds, each stacked pair being spaced apart by a distance greater than the diameter of any of the plurality of cuff elastics in an untensioned state.

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