Systems and methods for anchoring and constraining elastic strands

Abstract

A system for anchoring and constraining elastic strands within an elastic composite component (12) including a first bonding apparatus (70) and a second bonding apparatus (94). The first bonding apparatus (70) includes a first horn (72) and a first anvil (74) having a first anvil surface to impart a first bonding pattern (138) on an elastic composite component (302 / 308 in fig.12B) to anchor a first plurality of elastic strands (20) between a first web layer (14) and a second web layer (16). The second bonding apparatus (94) includes a second horn (96) and a second anvil (98) having a second anvil surface to impart a second bonding pattern (146) on the elastic composite component (306 / 310 in fig.12B) to constrain a second plurality of elastic strands (28) between a third web layer (26) of the elastic composite component (12) and the first or second web layer (12, 14).

Description

PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 SYSTEMS AND METHODS FOR ANCHORING AND CONSTRAINING ELASTIC STRANDSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 747,752 filed January 21, 2025, which is herein incorporated by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not applicable.BACKGROUND

[0003] The present disclosure relates to absorbent sanitary products, and, more specifically to improved systems and methods of for manufacturing an elastic composite component for use in an absorbent sanitary product by securing curved elastic strands therein.

[0004] Food containers, bags, single-use medical products, absorbent hygiene products, and other disposal products have become a ubiquitous part of our modem lives, which has been accompanied by an increase in the demand of such products in recent years. As a result, manufacturers of consumer products face growing pressure to increase the production quantity and efficiency while preserving or elevating product quality to maintain customer satisfaction. Failure to comply with growing market pressure can result in missed opportunities and loss of market share, as consumers are more likely to choose manufacturers who can provide the products that they desire promptly than those who do not. Moreover, meeting consumer demand fosters brand loyalty and positive customer relationships, which in turn can lead to repeated business and word-of-mouth referrals. Thus, a deep understanding and commitment to fulfilling consumer demand is at the core of a successful and enduring manufacturing enterprise.

[0005] One facet of such an understanding is the consideration of how consumers respond to the form and fit of a product. For example, consumers generally expect products, such as absorbent sanitary products (e.g., diapers), to fit uniformly from one product to the next. Correspondingly, the fit of absorbent sanitary products is often provided, in part, by elastic components incorporated therein, such as elastic threads or strands. These elastic components may be positioned at various- 1 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 locations throughout the product, including in the waistbands, leg cuff regions, and throughout portions of the front and / or back panels of the product.

[0006] Further, elastic strands may be kept under tension between inner and outer layers of an elastic composite component. In such arrangements, the elastic strands are typically secured in position between the inner and outer layers of the elastic composite component by means of an adhesive. However, adhesives that are typically used in the manufacture of absorbent sanitary products are relatively expensive due to the cost of the adhesive itself and the need for complex delivery systems to apply the adhesive during manufacturing. Welding has been used as an alternative to secure elastic strands between the inner and outer layers of elastic composite components, but welding has not been found to be a reliable alternative to adhesive for securing the elastic strands in all absorbent sanitary product locations (e.g., leg cuff regions) due to processing challenges associated with welding non-linear or curved elastic strands. Thus, some conventional welding techniques fail to secure curved elastic strands, which can impact the fit and performance of the final product and lead to diminished consumer satisfaction.

[0007] In addition, many manufacturers desire to produce products with different sizes and / or shapes to meet customer demands. However, the manufacturing machinery that is used in a manufacturing process or line is often specialized for a single product or product size, thus requiring manufacturers to purchase new machinery to accommodate different products. This is especially true for machinery such as bonding apparatuses that include horns and anvils, as anvils typically include specialized surface patterns that are configured to create particular bonding patterns within a product. Failure to use machinery that is compatible with a particular product can result in misaligned elastic strands, which in turn can lead to elevated production costs, additional labor expenditures, and a potential increase in waste due to rejected materials or products. Accordingly, there is typically a high cost for altering a preexisting manufacturing process to produce a different product or a differently sized product if a manufacturer desires to maintain product quality.

[0008] Accordingly, there remains a need for improved systems and methods for fabricating an elastic composite component of an absorbent sanitary product with curved elastic strands that leverages the advantages of welding while mitigating the additional costs associated with the use of adhesive and / or purchasing new, specialized equipment for different products. That is, there- 2 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 remains a need to ensure product quality to maintain consumer satisfaction and minimize manufacturing cost due to material waste and / or capital expenditure.

[0009] The current disclosure addresses these and other issues.SUMMARY

[0010] In one aspect of the disclosure, a system for bonding an elastic composite component, comprising: a first bonding apparatus including a first horn and a first anvil having a first anvil surface, the first anvil surface including an anchoring region defined by a plurality of non-linear continuous ridges; and a second bonding apparatus including a second horn and a second anvil having a second anvil surface, the second anvil surface including a constraining region defined by a plurality of discrete nodules that protrude outward from the second anvil surface; wherein at least one of the plurality of discrete nodules comprises a sidewall that is angled with respect to the second anvil surface at an angle selected to constrain an elastic strand in a selected trajectory.

[0011] The second horn may interact with the plurality of discrete nodules of the second bonding apparatus to form a matrix of constraining bonds that are spaced apart at a distance greater than a distance between adjacent anchoring bonds formed when the first horn interacts with the anchoring region of the first bonding apparatus.

[0012] The sidewall may be angled at an acute angle with respect to the second anvil surface, at an obtuse angle with respect to the second anvil surface, or at a right angle with respect to the second anvil surface.

[0013] The at least one of the plurality of discrete nodules may further comprise a second sidewall that is at one of an acute angle an obtuse angle with respect to the second anvil surface, and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface.

[0014] The at least one of the plurality of discrete nodules may further comprise a second sidewall that is at a right angle with respect to the second anvil surface, and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface. The at least one of the plurality of discrete nodules may further comprise a second sidewall that is at an obtuse angle or a right angle with respect to the second anvil surface,- 3 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface.

[0015] Each of the plurality of discrete nodules may comprise a sidewall that is angled with respect to the anvil surface at an angle selected to maintain an elastic strand in a selected trajectory.

[0016] The system may further comprise: a first web infeed assembly to feed a first web layer in a machine direction toward the first bonding apparatus; a second web infeed assembly to feed a second web layer in the machine direction toward the first bonding apparatus; and at least one tensioning device to provide a first plurality of elastic strands between the first web layer and the second web layer; and wherein the anchoring region of the first anvil surface imparts a nondinear pattern of anchoring bonds on the first web layer, the second web layer, or both to anchor the first plurality of elastic strands between the first web layer and the second web layer. The system may also comprise: a third web infeed assembly to feed a third web layer in a machine direction toward the second bonding apparatus; and at least another tensioning device to feed a second plurality of elastic strands in the machine direction, the second plurality of elastic strands disposed between the third web layer and either the first web layer or the second web layer; and wherein the constraining region of the second anvil surface imparts a matrix of constraining bonds on the third web layer and at least one of the first web layer and the second web layer to constrain the second plurality of elastic strands between the third web layer and either the first web layer or the second web layer. The system may further comprise a strand guide that maintains the first plurality of elastic strands in a substantially straight configuration; and a curved strand laydown guide that guides the second plurality of elastic strands in a curved laydown pattern.

[0017] In another aspect of the disclosure, a system for anchoring and constraining elastic strands within an elastic composite component is provided, the system comprising: a first ultrasonic bonding apparatus including a first horn and a first anvil having a first anvil surface to impart a first bonding pattern on an elastic composite component to anchor a first plurality of elastic strands between a first web layer of the elastic composite component and a second web layer of the elastic composite component; and a second ultrasonic bonding apparatus including a second horn and a second anvil having a second anvil surface to impart a second bonding pattern on the elastic composite component to constrain a second plurality of elastic strands between a third web layer of the elastic composite component and either the first web layer or the second- 4 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 web layer; wherein the first anvil surface comprises a plurality of continuous ridges and the second anvil surface comprises a plurality of discrete nodules, each of the discrete nodules comprising a working surface located above the anvil surface and at least one sidewall extending between the second anvil surface and the working surface.

[0018] At least one sidewall of each of the plurality of discrete nodules angles may be at an acute angle relative to the second anvil surface, at an obtuse angle relative to the second anvil surface, or at a right angle with respect to the second anvil surface.

[0019] The first ultrasonic bonding apparatus may be upstream of the second ultrasonic bonding apparatus in a machine direction, and the second ultrasonic bonding apparatus may be aligned relative to the first ultrasonic bonding apparatus such that the second bonding pattern overlaps the first bonding pattern in the elastic composite component.

[0020] The plurality of continuous ridges may be sinusoidal, and the plurality of continuous ridges may be planar or grooved.

[0021] A working surface of at least one of the first and second horns may be grooved.

[0022] The first plurality of elastic strands may be straight elastic strands, and the first bonding pattern may be configured to anchor the straight elastic strands within the elastic composite component between facing bonds of a pair of anchoring bonds of the first bonding pattern; and wherein the second plurality of elastic strands may be curved elastic strands, and wherein the second bonding pattern may be configured to constrain the curved elastic strands within the elastic composite component within a matrix of constraining bonds; and wherein an unbonded interval between adjacent constraining bonds may be greater than an unbonded interval between adjacent anchoring bonds of the first bonding pattern.

[0023] The system may further comprise: an elastic strand guide that guides the first plurality of elastic strands onto the first web layer or the second web layer in a curved configuration; and a curved strand laydown guide that guides the second plurality of elastic strands onto the first web layer or the second web layer in a curved configuration, wherein the curved strand laydown guide is downstream of the first ultrasonic bonding apparatus and upstream of the second ultrasonic bonding apparatus in a machine direction. The curved strand laydown guide may comprise one or more swinging arms or a crank and arm assembly.- 5 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0024] The first ultrasonic bonding apparatus may be configured to join the first web layer of the elastic composite component and the second web layer of the elastic composite component; and the second ultrasonic bonding apparatus may be configured to join a third web layer to the joined first and second web layers.

[0025] The system may further comprise a third ultrasonic bonding apparatus downstream of the first and second ultrasonic bonding apparatuses in a machine direction, the third ultrasonic bonding apparatus comprising at least one horn that cooperates with a working surface of at least one anvil having a third bonding pattern thereon, the third bonding pattern configured to form intermittent anchoring bond patterns in a machine direction and / or at locations adjacent at least one side seam region of the elastic composite component, The third ultrasonic bonding apparatus may be aligned relative to the first ultrasonic bonding apparatus and / or the second ultrasonic bonding apparatus such that the third bonding pattern overlaps the first bonding pattern and / or the second bonding pattern on the elastic composite component.

[0026] The system may further comprise a bonding apparatus comprising an adhesive applicator, the adhesive applicator being configured to create discrete anchor regions for the second plurality of elastic strands at locations adjacent at least one side seam region of the elastic composite component.

[0027] In yet another aspect of the disclosure, a method of anchoring and constraining elastic strands within an elastic composite component is provided, the method comprising: bonding, with a first bonding apparatus, a first web layer with a second web layer to anchor a first plurality of elastic strands in position relative to the first and second web layers and form a first intermediate product, the first bonding apparatus including a first horn and a first anvil having a first plurality of bonding features arranged on a surface thereof that interact with the first horn to form a first bonding pattern comprising pairs of anchoring bonds that anchor the first plurality of elastic strands; guiding a third web layer and a second plurality of elastic strands onto the first intermediate product; and bonding, with a second bonding apparatus positioned downstream from the first bonding apparatus, the third web layer with the first intermediate product to constrain the second plurality of elastic strands within a curved profile relative to the third web layer and the first intermediate product and form a second intermediate product, the second bonding apparatus including a second horn and a second anvil having a second plurality of bonding features arranged- 6 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 on a surface thereof that interact with the second horn to form a second bonding pattern comprising constraining bonds, wherein the constraining bonds are spaced apart at a distance greater than the pairs of anchoring bonds.

[0028] The first bonding pattern may be a non-linear bonding pattern.

[0029] The second bonding pattern may be a constraining dot bonding pattern.

[0030] The method may further comprise bonding, with a third bonding apparatus, the second intermediate product to anchor the second plurality of elastic strands adjacent a deactivated region of the elastic composite component, to anchor cut ends of the second plurality of elastic strands, or to bond side seam regions of the second intermediate product.

[0031] The bonding the side seam regions of the second intermediate product may include anchoring ends of the first plurality of elastic strands, the second plurality of elastic strands, or both within the side seam regions.

[0032] Guiding the second plurality of elastic strands onto the elastic composite component may include placing the second plurality of elastic strands onto the elastic composite component in a curved configuration using a curved strand laydown guide.

[0033] The method may further comprise forming the second bonding pattern to partially overlap the first bonding pattern.

[0034] In yet another aspect of the disclosure, an elastic composite component is provided, the elastic composite component comprising: a first web layer; a second web layer; a first plurality of elastic strands anchored between the first web layer and the second web layer by a first bonding pattern comprising a non-linear pattern of ultrasonic anchoring bonds; and a second plurality of elastic strands constrained between a third web layer and either the first web layer or the second web layer by a second bonding pattern comprising a matrix of ultrasonic constraining bonds; and wherein an unbonded interval between adjacent constraining bonds of the second bonding pattern is greater than an unbonded interval between adjacent anchoring bonds of the first bonding pattern.

[0035] The first bonding pattern may partially overlap the second bonding pattern.

[0036] The first plurality of elastic strands may be straight elastic strands that are anchored within the elastic composite component between facing bonds of a pair of anchoring bonds; and the second plurality of elastic strands may be curved elastic strands that are constrained in a curved path within the matrix of constraining bonds.- 7 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0037] The second plurality of elastic strands may be further secured within a leg region of the elastic composite component at a plurality of discrete anchor regions, and the discrete anchor regions may comprise one of an adhesive material and a plurality of ultrasonic anchoring bonds.

[0038] The elastic composite component may include discrete anchor regions located adjacent at least one side seam region of the elastic composite component. The discrete anchor regions may be located adjacent a deactivated region of the elastic composite component, and / or adjacent cut ends of the second plurality of elastic strands.

[0039] In still another aspect of the disclosure, a system for bonding an elastic composite component, comprising: an anvil comprising a work surface, the work surface divided into an anchoring region comprising a plurality of continuous ridges configured to anchor an elastic strand, and a constraining region having a plurality of discrete nodules, each of the plurality of discrete nodules comprising a work surface and at least one sidewall extending from the work surface to a surface of the anvil, the plurality of discrete nodules configured to constrain an elastic strand; a first horn located to direct ultrasonic energy to at least a first portion of the anchoring region; and a second horn located downstream of the first horn to direct ultrasonic energy to the constraining region.

[0040] At least one of the plurality of discrete nodules may comprise a sidewall that is angled with respect to the surface of the anvil at an angle selected to constrain an elastic strand in a selected curved trajectory. The sidewall may be angled at an acute angle with respect to the surface of the anvil.

[0041] The system may further comprise a first web infeed assembly and a second web infeed assembly to feed a first web layer a second web layer toward the anvil at a location upstream of the first horn in a machine direction; at least one tensioning device to provide a first plurality of elastic strands between the first web layer and the second web layer; and a third web infeed assembly to feed a third web layer toward the anvil at a location downstream of the first horn and upstream of the second horn in the machine direction; and at least another tensioning device to feed a second plurality of elastic strands in the machine direction, the second plurality of elastic strands disposed between the third web layer and either the first web layer or the second web layer.

[0042] The plurality of continuous ridges may impart a non-linear pattern of anchoring bonds on the first web layer, the second web layer, or both to anchor the first plurality of elastic strands- 8 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 between the first web layer and the second web layer, and the plurality of discrete nodules may impart a constraining dot bonding pattern on the third web layer and at least one of the first web layer and the second web layer to constrain the second plurality of elastic strands between the third web layer and either the first web layer or the second web layer.

[0043] The system may further comprise a strand guide that maintains the first plurality of elastic strands in a substantially straight configuration; and a curved strand laydown guide that guides the second plurality of elastic strands in a curved laydown pattern.

[0044] The second horn may be located to direct ultrasonic energy to a second portion of the anchoring region.

[0045] In yet still another aspect of the disclosure, a method of anchoring and constraining elastic strands within an elastic composite component is provided. The method comprises: bonding a first web layer with a second web layer to form a first bonding pattern that anchors a first plurality of elastic strands in position relative to the first and second web layers and form a first intermediate product via interaction between a first horn and an anchoring region of a first anvil of a first bonding apparatus, the anchoring region comprising a plurality of continuous ridges; guiding a third web layer and a second plurality of elastic strands onto the first intermediate product at a location downstream of the first hom; and bonding the third web layer with the first intermediate product to form a second bonding pattern that constrains the second plurality of elastic strands within a curved profile relative to the third web layer and the first intermediate product and form a second intermediate product via interaction between a second hom and a constraining region of the first anvil of the first bonding apparatus, the constraining region having a plurality of discrete nodules, each of the plurality of discrete nodules comprising a work surface and at least one sidewall extending from the work surface to a surface of the anvil.

[0046] The first bonding pattern may be a non-linear bonding pattern. The second bonding pattern may be a constraining dot bonding pattern.

[0047] The method may further comprise bonding, with a second bonding apparatus, the second intermediate product to bond side seam regions of the second intermediate product, to anchor the second plurality of elastic strands adjacent a deactivated region of the elastic composite component, and / or to anchor cut ends of the second plurality of elastic strands. Bonding the side- 9 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 seam regions of the second intermediate product may include anchoring ends of the first plurality of elastic strands, the second plurality of elastic strands, or both within the side seam regions.

[0048] Guiding the second plurality of elastic strands onto the elastic composite component may include placing the second plurality of elastic strands onto the elastic composite component in a curved configuration using a curved strand laydown guide.

[0049] The method may further comprise forming the second bonding pattern to partially overlap the first bonding pattern.

[0050] In embodiments, one or more rotary or blade-style ultrasonic horns with a smooth or grooved work surface might be used in combination with one or more opposing anvils having a grooved working surface such that the waist elastic strands are fed under tension in the feed direction between the grooves formed in the working surface of the anvil(s) and any grooves in the working surface of the horn(s) so as to allow welding of the respective top and back sheet strips to each other on opposing sides of each of the waist elastic strands intermittently in the feed direction.

[0051] Anchoring bonds are formed when the working surfaces of the horn(s) and anvil(s) engage sheets located on opposite sides of the elastic strands to melt and at least partially encapsulate the elastic strands and / or frictionally engage the elastic strands in position relative to the facing sheets welds. The resulting anchoring bonds may be pairs of welds that are positioned on opposing sides of a given elastic strand and that, in some embodiments, partially overlap the given elastic strand, or as a singular weld or pair of welds that span(s) at least the width of the elastic strand. The anchoring (i.e., entrapment) of the waist elastic strands relative to the facing sheets provides the required elastication in waist sections of the resultant torso encircling portions.

[0052] Constraining bonds are formed when the working surfaces of the horn(s) and anvil(s) engage sheets at locations proximate curved elastic strands to define a matrix of bond points in the facing sheets welds, with adjacent bond points spaced at a great enough distance so they do not encapsulate the elastic strands or form pairs of bonds that frictionally engage the elastic strands in position relative to the facing sheets. Rather, the constraining bonds define a passageway that constrains the curved elastic strand within a desired curved path.- 10 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0053] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The features, aspects and advantages of the disclosure will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings.

[0055] FIG. 1 is a top view of a pant-style diaper product incorporating elastic composite components manufactured in accordance with the present disclosure.

[0056] FIG. 2 is a cross-sectional view of a first torso construction of the product of FIG. 1 taken along line 2-2 of FIG. 1.

[0057] FIG. 3A is a cross-sectional view of an alternative torso construction of the product of FIG. 1 taken along line 3A-3A of FIG. 1.

[0058] FIG. 3B is a cross-sectional view of another example second torso portion of the product of FIG. 1 taken along line 3A-3A of FIG. 1.

[0059] FIG. 3C is a cross-sectional view of the example second torso portion of FIG. 3A taken along line 3C-3C of FIG. 1.

[0060] FIG. 4 is a schematic view of a portion of a manufacturing process for fabricating the product of FIG. 1.

[0061] FIG. 5 is a schematic view of another portion of the manufacturing process of FIG. 4 for fabricating the product of FIG. 1.

[0062] FIG. 6 is a detail view of a first example anvil surface defining a sinusoidal ridge pattern.

[0063] FIG. 7 is a detail view of a second example anvil surface defining an example constraining dot pattern.

[0064] FIG. 8 is a detail view of a third example anvil surface defining another example constraining dot pattern.

[0065] FIGS. 9A-9D are cross-sectional views of bonding nodules on a fourth example anvil surface.- 11 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0066] FIG. 10 is a flow chart of a method of anchoring and constraining elastic strands within an elastic composite component according to one example.

[0067] FIGS. 11-12B are schematic representations of portions of an elastic composite component during portions of a manufacturing method forming patterns of anchoring and constraining bond patterns.

[0068] FIGS. 13 and 14 are schematic representation of portions of an elastic composite component during a portion of a manufacturing method forming intermittent anchoring bond pattern regions, according to alternative examples.

[0069] FIG. 14A is a detail view of a portion of the elastic composite component of FIG. 14.

[0070] FIGS. 15 and 16 are schematic representations of portions of an elastic composite component during portions of a manufacturing method forming patterns of anchoring and constraining bond patterns according to another example.

[0071] FIGS. 15A and 16B are cross-sectional views of the elastic composite component represented in FIGS. 15 and FIG. 16, respectively.

[0072] FIG. 15B is a cross-sectional view of the elastic composite component represented in FIG. 15 according to another example.

[0073] FIG. 16B is a detail view of a portion of the elastic composite component of FIG. 16.

[0074] FIGS. 17 and 18 are schematic representation of portions of an elastic composite component during a portion of a manufacturing method forming intermittent anchoring bond patterns, according to alternative examples.

[0075] FIGS. 17A and 18A are detail views of a portion of the elastic composite component of FIG. 17 and FIG. 18, respectively.

[0076] FIG. 19 is a schematic view of a portion of a manufacturing process for fabricating the product of FIG. 1 according to another example.

[0077] FIG. 20 is a detail view of an example anvil surface defining an example constraining pattern and an example anchoring pattern.

[0078] FIGS. 21 and 22 are schematic representations of portions of an elastic composite component during portions of a manufacturing method forming patterns of anchoring and constraining bond patterns according to another example.- 12 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0079] FIGS. 21 A and 22A are cross-sectional views of the elastic composite component represented in FIG. 21 and FIG. 22, respectively.

[0080] FIG. 23 is a schematic representation of portions of an elastic composite component during a portion of a manufacturing method forming intermittent anchoring bond patterns.

[0081] FIG. 24 is a schematic representation of a portion of an elastic composite component during a portion of a manufacturing method forming patterns of anchoring and constraining bond patterns according to another example.

[0082] FIG. 24A is a cross-sectional view of the elastic composite component of FIG. 24.

[0083] FIG. 25 is a schematic representation of portions of an elastic composite component during a portion of a manufacturing method forming intermittent anchoring bond patterns.

[0084] FIG. 26 is a schematic representation of a portion of an elastic composite component during a portion of a manufacturing method forming patterns of anchoring and constraining bond patterns and intermittent anchoring bond patterns according to another example.

[0085] FIG. 25B is a detail view of a portion of the elastic composite component of FIG. 25.

[0086] FIG. 26 is a schematic representation of a portion of an elastic composite component during a portion of a manufacturing method that forms patterns of anchoring and constraining bond patterns and includes optional adhesive regions according to another example.

[0087] FIG. 27 is a schematic representation of a portion of an elastic composite component during a portion of a manufacturing method that forms patterns of anchoring and constraining bond patterns and intermittent anchoring bond patterns according to another example.

[0088] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.DETAILED DESCRIPTION

[0089] As generally mentioned above, the present disclosure relates to systems and methods for securing elastic strands in manufactured articles or components. In some examples, manufactured components can include non-disposable or disposable products such as, for example, paper products, plastic products, medical products, hygiene products, outdoor products, sporting good products, etc. Such components may incorporate an elastic composite component comprising one or more continuous web layers and one or more elastic strands. For example, an elastic- 13 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 composite component may be provided, in part, as a waistband for an absorbent sanitary product (e.g., a diaper, disposable adult pant, or feminine care product) that includes activated or elasticized zones and deactivated or inelastic zones.

[0090] In conventional folding processes, web layers and elastic strands can be provided to one or more idler rollers to arrange the web layers and elastic strands into an elastic composite component. An elastic composite component can be fed into a bonding apparatus to bond or weld the web layers to one another and sandwich the elastic strands therebetween. However, conventional mechanical bonding techniques often fail to account for curved elastic strands, which can require bonding patterns that are different than bonding patterns that are used to hold straight elastic strands in place. Additionally, known methods of welding elastic strands between facing web layers can cause curved elastic strands to break during the bonding process, lose tension and / or become disordered within an elastic composite component, thereby impacting the performance of the final product. This in turn can result in a variety of undesirable consequences to manufacturers and consumers, as discussed above.

[0091] The present disclosure can provide improvements upon conventional techniques for manufacturing elastic composite components that include curved elastic strands. In particular, the present disclosure relates to improved bonding systems that are capable of securing curved elastic strands without any adhesive or with minimal use of adhesive regardless of strand arrangement or product size. More specifically, the present disclosure relates to bonding patterns provided by projections on bonding surfaces (e.g, surfaces of anvils and / or horns that come into contact with web layers of an elastic composite component) that are configured to secure curved elastic strands within an elastic composite component.

[0092] Referring now to FIGS. 1-3C, an example pant-style diaper product 10 is illustrated in a laid-open position. Product 10 includes a pair of torso encircling portions, referred to hereafter as first torso portion 34 and second torso portion 36, each of which incorporates facing web layers with one or more elastic strands therebetween. First torso portion 34 may function as the front waistband of the product 10 and second torso portion 36 may function as the rear waistband of the product 10. The manufacture of second torso portion 36 is described in detail herein. However, one skilled in the art will recognize that first torso portion 34 may be made in a similar manner- 14 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 and / or as part of the same process as part of a wider composite structure and slit apart from second torso portion 36 in a downstream processing step.

[0093] Second torso portion 36 includes an elastic composite component 12 having a first web layer 14 and a second web layer 16, which can be materials that are capable of fusing to one another upon application of an applied energy that causes one or both of the first and second web layers 14, 16 to soften or melt and join together without the use of an intermediate layer of adhesive material (e.g., glue). Further, the first and second web layers 14, 16 may comprise the same type of material or different materials. As non-limiting examples, the first and second web layers 14, 16 may include nonwoven materials, woven materials, films, foams, and / or composites or laminates of any such materials. A first plurality of elastic strands 20 can be disposed between the first and second web layers 14, 16 to provide the product 10 with particular elastic qualities. The first plurality of elastic strands 20 may be provided as substantially straight elastic strands positioned to provide a desired elastic profile for the waist region of the product 10. In some examples, bonding the first web layer 14 to the second web layer 16 entraps (i.e., anchors) the first plurality of elastic strands 20 within the elastic composite component 12 without the use of an intermediate layer of adhesive material (e.g., glue).

[0094] Optionally, a second plurality of elastic strands 24 can be disposed between the first and second web layers 14, 16 to provide the product 10 with particular elastic qualities. For example, the second plurality of elastic strands 24 may be provided as substantially straight elastic strands to define a desired elastic profile for the belly region of product 10. It is contemplated that the second plurality of elastic strands 24 may have similar or differing elastic properties and / or spacing of the first plurality of elastic strands 20. In some examples, bonding the first web layer 14 to the second web layer 16 entraps (i.e., anchors) the second plurality of elastic strands 24 within the elastic composite component 12.

[0095] The first and second pluralities of elastic strands 20, 24 may be composed of any suitable elastic material including, for example, sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or LYCRA, as non-limiting examples. Each elastic strand 20, 24 may be provided in the form of an individual elastomeric strand or be a manufactured multi-filament product that includes many individual elastomeric filaments joined together (e.g., using a dry-spinning manufacturing process) to form a single, coalesced elastic strand 20, 24.- 15 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 Further, the elastic strands 20, 24 may have any suitable cross-sectional shape that facilitates formation of an elastic composite component having desired elasticity, visual aesthetic, and manufacturability qualities as discussed above. For example, the elastic strands 20, 24 may each have a cross-sectional shape that is round, rectangular, square, or irregular, as may be the case where each elastic strand 20, 24 is a multifilament product.

[0096] In some examples, the elastic composite component 12 can further include a third web layer 26 and / or a third plurality of elastic strands 28, which may be provided as curved elastic strands to improve the fit of the product 10 in a leg region 40, as will be discussed below. Similar to the first and second elastic strands 20, 24, the third elastic strands 28 may comprise any suitable elastic material including, for example, sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or LYCRA, as non-limiting examples. The third web layer 26 may be capable of being bonded to the first web layer 14 and / or the second web layer 16 to constrain the third plurality of elastic strands 28 within the elastic composite component 12. For example, and with reference to FIGS. 3A-3C, the third web layer 26 is capable of fusing to the second web layer 16 upon application of an applied energy that causes one or both of the second and third web layers 16, 26 to soften or melt and join together without the use of an intermediate layer of adhesive material (e.g., glue). An optional adhesive material 32 can be disposed on one or both sides of the third plurality of elastic strands 28 to adhere the third plurality of elastic strands 28 in place at select regions within the elastic composite component 12.

[0097] As illustrated in FIG. 3A, the third web layer 26 may be bonded to the second web layer 16 to constrain the third plurality of elastic strands 28 therebetween. That is, the second web layer 16 may separate the second plurality of elastic strands 24 from the third plurality of elastic strands 28. In an alternative construction of the product 10, the first web layer 14 can be bonded directly to the third web layer 26 such that the second plurality of elastic strands 24 are positioned in line with the third plurality of elastic strands 28, as illustrated in FIG. 3B. Thus, it will be understood that the third plurality of elastic strands 28 may be located within several different locations within the product 10 based on design specifications and / or desired material usage. In a side seam region 44 A, 44B of the product 10, the third plurality of elastic strands 28 may overlap with the second plurality of elastic strands 24 in the thickness direction T of the product 10, as illustrated in FIG. 3C.- 16 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0098] It is contemplated that the elastic composite component 12 can be included in any suitable product, such as those discussed above. In the illustrated non-limiting example in FIG. 1, the product 10 is provided as a disposable hygiene (e.g., a pant-style diaper) with different regions shaped and configured to correspond to different areas of a user’s body. The elastic composite component 12 may define particular regions of the product 10, such as a first torso portion 34 and a second torso portion 36, which can be configured to cover opposite sides of a user’s torso when the product 10 is worn. Further, the first torso portion 34 may define a first waist region 38A, and the second torso portion 36 may define a second waist region 38B, a belly region 39, and a leg region 40. As illustrated in FIGS. 1 and 2, the first waist region 38A can be made by coupling (e.g., bonding, welding, and / or adhering) the first web layer 14 to the second web layer 16. In some examples, an outer edge 42A of the first web layer 14 is folded over and trapped between an outer edge 42B of the second web layer 16, which can provide a smooth, finished edge of the first waist region 38 A. Outer edges 42A and 42B may be folded over or under one another in alternative orientations or remain unfolded in alternative embodiments. During manufacture of the product 10, the first plurality of elastic strands 20 can be anchored between the first and second web layers 14, 16, as will be discussed below.

[0099] In some examples, the first plurality of elastic strands 20 can be substantially straight elastic strands that extend throughout the first waist region 38A to allow the first waist region 38A to serve, in part, as a waistband portion of the product 10 that stretches around a user’s waist when worn. In the illustrated non-limiting example, the first torso portion 34 is provided as a substantially rectangular shape, and the first plurality of elastic strands 20 extend in a direction that is substantially parallel with respect to a width W of the first torso portion 34. However, it is contemplated that first torso portion 34 may be provided in any suitable shape, and include curved or wavy waist and / or leg edges. Further, all or a subset of the first plurality of elastic strands 20 may extend in a non-linear or curved path across the width W of the first torso portion 34. The first plurality of elastic strands 20 can be equidistantly spaced apart from one another in a direction that is parallel with respect to the width W of the first torso portion 34, or the first plurality of elastic strands 20 can be spaced apart from one another at varying distances to alter the elastic profile of the first waist region 38A.- 17 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0100] The first plurality of elastic strands 20 can be secured between the first and second web layers 14, 16 at any location(s) within the first torso portion 34. In some examples, a first bonding pattern (e.g., a non-linear bonding pattern such as, for example, a wave-like or sinusoidal bonding pattern) of discrete bonds is imparted on the first web layer 14 to entrap or anchor the first plurality of elastic strands 20 therein, as will be discussed below. In addition, the first plurality of elastic strands 20 may be secured at either side of the first torso portion 34 (z.e., ends of the first torso portion 34 between which the width W is measured) by first and second side seam regions 44A, 44B, which can extend in a direction that is substantially parallel with respect to the width W of the first torso portion 34. The first and second side seam regions 44A, 44B may be regions of the first torso portion 34 is coupled to the second torso portion 36 (e.g. , via bonding, welding, adhering, etc.).

[0101] Further, the first torso portion 34 is coupled to the second torso portion 36 by a crotch portion 46. Specifically, the crotch portion 46 can extend between the first waist region 38A of the first torso portion 34 and the leg region 40 of the second torso portion 36, thereby bridging the torso portions 34, 36 of the product 10. In some examples, the crotch portion 46 includes a liquid permeable layer on an upper surface 48 thereof, one or more absorbent layers (not shown), and an outer, liquid impermeable layer on an underside (not shown) thereof.

[0102] With continued reference to FIG. 1, the second waist region 38B may be similar in some aspects to the first waist region 38A. In some examples, the second waist region 38B, the belly region 39, and / or the leg region 40 can be created by coupling (e.g., bonding, welding, and / or adhering) the first web layer 14 to the second web layer 16 in a similar manner as described above. With additional reference to FIG. 3A, an outer edge 42C of the first web layer 14 is folded over and trapped between an outer edge 42D of the second web layer 16, which can provide a smooth, finished edge of the first waist region 38A. Outer edges 42C and 42D may be folded over or under one another in alternative orientations or remain unfolded in alternative embodiments. During manufacture of the product 10, the second plurality of elastic strands 24 can be anchored or constrained between the first and second web layers 14, 16 or between the first and third web layers 14, 26, as will be discussed below.

[0103] The second plurality of elastic strands 24 may be similar to the first plurality of elastic strands 20, meaning that the second plurality of elastic strands 24 can be substantially straight- 18 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 strands that allow the second waist region 38B to serve, in part, as a belly portion of the product 10 that stretches around a user’s abdomen when worn. Further, the second plurality of elastic strands 24 may be secured within the second torso portion 36 via the first bonding pattern and / or at either side of the second torso portion 36 ( / .<?., ends of the second torso portion 36) in the first and second side seam regions 44 A, 44B.

[0104] The second waist region 38B and / or the leg region 40 can be made of the third web layer 26 as well, the third web layer 26 being coupled (e.g., bonded, welded, adhered, etc.) to the second web layer 16 and constraining the third plurality of elastic strands 28 within the elastic composite component 12. In some examples, the third plurality of elastic strands 28 can be substantially curved elastic strands to allow the leg region 40 to receive (e.g., to conform to the shape of) a user’s legs when worn. In the illustrated non-limiting example, the leg region 40 can define, in part, a curved (e.g., concavely and / or convexly curved) outer profile, and the third plurality of elastic strands 28 can follow the curved profile of the leg region 40. That is, the third plurality of elastic strands 28 may define one or more concave and / or convex curves to match the outer profile of the leg region 40.

[0105] The third plurality of elastic strands 28 can be secured with the elastic composite component 12 (e.g., between the second and third web layers 16, 26) at any location(s) within the leg region 40. In some examples, a second bonding pattern (e.g., a constraining dot bonding pattern) is imparted on the second and / or third web layers 16, 26 to constrain the third plurality of elastic strands 28 between the second and third web layers , as will be discussed below. In addition, the third plurality of elastic strands 28 may be secured at the first and second side seam regions 44A, 44B, along with the second plurality of elastic strands 24. In some aspects, the third plurality of elastic strands 28 are further secured within the leg region 40 at one or more optional discrete anchor regions 50 via adhesive material 32. For example, the third plurality of elastic strands 28 may be secured at optional anchor regions 50 that are located adjacent both side seam regions 44A, 44B and on opposing edges of the crotch portion 46 (e.g., segments of the crotch portion 46 that overlap the leg region 40). The anchor regions 50 may be areas where the third web layer 26 is coupled (e.g., bonded, welded, adhered, etc.) to the second web layer 16. In regions of the product 10 where the crotch portion 46 overlaps with the torso portions 34, 36, the pluralities of elastic- 19 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 strands 20, 24, 28 may be deactivated (e.g., severed, deadened or otherwise treated to reduce or eliminate elasticity thereof) within the crotch portion 46 to prevent bunching therein.

[0106] Referring now to FIG. 4, a portion of an exemplary manufacturing process 52 is illustrated that can be used to fabricate the elastic composite component 12. As shown, the first web layer 14 can be provided by a first web infeed assembly 54, and the second web layer 16 can be provided by a second web infeed assembly 56. Together or separately, the web layers 14, 16 can be fed by the respective web infeed assemblies 54, 56 in amachine direction 58 (i.e., a direction corresponding to the width W of the elastic composite component 12). In particular, the web layers 14, 16 can be provided to one or more feeding assemblies (e.g., a first guide roller 60 to receive the first web layer 14, a second guide roller 62 to receive the first web layer 14 and / or the second web layer 16, and / or a third guide roller 64) to further direct and / or tension the web layers 14, 16 along the machine direction 58. Further, the second guide roller 62 can receive the first plurality of elastic strands 20 and / or the second plurality of elastic strands 24, which can be provided along the machine direction 58 and kept under tension by one or more creel assemblies 66 or similar tensioning device(s).

[0107] With continued reference to FIG. 4, the elastic strands 20, 24 can be received by one or more optional strand guides 68 (e.g., a guide roller, a comb guide, a brush guide, a non-rotary flat plate guide that includes grooves, individual eyelets for each strand, individual bearing rollers for each strand, a groove-free roller with a compliant or smooth surface, one or more tubes that receive the strands, etc.) that is configured to direct and / or tension the elastic strands 20, 24 as they move in the machine direction 58. In the illustrated non-limiting example, the strand guide 68 can define a plurality of grooves in which to receive the elastic strands 20, 24 and space individual strands apart from one another. That is, the strand guide 68 can maintain the elastic strands 20, 24 in a desired spacing e.g., a substantially straight) configuration, which can help provide uniform elastic properties across different products that are fabricated using the manufacturing process 52, such those discussed above with respect to the waist regions 38A, 38B of the product 10 (see FIG.1).

[0108] In addition, the strand guide 68 can provide the elastic strands 20, 24 to the second guide roller 62 such that the elastic strands 20, 24 are positioned or sandwiched between the first web layer 14 and the second web layer 16 to define the elastic composite component 12. Put- 20 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 another way, the elastic strands 20, 24 can be captured between the first and second web layers 14, 16 as the web layers 14, 16 and the elastic strands 20, 24 wrap around the second guide roller 62. While the first web layer 14 and the second web layer 16 are illustrated and described herein as physically separate components, it is contemplated that some examples may utilize a unitary web structure that is folded to capture the elastic strands 20, 24 between upper and lower layers of the unitary web structure. In such an example, the portion of the unitary structure positioned on a first side of (z.e., below) the elastic strands 20, 24 may be referred to as the first web layer 14 and the portion of the unitary structure positioned on a second side of (z.e., above) the elastic strands 20, 24 may be referred to as the second web layer 16.

[0109] Furthermore, the one or more feeding assemblies (e.g., the guide rollers 60, 62 and the elastic strand guide 68) can be positioned along the manufacturing process 52 to accurately arrange and / or tension the elastic composite component 12 as it travels in the machine direction 58. In some examples, the third guide roller 64 is positioned downstream of the second guide roller 62 to further tension the elastic composite component 12 before it is received by a first bonding apparatus 70. That is, the guide rollers 60, 62, 64 may define an S-wrap web path in which the elastic composite component 12 wraps around the second guide roller 62 (e.g., around a portion of the second guide roller 62 and / or a first predefined number of degrees of wrap) and also wraps around third guide roller 64 (e.g., around a portion of the third guide roller 64 and / or a second predefined number of degrees of wrap). In some examples, each of the first and second predefined number of degrees of wrap may be between about 60 degrees and about 240 degrees, or between about 90 degrees and about 180 degrees, or between about 90 degrees and about 150 degrees, or between about 110 degrees and about 130 degrees, or about 120 degrees. In some aspects, the first and second predefined number of degrees of wrap are accomplished by locating the second guide roller 62 closer to the first bonding apparatus 70 than the first guide roller 60 and / or the third guide roller 64 with respect to the machine direction 58. Such an arrangement can optimize the tension of the web layers 14, 16 and the elastic strands 20, 24 anchored therein before the elastic composite component 12 enters the first bonding apparatus 70, which can help promote rethreading of the elastic strands 20, 24 in case of severance during bonding. For example, if an elastic strand 20, 24 break occurs, severed ends of the elastic strand(s) 20, 24 are prevented from retracting upstream- 21 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 of the second guide roller 62 due to the friction and / or pressure between the web layers 14, 16 and the elastic strand(s) 20, 24.

[0110] Still referring to FIG. 4, the elastic composite component 12 can be fed from the third guide roller 64 to the first bonding apparatus 70 along the machine direction 58. It is contemplated that the first bonding apparatus 70 may be implemented using any known ultrasonic welding system such as, for example, rotary ultrasonic welding systems and / or blade ultrasonic welding systems. In the illustrated non-limiting example, the first bonding apparatus 70 can include one or more first ultrasonic blade or rotary horns 72 (e.g., a sonotrode) and one or more first rotary anvils 74 that are arranged in an opposing configuration with one another. In some examples, the first horn 72 and / or the first anvil 74 are moveable with respect to one another such that a distance or clearance therebetween can be adjusted. For example, the first horn 72 and the first anvil 74 may be distanced sufficiently close to one another to effect a weld, or the first horn 72 and the first anvil 74 may be in contact with each other such that no clearance exists therebetween. In some aspects, a gap can be defined between the first horn 72 and the first anvil 74, and the size of the gap may be determined based on parameters of the manufacturing process to facilitate bonding between the web layers 14, 16 without damaging the elastic composite component 12, as discussed below. In some aspects, the first horn 72 can define a working surface 76 that opposes the first anvil 74, and the working surface 76 of the first horn 72 may define a plurality of horn grooves thereon that are substantially parallel with respect to the machine direction 58. In other embodiments the working surface 76 of the horn 72 is smooth (i.e., un-grooved). In either case, working surface 76 cooperates with the anvil 74 to form discrete welds in the elastic composite component 12.

[0111] Further, the working surface 76 of the first horn 72 can be arranged opposite to a first anvil surface 78 defined by the first anvil 74 (e.g., a circular or curved surface). An arrangement of discrete bonding features protrude outward from the first anvil surface 78 to define a first bonding pattern thereon. In some examples, the bonding features are continuous ridges that extend across a length of the first anvil surface 78 in a direction generally parallel with the axis of rotation of the anvil. These ridges may have planar working surfaces or grooved working surfaces. In either case, the horn 72 and anvil 74 cooperate to form discrete bonds between the first and second web layers 14, 16 that anchor the elastic strands 20, 24 (i.e., straight elastic strands) within the elastic composite component 12. To accomplish this, the first anvil surface 78 can include any suitable- 22 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 pattern of ridges that extends outward therefrom to form the first bonding pattern on the elastic composite component 12 (e.g., a sinusoidal wave pattern, a linear pattern, a non-linear pattern, a constraining pattern of dots or other geometric shapes, a random pattern, and / or a graphic image pattern), as will be discussed below in greater detail.

[0112] During bonding, the elastic composite component 12 can be received between the first horn 72 and the first anvil 74, which can cooperate with one another to bond or fuse the elastic composite component 12. That is, the first horn 72 and first anvil 74 can be positioned in an opposing configuration relative to one another to facilitate ultrasonic bonding the first and second web layers 14, 16 while the elastic strands 20, 24 are tensioned. Specifically, the working surface 76 of the first horn 72 can selectively contact the first anvil surface 78 of the first anvil 74 to impart the first bonding pattern on the elastic composite component 12. During bonding, the first and second web layers 14, 16 can be exposed to an ultrasonic emission from the first horn 72 (e.g., on the working surface 76 of the first horn 72) that increases the vibration of the particles in the first and second web layers 14, 16. In this way, the first horn 72 can melt the first web layer 14 with or to the second web layer 16 and anchor the first plurality of elastic strands 20 and, in some embodiments, anchor the second plurality of elastic strands 24 within the elastic composite component 12. Simultaneously, the first anvil 74 can be rotated such that the first anvil surface 78 contacts and imparts the first bonding pattern on the elastic composite component 12. In this way, the ultrasonic emission or energy can be concentrated at specific bond points where frictional heat fuses the first and second web layers 14, 16 together, which can eliminate the need for consumable adhesives.

[0113] While first bonding apparatus 70 is described herein as an ultrasonic bonding assembly that ultrasonically fuses the first web layer 14 to the second web layer 16, it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse together two or more material layers without the use of adhesive, including sonic bonding techniques, thermal bonding techniques, pressure bonding techniques, and / or other suitable forms of welding.

[0114] With continued reference to FIG. 4, the bonded elastic composite component 12 can exit the first bonding apparatus 70 and continue downstream along the machine direction 58. As discussed above, the third web layer 26 and the third plurality of elastic strands 28 can be added- 23 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 to the elastic composite component 12 during fabrication of the product 10 to provide additional elastic qualities (e.g., elastic qualities for the leg region 40 of the product 10, see FIG. 1). In some examples, the third web layer 26 can be provided by a third web infeed assembly 86 to a fourth guide roller 88 arranged along the manufacturing process 52, and the fourth guide roller 88 can be configured to direct and / or tension the third web layer 26 along the machine direction 58 and through the manufacturing process 52. The optional adhesive material 32 may be applied via optional adhesive applicator 33 to the third web layer 26 as it exits the third web infeed assembly 86 and travels to the fourth guide roller 88, which may aid in securing the third elastic strands 28 and / or bonding the side seam regions 44A, 44B of the product (see FIG. 1). It is to be appreciated that the adhesive applicator 33 may be configured in various ways, such as for example, as a spray nozzle and / or a slot coating device. In addition, the fourth guide roller 88 can receive the third plurality of elastic strands 28, which can be provided along the machine direction 58 and kept under tension by one or more second creel assembly(ies) 90 or similar tensioning device(s). In some examples, the second plurality of elastic strands 24 can be fed from a creel assembly (not shown) located downstream from bonding apparatus 70 such that second plurality of elastic strands 24 are received with the third web layer 26 and the third plurality of elastic strands 28 on the fourth guide roller 88 instead of at the upstream location relative to first bonding apparatus 70 shown in FIG. 4. In some examples, the second plurality of elastic strands 24 are omitted entirely.

[0115] Further, the third elastic strands 28 may be placed or laid down on the third web layer 26 before the third web layer 26 and the third elastic strands 28 are combined with the elastic composite component 12, or the third elastic strands 28 can be laid down directly on the elastic composite component 12. To accomplish this, the second creel assembly 90 can provide the third elastic strands 28 to a curved strand laydown guide 92, which can be configured to apply the third elastic strands 28 in a particular pattern (e.g., a curved, sinusoidal, and / or wave pattern) on the elastic composite component 12 and / or the third web layer 26. For example, the curved strand laydown guide 92 may be provided as one or more swinging arms that can be include eyelets to receive individual strands of the third elastic strands 28. The swinging arms can be programmed to move in a predetermined pattern (e.g., oscillating from side to side), and the eyelets can pull the third elastic strands 28 according to the motion of the swinging arms. In this way, the curved strand laydown guide 92 can adjust the curvature of the third elastic strands 28 while applying the same- 24 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 to the third web layer 26. The swinging arms can also be maintained in a constant position to apply the third elastic strands 28 in a substantially straight configuration, if desired.

[0116] The curved strand laydown guide 92 may also be provided as a crank and arm assembly which can include an arm coupled to laydown carriage having eyelets and / or hooks to receive the third elastic strands 28. The support arm can be oscillated by a crank to apply the third elastic strands 28 in a curved configuration on the elastic composite component 12 and / or the third web layer 26. In some examples, the curved strand laydown guide 92 can be operated or programmed to apply the third elastic strands 28 in a particular curved pattern, such as the curved configuration illustrated in FIG. 1. In addition, the curved strand laydown guide 92 can be configured to adjust spacing between and / or curvature of individual strands by adjusting the position of individual eyelets that receive the third elastic strands 28. It is contemplated that the positions of the eyelets of the curved strand laydown guide 92 may be preset prior to receiving the third elastic strands 28, or the positions of the eyelets can be dynamically adjusted during strand laydown to provide the third elastic strands 28 in particular arrangements (e.g, wave-like and / or sinusoidal patterns). Thus, the curved strand laydown guide 92 may be provided as any suitable assembly for applying the third elastic strands 28 in a curved configuration, such as the assemblies described in U.S. Pat. No. 11,34,543, which is incorporated by reference herein in its entirety.

[0117] Still referring to FIG. 4, the third web layer 26 and the third elastic strands 28 (and in some examples, the second elastic strands 24) can be placed onto the elastic composite component 12 as they exit the fourth guide roller 88, and the resulting elastic composite component 12 can be provided to a second bonding apparatus 94 along the machine direction 58. The fourth guide roller 88 can be positioned directly upstream of the second bonding apparatus 94 to minimize the distance travelled by the elastic composite component 12 between the fourth guide roller 88 and the second bonding apparatus 94, which can help to prevent the third elastic strands 28 from becoming misaligned prior to bonding.

[0118] The second bonding apparatus 94 may be similar to the first bonding apparatus 70, except that the second bonding apparatus may be configured to impart a second bonding pattern on the elastic composite component 12 to constrain the third elastic strands 28 (i.e., the curved elastic strands) and optionally the second elastic strands 24 in position between the facing web layers 14, 16, and / or 24. Correspondingly, the second bonding apparatus 94 may be implemented- 25 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 using any known ultrasonic welding system such as, for example, rotary ultrasonic welding systems and / or blade ultrasonic welding systems. In the illustrated non-limiting example, the second bonding apparatus 94 can include one or more second blade or rotary horns 96 and a second rotary anvil 98 arranged in an opposing configuration with the second horn 96, the second anvil 98 defining a second anvil surface 100. The second horn 96 and the second anvil 98 may be distanced sufficiently close to one another to effect a weld, or the second horn 96 and the second anvil 98 may be in contact with each other such that no clearance exists therebetween. In some examples, a gap can be defined between the second horn 96 and the second anvil 98, and the size of the gap may be determined and / or adjusted based on parameters of the manufacturing process to facilitate bonding between the third web layer 26 and the first and / or second web layers 14, 16 without damaging the elastic composite component 12 (e.g, accounting for splices within the web layers 14, 16, 26).

[0119] The second anvil surface 100 includes bonding features that define a second bonding pattern thereon. In some examples, the second bonding pattern is configured to constrain the third elastic strands 28 (z.e., curved elastic strands) within the elastic composite component 12 during bonding. To accomplish this, the second anvil surface 100 can include any suitable pattern of raised, discrete nodules that extend outward therefrom to form the second bonding pattern on the elastic composite component 12 (e.g., a linear pattern, a non-linear pattern, a wave pattern, and / or a graphic image pattern) that creates a matrix of discrete bonds that join the facing web layers together and constrain the third elastic strands 28 in a desired arcuate or curved path between such web layers, as will be discussed below in greater detail. The discrete nodules may be scattered at specific locations on the second anvil surface 100 or regularly spaced thereon. In some examples, the discrete nodules may be spaced apart at a distance great enough so as to not create anchoring bond pairs that anchor the third elastic strands 28 in position relative to the facing web layers -meaning that the constraining bonds formed by the discrete nodules do not pinch the side edges of the third elastic strands so as to limit the expansion of the third elastic strands when tension is released on the strands and do not pinch the third elastic strands from the top and bottom of the strands in a manner that causes portions of the third elastic strands 28 to be fused in position between melted regions of the facing web layers.- 26 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0120] During bonding, the elastic composite component 12 can be received between the second horn 96 and the second anvil 98, which can cooperate with one another to bond or fuse the elastic composite component 12. That is, the second horn 96 and second anvil 98 can be positioned in an opposing configuration relative to one another to facilitate ultrasonic bonding the third web layer 26 to the first and / or second web layers 14, 16 while the third elastic strands 28 are tensioned. Specifically, the second horn 96 can selectively contact the second anvil surface 100 of the second anvil 98 to impart the second bonding pattern on the elastic composite component 12, and the second horn 96 can be selectively moved away from the second anvil surface 100 to facilitate continuous machine run time (e.g., to allow the second bonding apparatus 94 to account for splices in the web layers 14, 16, 26). During bonding, the web layers 16, 26, and in some embodiments a portion of web layer 14, can be exposed to an ultrasonic emission from the second horn 96 that increases the vibration of the particles in the web layers 14, 16, 26. In this way, the second horn 96 can melt the third web layer 26 with the first and / or second web layers 14, 16 and constrain the third elastic strands 28, and in some embodiments second elastic strands 24, within the elastic composite component 12. Simultaneously, the second anvil 98 can be rotated such that the second anvil surface 100 contacts and imparts the second bonding pattern on the elastic composite component 12. Put another way, operation of the second horn 96 and the second anvil 98 can result in the formation of the second bonding pattern between the web layers 16, 26 at the points of contact between the second horn 96 and the second anvil 98.

[0121] With additional reference to FIG. 1, the second bonding apparatus 94 may be programmed to impart the second bonding pattern on a specific region of the product 10, such as the leg region 40 where the third elastic strands 28 are disposed and in some embodiments the belly region 39 where the second plurality of elastic strands 24 are disposed. In some examples, however, the second bonding pattern is imparted on the entirety of the product 10 (e.g., the first and second torso portions of the product 10. In some examples, the second bonding pattern covers between about 10% and about 100% of an area of the product 10, or between about 10% and about 75% of an area of the product 10, or between about 10% and about 50% of an area of the product 10, or between about 25% and about 50% of an area of the product 10.

[0122] In this way, the ultrasonic emission or energy can be concentrated at specific bond points where frictional heat fuses the third web layer 26 with first and / or second web layers 14,- 27 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 16, which can eliminate the need for consumable adhesives. While second bonding apparatus 94 is described herein as an ultrasonic bonding assembly that ultrasonically fuses the third web layer 26 with the first and / or second web layers 14, 16, it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse together two or more material layers and entrap and / or constrain elastic strands therebetween without the use of adhesive, including sonic bonding techniques, thermal bonding techniques, pressure bonding techniques, and / or other suitable forms of welding.

[0123] Referring to FIG. 4, the bonded elastic composite component 12, including web layers 14, 16, 26, can exit the second bonding apparatus 94 and continue downstream along the machine direction 58. In some examples, the elastic composite component 12 can be provided from the second bonding apparatus 94 to a third bonding apparatus 102 along the machine direction 58. The third bonding apparatus 102 may be similar to the first bonding apparatus 70 except that the third bonding apparatus 102 may be configured to create localized, intermittent regions of anchoring bonds that form anchor regions 50 (see FIG. 1), which aid in securing the elastic strands 20, 24, 28 in position relative to the facing web layers 14, 16, and / or 24. Such anchor regions 50 may be located adjacent the side seam regions 44A, 44B and / or adjacent deactivation regions on the product 10 to aid in anchoring the cut ends of the elastic strands 20, 24, 28 in the completed product 10 and / or adjacent inflection points of the third plurality of elastic strands 28 to aid in maintaining the elastic strands 28 in a desired curved profile.

[0124] The third bonding apparatus 102 can include a third blade or rotary horn 104 and a third rotary anvil 106 arranged in an opposing configuration with the third horn 104, the third anvil 106 defining a third anvil surface 108. The third horn 104 and the third anvil 106 may be distanced sufficiently close to one another to effect a weld, or the third horn 104 and the third anvil 106 may be in contact with each other such that no clearance exists therebetween. The third anvil surface 108 includes bonding features in the form of ridges and / or nodules that define a third bonding pattern. These bonding features may be integrated within the third anvil surface 108, extending outward therefrom, or may extend outward from a surface of one or more anvil inserts (not shown) that is coupled to the third anvil surface 108. In general, embodiments may include ridges with or without internal grooves (i.e., grooved working surfaces). The bonding features may have the overall shape of angled bars, arcs, curved or chevron-shaped bars generally extending along the- 28 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 length of the anvil insert, dots, angled bars, horizontal bars, vertical bars, or any other circular, rectangular, crescent shaped, or irregular shapes such as those shown in U.S. Patent Application 63 / 495,603, the disclosure of which is incorporated herein by reference in its entirety. In various examples, the bonding features may be arranged in a pattern of at least one of dots, vertical lines, horizontal lines, angled lines, and curved lines. Third horn 104 interacts with the bonding features to form a plurality of discrete ultrasonic anchoring bonds corresponding to each dot or line of the third bonding pattern.

[0125] During bonding, the elastic composite component 12 can be received between the third horn 104 and the third anvil 106, which can be positioned in an opposing configuration relative to one another to facilitate ultrasonic bonding at the anchor regions 50 (see FIG. 1). During bonding, the web layers 14, 16, and / or 26 can be exposed to an ultrasonic emission from the third horn 104 that increases the vibration of the particles in the web layers 14, 16, and / or 26, and the third anvil 106 can be rotated such that the third anvil surface 108 contacts and imparts the third bonding pattern on the elastic composite component 12. In this way, the third horn 104 can melt the web layers 14, 16, and / or 26 together along the side seam regions 44A, 44B (see FIG. 1) and impart the third bonding pattern thereon, thereby anchoring ends of the elastic strands 20, 24, and / or 28 in the anchoring regions 50. This advantageously reduces and / or eliminates the need for adhesive along the side seam regions 44 A, 44B (see FIG. 1) to secure ends of the elastic strands 20, 24, 28 (e. , elastic strand ends that are severed during bonding and / or downstream cutting processes) and / or restrain curved elastic strands 28 at select inflection points.

[0126] Thus, the manufacturing process 52 can include a variety of bonding apparatuses (e.g., bonding apparatuses 70, 94, 102) to weld the web layers 14, 16, 26 to one another and anchor and / or constrain the elastic strands 20, 24, 28 within the elastic composite component 12. In some examples, the horns 72, 96, 104 and the respective anvils 74, 98, 106 are arranged differently along the manufacturing process 52. While three separate bonding apparatuses are described herein, it will be understood that the functionality of two or all of the bonding apparatuses 70, 94, 102 may be combined into a common bonding apparatus e.g., one or more horns acting against a single anvil). Accordingly, a single anvil may include one or more different bonding patterns thereon to selectively anchor straight strands and / or constrain curved elastic strands within the elastic composite component 12. That is, the first, second, and / or third bonding patterns may be combined- 29 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 onto a single anvil surface such that the elastic composite component 12 need only be passed through a single bonding apparatus to entrap and / or constrain the elastic strands 20, 24, 28, which may be advantageous to streamline the manufacturing process and reduce equipment expenses.

[0127] In some examples, the bonding patterns discussed herein are provided on solely on the anvils 74, 98, 106 and in others the bonding patterns are defined, in part, based on mating features of the horns 72, 96, 104 and the anvils 74, 98, 106. Thus each bonding apparatus 70, 94, 102 may be provided in the form of an ultrasonic bonding system including one or more rotary or bladestyle hom(s) having either a smooth or grooved working surface and one or more anvils having a working surface that includes smooth or grooved bonding features. Therefore, it will be understood that the bonding patterns discussed herein for entrapping and constraining elastic strands are compatible with a variety of different bonding apparatuses and processes.

[0128] Moreover, any of the anvil surfaces 78, 108 may include curved or wave-like projections, linear projections, non-linear projections, a plurality of land surfaces and / or notches, a smooth land surface, discrete patterns of raised protrusions (e.g., dots or other geometric shapes), and / or any other suitable bonding pattern that functions to anchor the elastic strands, such as the patterns described in U.S. Pat. No. 10,889,066 and U.S. Pat. No. 11,701,268, each of which is incorporated by reference herein in its entirety.

[0129] Referring now to FIG. 5, another portion of the manufacturing process 52 is illustrated for manufacturing the product 10. As shown, the process for manufacturing the product 10 may include additional steps in comparison with those discussed above with respect for the portion of the manufacturing process 52 illustrated in FIG. 4. In the non-limiting example of FIG. 5, the first and second web layers 14, 16 can be fed along the machine direction 58 and provided to respective optional slitting assemblies 110, 112, which can each include one or more cutting devices (e.g., knives, blades, razors, etc.) to separate the first and second web layers 14, 16, respectively, into sheets (e.g., separate the first web layer 14 into a first front sheet 17A, a second front sheet 17B, and the third web layer 26, and to separate the second web layer 16 into a first back sheet 22A and a second back sheet 22B). The first and second front and back sheets 17A, 17B, 22A, 22B can each be directed downstream from the respective optional slitting assemblies 110, 112 by one or more guide rollers 114, with first front sheet 17A and first back sheet 22A aligned to form the first torso portion 34 and second front sheet 17B aligned with second back sheet 22B to form the second- 30 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 torso portion 36 prior to entering the first bonding apparatus 70. In an alternative example, one or both of slitting assemblies 110, 112 are omitted such that first and second web layers 14, 16 enter first bonding apparatus 70 having a combined width of the first and second torso portions 34, 36. A slitting assembly (not shown) would then be provided downstream of the first bonding apparatus 70 to separate the bonded first and second web layers 14, 16 into first and second torso portions 34, 36.

[0130] Further, the first and / or second elastic strands 20, 24 can be fed along the machine direction 58 and provided to the elastic strand guide 68, which can accurately arrange the elastic strands 20, 24 in a substantially straight configuration and tension the elastic strands 20, 24 as they are fed between the front and back sheets 17, 22. For example, a portion of the first elastic strands 20 can be fed between the first front sheet 17A and the first back sheet 22A to form the first waist region 38A of the product 10, and another portion of portion of the first elastic strands 20 along with the second elastic strands 24 can be fed between the second front sheet 17B and the second back sheet 22B to form the second waist region 38B (see FIG. 1).

[0131] In some aspects, a one or more optional folding units (e. ., a waist edge folding unit) 116 is provided along the manufacturing process 52 to fold select outer edges of the front and / or back sheets to provide smooth and finished edges of the waist regions 38, as discussed above with respect to FIGS. 2-3C. The first folding unit 116 may be positioned at any location downstream of the slitting assemblies 110, 112. In some examples, the first folding unit 116 may be omitted.

[0132] With continued reference to FIG. 5, the elastic composite component 12 (i.e., a first intermediate product including the web layers 14, 16 and the elastic strands 20, 24) can be fed along the machine direction 58 and into the first bonding apparatus 70. As discussed above, the first anvil 74 may exert a bonding force or pressure on the first horn 72 to impart a first bonding pattern (e.g. a pattern provided by projections and / or ridges defined by the first anvil surface 78 interacting with the smooth or grooved working surface of first horn 72) on the elastic composite component 12 that is fed between the first horn 72 and the first anvil 74. In particular, the first anvil surface 78 may include sinusoidal or wave-like ridges that are configured to create weld lines to anchor the elastic strands 20, 24 i.e., straight elastic strands) within the elastic composite component 12.- 31 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0133] Downstream of the first bonding apparatus 70, the third web layer 26 and the third elastic strands 28 can be fed along the machine direction 58 and overlaid on the elastic composite component 12. In some aspects, the third web layer 26 is part of the first web layer 14, and the third web layer 26 can be formed by splitting the first web layer 14 with the first slitting assembly 110. Accordingly, the third web layer 26 can be fed from the first slitting assembly 110 to the elastic composite component 12 downstream of the first bonding apparatus 70 and upstream of the second bonding apparatus 94. Further, and as discussed above, the curved strand laydown guide 92 can be used to apply the third elastic strands 28 in a curved pattern (e.g., a sinusoidal or otherwise curved configuration that follows the outer profile of the leg region 40, see FIG. 1) within the elastic composite component 12. In some examples, the optional adhesive material 32 is applied to the third web layer 26 and / or the third elastic strands 28 via an optional adhesive applicator 35 to form anchor regions 50 (see FIG. 1) that help the third elastic strands 28 retain their curved configuration prior. It is to be appreciated that the adhesive applicator 35 may be configured in various ways, such as for example, as a spray nozzle and / or a slot coating device.

[0134] Once the third web layer 26 and the third elastic strands 28 are applied to the elastic composite component 12 and / or wrapped on a portion of the second anvil surface 100, the elastic composite component 12 can be fed along the machine direction 58 and into the second bonding apparatus 94. As discussed above, the second anvil 98 may exert a bonding force or pressure on the second horn 96 to impart a second bonding pattern (e.g. a pattern defined by projections on the second anvil surface 100 interacting with the smooth or grooved surface of the second horn 96) on the elastic composite component 12 that is fed between the second horn 96 and the second anvil 98. In particular, the second anvil surface 100 may include a constraining dot pattern that is configured to create a corresponding constraining dot weld line pattern on the elastic composite component 12 to bond the third web layer 26 with the first and / or second web layers 14, 16 and to constrain the third elastic strands 28 (Ze., curved elastic strands) within the elastic composite component 12. In this way, the second bonding pattern provided by the second anvil surface 100 reduces and / or eliminates the need for adhesive to hold curved elastic strands within the elastic composite component 12, thus enhancing the integrity of the product 10 and reducing material expenses.- 32 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0135] With continued reference to FIG. 5, the elastic composite component 12 (i.e., a second intermediate product including the web layers 14, 16, 26 and the elastic strands 20, 24, 28) can be fed downstream along the machine direction 58 from the second bonding apparatus 94 to the optional third bonding apparatus 102, in some examples. As discussed above, the third anvil 106 may exert a bonding force or pressure on the third horn 104 to impart a third bonding pattern (e.g. an intermittent anchoring bond pattern provided by projections and / or ridges defined by the third anvil surface 108) on the elastic composite component 12 that is fed between the third horn 104 and the third anvil 106. In particular, the third anvil surface 108 may include projections and / or ridges arranged in an intermittent anchoring bond pattern to create weld lines on the elastic composite component 12 to anchor the ends of the elastic strands 20, 24, 28 (e.g., severed ends created during bonding and / or cutting) within the elastic composite component 12. For example, and with additional reference to FIG. 1, the third anvil surface 108 can be configured to impart weld lines on the side seam regions 44 of the product 10 to secure severed ends of the elastic strands 20, 24, 28 within or adjacent the side seam regions 44A, 44B. Moreover, the third bonding pattern can create the anchor regions 50 at various locations within the leg region 40 of the second torso portion 36 of the product 10 to help retain the third elastic strands 28 in their curved configuration. It is contemplated that the third bonding apparatus 102 may be combined with one or both of the first and second bonding apparatuses 70, 94, such that the first and / or second anvil surfaces 78, 100 may include projections that are arranged to provide the anchoring bonds in the anchor regions 50 provided by the intermittent anchoring bonding pattern discussed above.

[0136] With reference to FIGS. 1 and 5, the manufacturing process 52 can include additional equipment and processes to process the product 10 downstream of the third bonding apparatus 102. While the specifics of such additional equipment is outside the scope of the present invention, one skilled in the art will recognize that such equipment may include any combination of all or some of the following exemplary processing units, along with additional processing units as known in the art: an optional deactivation unit 120 to optionally deactivate the elastic strands 20, 24, 28 within particular regions of the product 10 (e.g., the crotch portion 46); a transfer unit 122 (optionally with cutting functionality) to handle and place absorbent pucks or inserts 124 on the product (e.g., within the crotch portion 46); a first cutting unit 126 in which regions (e.g., the leg region 40) of the product 10 are cut to create curved leg profiles with leg openings; a second- 33 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 folding unit 128 in which one of the first and second torso portions 34, 36 is folded over the other; one or more additional bonding apparatuses 130 in which the first and second torso portions 34, 36 are joined together at the side seam regions 44A, 44B; a second cutting unit 132 in which the continuous web product 10 is separated into discrete products 10; and / or a third folding unit 134 in which the discrete products 10 are picked up, turned into a packaging orientation, and / or folded for packaging. In some examples, the one or more additional bonding apparatuses 130 are ultrasonic bonding apparatuses that include one or more horns 131 that interact with one or more anvils 133 to weld the torso portions 34, 36 together alone the side seam regions 44A, 44B. The anvil(s) 133 of such ultrasonic bonding apparatus(s) may include anchoring bonding features that interact with the hom(s) 131 to form anchoring bond regions in the products 10. Thus, the additional bonding apparatus(es) 130 may serve the dual function of bonding the side seams of the product 10 and forming anchoring bond regions 50. In such examples, a standalone third bonding assembly 102 would be omitted from the manufacturing process 52 and instead the additional bonding apparatus(es) 130 may be constructed in any of the manners and with any of the bond pattern options described herein with respect to third bonding assembly 102 (FIG. 4) or the additional bonding assembly 422 (FIG. 19). In other examples, the one or more additional bonding apparatuses 130 are adhesive bonding units that utilize adhesive to secure the torso portions 34, 36 together along the side seam regions 44A, 44B. It is contemplated that any or all of the example processing units discussed above can be utilized in other aspects and in combinations other than that illustrated in FIG. 5. Accordingly, the present disclosure is not limited to the manufacturing process specifically shown.

[0137] Referring now to FIG. 6, a detail view of is illustrated of a first example anvil surface 136 for bonding web layers together and anchoring elastic strands within an elastic composite component. In will be understood that any or all of the anvil surfaces 78, 108 (see FIG. 5) may incorporate the first example anvil surface 136. In some examples, the first example anvil surface 136 is configured to impart a particular bonding and / or anchoring pattern on an elastic composite component to anchor substantially straight elastic strands therein. Thus, the first example anvil surface 136 may correspond to the first anvil surface 78 (see FIG. 5).

[0138] As shown, the first example anvil surface 136 may define one or more non-linear continuous ridges 138 that are spaced from one another with respect to a circumferential direction- 34 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 140. The ridges 138 may extend along an axial direction 142 that is substantially perpendicular to the circumferential direction 140. In some aspects, the ridges 138 can define variable or uniform spacing relative to one another on the first example anvil surface 136 with respect to the circumferential direction 140. In some examples, the ridges 138 define curved and / or sinusoidal profiles, which allows the first example anvil surface 136 to impart a substantially sinusoidal bonding pattern (z.e., sinusoidal anchor regions or weld lines) on an elastic composite component during bonding. In some aspects, imparting a sinusoidal bonding pattern on an elastic composite component advantageously improves anchoring of substantially straight elastic strands (e.g.. the first and second elastic strands 20, 24, see FIG. 1) by varying the anchoring location of adjacent elastic strands. That is, the sinusoidal bonding pattern anchors adjacent elastic strands at different locations with respect to the circumferential and axial directions 140, 142, which in turn strengthens anchoring strength throughout a product.

[0139] Alternative bonding patterns may be achieved by varying the geometry of the ridges 138. In some aspects, the ridges 138 have substantially smooth working surfaces configured to interface with a grooved working surface of a horn to create a pattern of discrete, intermittent welds or the ridges 138 have working surfaces having a plurality of grooves formed therein, which interact with a smooth or grooved working surface of a horn to create a pattern of discrete intermittent welds. In either case, the grooves are sized and spaced relative to the specifications of the facing web layers 14, 16, and the elastic strands 20, 24 to create a pattern of welds that at least partially encapsulate the elastic strands 20, 24 and / or frictionally engage the elastic strands 20, 24 in position relative to the facing web layers 14, 16.

[0140] Referring now to FIGS. 7 and 8, detail views are illustrated of a second example anvil surface 144 and a third example anvil surface 148, respectively, for bonding web layers together and constraining the third plurality of elastic strands 28 (and optionally the second plurality of elastic strands 24) within an elastic composite component 12. In will be understood that anvil surface 100 (see FIG. 5) may incorporate the second or third example anvil surfaces 144, 148.

[0141] Further, the second and third example anvil surfaces 144, 148 may each define a plurality of nodules or projections 146 (e.g., rods or pegs) that extend outward therefrom (e.g., in a radial direction that is perpendicular to the circumferential and / or axial directions 140, 142). In some examples, the nodules 146 are cylindrical in shape, although it is contemplated that any other- 35 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 suitable shape may be used as well (e.g., rectangular, triangular, elliptical, and / or crescent-shaped protrusions). The nodules 146 may be arranged to impart a constraining dot pattern on an elastic composite component to weld web layers together and / or constrain curved elastic strands within the elastic composite component. That is, curved elastic strands that are laid down on the elastic composite component can be allowed or encouraged to meander (e.g., curve) around the projections 146. Such curved elastic strands may experience a high frictional force against bonded segments of the elastic composite component due to the serpentine (e.g., constraining) path of the strands about the anchor regions, which in turn can help to retain the curved elastic strands in place. Moreover, the constraining dot pattern(s) defined by the second and third example anvil surfaces 144, 148 can accommodate a variety of differently shaped elastic strands, products, and product sizes, thereby reducing the need for a manufacturer to purchase expensive, product-specific manufacturing equipment (e.g., anvils).

[0142] Referring specifically to the non-limiting example illustrated in FIG. 7, the constraining dot pattern may be provided as a grid-like pattern on the second example anvil surface 144. In such an arrangement, the nodules 146 can be arranged in rows 147 that are all substantially parallel with respect to the circumferential direction 140 and columns 149 that are all substantially parallel with respect to the axial direction 142, with a first series of adjacent rows 147A being disposed in line with a second series of adjacent rows 147B. That is, spacing between the nodules 146 may be uniform across the second example anvil surface 144.

[0143] In the non-limiting example illustrated in FIG. 8, the constraining dot pattern may be provided as a staggered grid-like pattern on the third example anvil surface 148. In such an arrangement, some (e.g., half) of the rows 147 and columns 149 may be staggered with respect to the circumferential and / or axial directions 140, 142. For example, the second series of adjacent rows 147B may be staggered with respect to the first series of adjacent rows 147A, and the second series of adjacent columns 149B may be staggered with respect to the first series of adjacent columns 149A. As a result, the spacing between the nodules 146 may be varied across the third example anvil surface 148. While only two specific examples of a constraining dot pattern are illustrated in FIGS. 7 and 8, it will be understood that the nodules 146 may be arranged in a variety of different configurations to create bonds between facing web layers that constrain the curved elastic strands within an elastic composite component. For example, the spacing between the rows- 36 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 147 and / or columns 149 of the nodules 146 may be varied to encourage elastic strands to retain the curved laydown pattern imparted by laydown guide 92.

[0144] Referring now to FIGS. 9A and 9B, cross-sectional views of nodules 146 are illustrated according to alternate embodiments. Each nodule 146 includes sidewalls 156 that extend outward from the fourth example anvil surface 152 and are connected at distal ends thereof by a working surface 158 (e. ., an outer surface of the nodules 146 that contacts an elastic composite component during bonding). As the anvil 150 is rotated, the contact surfaces 158 can impart weld lines on a product, such as weld lines along a side seam region of a product to anchor ends of elastic strands within the product. Accordingly, the fourth example anvil surface 152 may correspond to the third anvil surface 108 (see FIG. 5).

[0145] To help prevent elastic strands from being severed during bonding and to aid in retaining the strand in its curved laydown profile, the sidewalls 156 may be angled with respect to the fourth example anvil surface 152. In some examples, an acute angle 160 (FIG. 9A) is defined between the fourth example anvil surface 152 and at least one sidewall 156 retain the third plurality of elastic strands 28 in their predefined or selected curved trajectory. Put another way, the nodules 146 are undercut to prevent elastic strands from catching on the sidewalls 156. In some examples the acute angle 160 defined between the fourth example anvil surface 152 and each sidewall 156 is between about 5 degrees and about 90 degrees, or between about 30 degrees and about 90 degrees, or between about 45 degrees and about 75 degrees, or between about 60 degrees and about 70 degrees, or about 68 degrees. Correspondingly, an undercut angle 162 formed between the sidewalls 156 of a single nodule 146 may be between about 5 degrees and about 60 degrees, or between about 30 degrees and about 60 degrees, or about 45 degrees.

[0146] In other examples, an obtuse angle 161 (FIG. 9B) is defined between the fourth example anvil surface 152 and at least one sidewall 156 retain the elastic strands in their curved pattern. In other examples, nodules 146A, 146B may include at least one sidewall 157 oriented at a ninety-degree angle or an obtuse angle 161 relative to the anvil surface 152 and at least one sidewall 156 oriented at an acute angle 160 relative to the anvil surface 152, as shown in FIG. 9C. In yet other examples, nodules 146 may include at least one sidewall 159 oriented generally perpendicular (i.e., at a right or ninety-degree angle 163) to the anvil surface 152, as shown in FIG.9D.- 37 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0147] The angles of the sidewalls of nodules 146 on the anvil surface 152 may vary throughout the constraining bonding pattern based on the desired curvature of a given elastic strand 28 on the product 10. For example, the nodule configuration shown in FIG. 9C may be used in a case where a curved elastic strand is desired to be constrained in a region of the product between constraining bonds formed by nodules 146A and 146B. In such case, nodules 146 may be arranged such that the sidewall 156 of a given nodule 146A that faces the desired position of the elastic strand in the product has an acute angle 160 to aid in retaining the strand in position between nodules 146A and 146B. The sidewall 157 of the opposing nodule 146B that also faces the desired elastic strand may also have an acute angle, to aid in catching and holding the elastic strand in position, or a straight or obtuse angle in alternate embodiments. Sidewalls of nodules that face away from the desired constrained position of the elastic strand, for example sidewall 157 of nodule 146A may have ninety degree or obtuse angles. Tension on the curved elastic strand, combined with the angled side profile of the sidewall 157 of the nodule 146A will encourage the curved elastic strand to slide up and over the obtusely angled sidewall of the nodule 146A prior to bonding and thus function to aid in repositioning the elastic strand within a desired curved path.

[0148] Referring now to FIG. 10, the present disclosure provides a method 200 of anchoring elastic strands and constraining elastic strands within an elastic composite component of a product (e.g., a paper product, a plastic product, a disposable product, a medical product, a personal hygiene product, an elastic composite component, etc.). At step 202, a first web layer can be bonded with a second web layer to anchor a first plurality of elastic strands and form a first intermediate product. In some examples, the first plurality of elastic strands are substantially straight waist elastic strands, and anchoring the first elastic strands includes anchoring the elastic strands between the web layers, by imparting a pattern of discrete ultrasonic anchoring bonds on the web layers such that the first plurality of elastic strands 20 are restrained in position relative to the facing web layers 14, 16 by adjacent pairs of anchoring bonds. In some examples, step 202 also includes bonding a second plurality of substantially straight elastic strands 24, e.g., belly elastic strands, between the first and second web layers 14, 16. At step 204, the method 200 can include guiding a third web layer and one or more additional elastic strands onto the first intermediate product. For example, the third web layer can be guided onto the elastic composite component by a guide roller, and the additional elastic strand(s) can be placed on the third web- 38 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 layer or the elastic composite component via an elastic strand laydown guide. In some aspects, the elastic strand laydown guide arranges a plurality of elastic strands in a curved configuration on the elastic composite component according to a desired elastic profile of the product. Step 204 may also include arranging a second plurality of substantially straight elastic strands, e.g., belly elastic strands, between the third web layer and the elastic composite component.

[0149] At step 206, the method 200 can include bonding the third web layer with the elastic composite component to constrain the second plurality of elastic strands and / or the curved elastic strand(s) and form a second intermediate product. Constraining these elastic strands can include imparting a constraining dot weld pattern on the third web layer and / or the elastic composite component to create a matrix of constraining points for the second plurality of elastic strands and / or the curved elastic strands. The constraining dot weld pattern may be provided by a plurality of projections arranged in a constraining dot pattern on an anvil surface. The method 200 may further include an optional step 207 of forming intermittent anchoring bond patterns to anchor ends and / or select regions of the second and / or third elastic strands within in the elastic composite component at select locations (e.g., adjacent the side seam regions, adjacent deactivation regions, and / or at inflection points). Thus, different anvil surfaces and corresponding projection patterns can be used to anchor straight elastic strands and constrain curved elastic strands within a product regardless of product size or shape, thus reducing the need for adhesive specialized manufacturing machinery, which in turn can decrease manufacturing costs and improve product quality.

[0150] Referring now to FIGS. 11-14, schematic representations of portions of elastic composite component 12 corresponding to the second torso portion 36 are illustrated during portions of the manufacturing method - namely as the elastic composite component 12 travels through the first, second, and third bonding apparatuses 70, 94, 102. Referring first to FIG. 11, second web assembly 16 has a width defined in the width direction W that covers the first plurality of elastic strands 20. The coverage area 300 of the working surface 76 of the first horn 72 (FIG. 4) is sized to span all or substantially all of the width of the second web layer 16 in the width direction W and form a first bonding pattern 302 of anchoring bonds, of any of the types previously described herein, within elastic composite component 12, which is continuous in the machine direction 58 and substantially covers the location of the first plurality of elastic strands 20 within the elastic composite component 12.- 39 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0151] Referring now to FIG. 12 together with FIGS. 12A and 12B, the second and third pluralities of elastic strands 24, 28 along with the third web layer 26 are shown, along with exemplary locations of anchor region 50, which may be provided as adhesive 32 in this embodiment. The coverage area 304 of the working surface of second horn 96 of second bonding apparatus 94 (FIG. 4) substantially spans the width of the third web layer 26 in the width direction W and forms a second bonding pattern 306 of ultrasonic constraining bonds 310, of any of the types previously described herein, which is continuous in the machine direction 58 and substantially covers the location of the second and third pluralities of elastic strands 24, 28 within the elastic composite component 12. The region that includes the second bonding pattern 306 is illustrated with stippling in Fig, 12, but the stippling is not included in the remaining drawings for clarity and simplicity.

[0152] FIG. 12B provides a detailed view of a portion of the elastic composite component 12 after the second bonding pattern 306 is formed. Select pairs of ultrasonic anchoring bonds 308 within the first bonding pattern 302 are positioned on opposing sides of elastic strands of the first plurality of elastic strands 20 to anchor such strands 20 in position between facing web layers 14, 16. Meanwhile, constraining bonds 310 of second bonding pattern 306 are positioned at locations adjacent opposing sides of elastic strands of the second and third pluralities of elastic strands 24, 28 in a manner that forms constraining passages for the second and third pluralities of elastic strands 24, 28 between facing web layers 14, 16. An unbonded interval 311 between adjacent constraining bonds 310 is larger than an unbonded interval 309 between adjacent anchoring bonds 308 within the first bonding pattern 302 when intervals 309, 311 are measured in the cross-machine direction 59. In some examples, the unbonded interval 309 is less than an un-tensioned diameter of a given elastic strand of the first plurality of elastic strands 20. The unbonded interval 309 may also be selected relative to the un-tensioned diameter of a given elastic strand of the first plurality of elastic strands 20 and the weight per square meter (i.e., GSM) of the facing web layers 14, 16 such that the given elastic strand 20 is at least partially encapsulated by the resulting anchoring bonds 308. The unbonded interval 311 of the constraining bonds 310 may be greater than the un-tensioned diameter of the second and third pluralities of elastic strands 24, 28 or otherwise sized such that the elastic strands 24, 28 are not frictionally engaged or encapsulated between facing web layers 14, 26. Anchor point 50 overlies portions of the second and third pluralities of elastic- 40 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 strands 24, 28 to aid in anchoring such strands in position relative to the facing web layers 14, 26. In examples, anchor regions 50 are formed via adhesive applicator 33 (FIG. 4) and may be provided at the locations shown in FIG. 12 or more or less locations than shown, or omitted entirely based on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the third plurality of elastic strands 28 in the product 10, and others.

[0153] FIG. 13 depicts a portion of the elastic composite component 12 in an example utilizing the third bonding apparatus 102. The coverage area 312 of the working surface of third horn 104 of third bonding apparatus 102 (FIG. 4) is sized to overlap a portion of each of the second and third pluralities of elastic strands 24, 28 on opposing sides of defined cut lines 314 aligned between the side seam regions 44A, 44B (FIG. 1) of adjacent products 10. As shown in FIG. 13 and FIG.13A, an intermittent anchoring bond pattern 50A is formed that is intermittent in the machine direction 58. Intermittent anchoring bond pattern 50A includes anchoring bonds 316 that act in pairs to anchor the second and third pluralities of elastic strands 24, 28 in position at select locations between the facing web layers 14, 26. Anchoring bonds 316 may be sized and spaced in a similar manner as anchoring bonds 308 or differently depending on desired function and aesthetics. In an example utilizing the third bonding apparatus 102, one or more anchoring regions 50 formed of adhesive 32 via adhesive applicator 33 (FIG. 4) may be included in an upstream process, or omitted entirely based on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the third plurality of elastic strands 28 in the final product 10 (for example within a deactivated region 313 of the product 10), and others.

[0154] FIGS. 14 and 14A depict a portion of the elastic composite component 12 in another example utilizing the third bonding apparatus 102. In this example, the coverage area 318 of the working surface of third horn 104 of third bonding apparatus 102 (FIG. 4) is wider, enabling larger regions of the intermittent anchoring bond pattern 50B to be intermittently formed at additional locations along the curvature of the third plurality of elastic strands 28. In this case, the bonding features on the third rotary anvil 106 (FIG. 4) would be pitched to correspond to the desired locations of the intermittent anchoring bond pattern 50B of the product, thus requiring the third rotary anvil 106 to be changed for product changeover. Other aspects of the anchoring bonds 316 and intermittent anchoring bond pattern 50B are similar to intermittent anchoring bond pattern 50A described above. It will be understood that the number and locations of intermittent anchoring- 41 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 bond pattern 50B in FIG. 14 are provided as examples only, and more or less regions of intermittent anchoring bond pattern 50B may be formed by third bonding apparatus 102 within a given product 10 depending on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the third plurality of elastic strands 28 in the final product 10 (for example within a deactivated region 313 of the product 10), and others.

[0155] Referring now to FIGS. 15-17, schematic representations of portions of elastic composite component 12 corresponding to the second torso portion 36 are illustrated during portions of the manufacturing method as the elastic composite component 12 travels through the first, second, and third bonding apparatuses 70, 94, 102 according to an alternate construction of product 10 wherein the first and second pluralities of elastic strands 20, 24 are supplied into the process contemporaneously and the first second web layer 16 has a width in the width direction W large enough to span the first and second pluralities of elastic strands 20, 24. In one example, shown in FIG. 15A, second web layer 16 is sized such that its upper end is substantially aligned with that of web layer 14. In another example, shown in FIG. 15B, second web layer 16 is narrower, however, the upper end of second web layer 16 still covers the second plurality of elastic strands 24. In either example, the coverage area 320 (FIG. 15) of the working surface 76 of the first horn 72 (FIG. 4) is sized to at least span the region of the elastic composite component 12 that includes the first and second pluralities of elastic strands 20, 24. The first bonding apparatus 70 then forms a first bonding pattern 322 of anchoring bonds, of any of the types previously described herein, which is continuous in the machine direction 58 and substantially covers the locations of the first and second pluralities of elastic strands 20, 24 within the elastic composite component 12.

[0156] Referring now to FIG. 16, the coverage area 324 of the working surface of second horn 96 of second bonding apparatus 94 (FIG. 4) is shown and substantially spans the width of the third web layer 26 in the width direction W and forms a second bonding pattern 326 of constraining bonds 310, of any of the types previously described herein, which is continuous in the machine direction 58 and substantially covers the third web layer 26 and the third plurality of elastic strands 28. FIG. 16B is a detailed view of a portion of the elastic composite component 12 after the second bonding pattern 326 is formed. Select pairs of anchoring bonds 308 within the first bonding pattern 322 are positioned on opposing sides of elastic strands of the first and second pluralities of elastic strands 20, 24 to anchor such strands 20 in position between facing web layers. Meanwhile,- 42 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 constraining bonds 310 of second bonding pattern 326 are positioned adjacent the third plurality of elastic strands 28 in a manner that forms constraining passages for the elastic strands 28 between facing web layers 16, 26. The first and second bonding patterns 322, 326 partially overlap one another. Anchoring region 50 overlies portions of the third plurality of elastic strands 28 to aid in anchoring such strands in position relative to the facing web layers 16, 26.

[0157] FIG. 17 depicts a portion of the elastic composite component 12 in an example utilizing the third bonding apparatus 102. The coverage area 328 of the working surface of third horn 104 of third bonding apparatus 102 (FIG. 4) is sized to overlap a portion of the third plurality of elastic strands 28 on opposing sides of defined cut lines 314 aligned between the side seam regions 44 A, 44B (FIG. 1) of adjacent products 10. As shown in FIGS. 17 and 17A, third bonding apparatus 102 creates an intermittent anchoring bond pattern 50A of anchoring bonds 316 in the machine direction 58, with the anchoring bonds 316 arranged in pairs that anchor the third plurality of elastic strands 28 in position at select locations between the facing web layers 16, 26. Anchoring bonds 316 may be sized and spaced in a similar manner as anchoring bonds 308 or differently depending on desired function and aesthetics.

[0158] FIGS. 18 and 18A depict a portion of the elastic composite component 12 in another example utilizing the third bonding apparatus 102. In this example, the coverage area 329 of the working surface of third horn 104 of third bonding apparatus 102 (FIG. 4) in direction W is larger, enabling intermittent anchoring bond pattern 50B to be formed at additional locations along the curvature of the third plurality of elastic strands 28. In this case, the bonding features on the third rotary anvil 106 (FIG. 4) would be pitched to correspond to the desired locations of the intermittent anchoring bond pattern 50B on the elastic composite component 12, thus requiring the third rotary anvil 106 to be changed for product changeover. Other aspects of the anchoring bonds 316 and intermittent anchoring bond pattern 50B are similar to intermittent anchoring bond pattern 50A described above. It will be understood that the number and locations of intermittent anchoring bond pattern 50B in FIG. 18 are provided as examples only, and more or less intermittent anchoring bond patterns 50B may be formed by third bonding apparatus 102 within a given product 10 depending on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the third plurality of elastic strands 28 in the product 10, and others.- 43 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094

[0159] Referring now to FIG. 19, an example of manufacturing process 52 is shown wherein the functionality of the previously described first and second bonding apparatuses 70, 94 are combined into a common bonding apparatus 402, which includes a rotary anvil 404 and one or more blade or rotary horns 406 arranged in an opposing configuration with one another. In some aspects, the horn 406 can define a working surface 408 that opposes the anvil 404 and the working surface 408 of the first horn 406 may define a plurality of horn grooves thereon that are substantially parallel with respect to the machine direction 58. In other embodiments the working surface 408 of the horn 406 is smooth (i.e., un-grooved). In either case, working surface 408 cooperates with the anvil 404 to form discrete bonds between facing web layers of the elastic composite component 12.

[0160] Further, the working surface 408 of the horn 406 can be arranged opposite to an anvil work surface 410 (e.g., a circular or curved surface) of the anvil 404 having an arrangement of discrete bonding features of ridges 414 and nodules 418 that protrude outward from the anvil work surface 410, as shown in FIG. 20, which is divided into an anchoring region 412 that includes a plurality of continuous ridges 414 and a constraining region 416 that includes a plurality of discrete nodules 418. As shown, ridges 414 extend across in the axial direction 142. These ridges 414 may have planar working surfaces or grooved working surfaces. Each of the plurality of discrete nodules 418 includes a work surface and at least one sidewall extending from the work surface to a base surface of the anvil 404. The anchoring ridges 414 and constraining nodules 418 can be configured in any of the patterns described above with respect to the bonding features that create anchoring and constraining bonding patterns on the elastic composite component 12 (e.g., a sinusoidal wave pattern, a linear pattern, a non-linear pattern, a constraining pattern of dots or other geometric shapes, a random pattern, and / or a graphic image pattern).

[0161] In a similar manner as described above with respect to FIG. 4, first web infeed assembly 54 and second web infeed assembly 56 feed a first web layer 14 and a second web layer 16 toward the anvil 404 at a location upstream of the first horn 406 in a machine direction 58. At least one tensioning device 66 provides a first plurality of elastic strands 20 between the first web layer 14 and the second web layer 16. The first horn 406 directs ultrasonic energy to at least a first portion of the anchoring region 412 of the anvil 404. The ridges 414 of the anvil work surface 410 impart a non-linear pattern of anchoring bonds on the first web layer 14, the second web layer 16, or both- 44 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 to anchor the first plurality of elastic strands between the first and second web layers 14, 16 when the anvil 404 interacts with the horn 406.

[0162] With continued reference to FIG. 19, the bonded intermediate elastic composite component 12 continues downstream along the machine direction 58 beyond horn 406. The third web layer 26 and the third plurality of elastic strands 28 are then added to the elastic composite component 12. The third plurality of elastic strands 28 are provided along the machine direction 58 and in some examples are kept under tension by one or more creel assemblies 67 or similar tensioning device(s). In some examples, the third web layer 26 can be provided by a third web infeed assembly 86 to a fourth guide roller 88 arranged along the manufacturing process 52, and the fourth guide roller 88 can be configured to direct and / or tension the third web layer 26 along the machine direction 58 and through the manufacturing process 52. Curved strand laydown guide 92 can be configured to apply the third elastic strands 28 in a particular pattern (e.g., a curved, sinusoidal, and / or wave pattern) on the third web layer 26. An optional adhesive material 32 may be applied to the third web layer 26 as it exits the third web infeed assembly 86 and travels to the fourth guide roller 88, which may aid in securing the third elastic strands 28 and / or bonding the side seam regions 44A, 44B of the product (see FIG. 1). In some embodiments, the second plurality of elastic strands 24 can be fed from a creel assembly (not shown) located downstream from horn 406 such that second plurality of elastic strands 24 are received with the third web layer 26 and the third plurality of elastic strands 28 on the fourth guide roller 88 instead of at the upstream location relative to first bonding apparatus 70 shown in FIG. 19.

[0163] Still referring to FIG. 19, the third web layer 26 and the third plurality of elastic strands 28 (and in some examples, the second plurality of elastic strands 24) can be joined with the intermediate elastic composite component 12 as they exit the fourth guide roller 88, and the resulting elastic composite component 12 can be provided between the anvil 404 and one or more second horns 420, which is located downstream of the first horn and aligned with the anvil 404 to direct ultrasonic energy to the constraining region 416 of the anvil 404. The nodules 418 impart a constraining dot bonding pattern on the third web layer 26 and at least one of the first web layer 14 and the second web layer 16 to constrain the third plurality of elastic strands 28, and optionally the second plurality of elastic strands 24, between the third web layer 26 and either the first web layer 14 or the second web layer 16 when the anvil 404 interacts with the horn 406. In some- 45 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 embodiments the one or more second horns 420 is also aligned with the anvil 404 to direct ultrasonic energy to a second portion of the anchoring region 412 of the anvil 404 to impart anchoring bonds on the elastic composite component 12. The fourth guide roller 88 can be positioned directly upstream of the second bonding apparatus 94 to minimize the distance travelled by the elastic composite component 12 between the fourth guide roller 88 and the second bonding apparatus 94, which can help to prevent the third elastic strands 28 from becoming misaligned prior to bonding. The second bonding pattern, which includes constraining bonds and, optionally, anchoring bonds, is imparted on the elastic composite component 12 as the elastic composite component 12 passes between the anvil 404 and one or more second rotary or blade horns 420. Horn(s) 420 is positioned such that its working surface 421, which may be smooth or grooved in alternate examples, interacts with a portion of the anvil surface 410 that includes the nodule bonding features that define the second bonding pattern, thus creating a matrix of bond points that joins web layer 26 to web layer 16 and that constrains the third plurality of elastic strands 28 in a desired arcuate or curved path.

[0164] In some examples, the elastic composite component 12 can be provided from bonding apparatus 402 to a downstream bonding apparatus 422 along the machine direction 58. This downstream bonding apparatus 422 may be similar to the third bonding apparatus 102 (FIG. 4) and is referred to with similar part numbers are used as appropriate. Downstream bonding apparatus 422 is configured to create localized regions of anchoring bonds that form anchor regions 50 (see FIG. 1), which aid in securing the elastic strands 20, 24, 28 in position relative to the facing web layers 14, 16, and / or 24.

[0165] Referring now to FIGS. 21-22, schematic representations of portions of elastic composite component 12 corresponding to the second torso portion 36 are illustrated during portions of the manufacturing method as the elastic composite component 12 travels through the bonding apparatuses 402, 422. Referring first to FIG. 21, second web assembly 16 has a width defined in the width direction W that covers the first plurality of elastic strands 20. The coverage area 424 of the working surface 408 of the first horn 406 (FIG. 19) is sized to substantially span the width of the second web layer 16 in the width direction W and form an anchoring bond pattern 426, of any of the types previously described herein, which is continuous in the machine direction- 46 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 58 and substantially covers the location of the first plurality of elastic strands 20 within the elastic composite component 12.

[0166] Referring now to FIG. 22 together with FIGS. 22A and 22B, the third plurality of elastic strands 28 along with the third web layer 26 are shown, along with exemplary locations of anchor regions 50, which may be formed with adhesive 32 in the manner described above. The coverage area 428 of the working surface 421 of second horn 420 of bonding apparatus 402 (FIG. 19) substantially spans the width of the third web layer 26 in the width direction W and interacts with the working surface 410 of the anvil 404 to form a pattern 430 of constraining bonds 310, of any of the types previously described herein, which substantially covers the location of the third plurality of elastic strands 28 in one or more regions within the elastic composite component 12. In some aspects, the second and / or third pluralities of elastic strands 24, 28 are further secured between facing web layer 14, 26 at one or more optional discrete anchor regions 50 via adhesive material 32. For example, the second and / or third plurality of elastic strands 24, 28 may be secured at optional anchor regions 50 that are located adjacent both side seam regions 44A, 44B, at inflection points of the curved path of strands 28, and / or and on opposing edges of the crotch portion 46 (FIG. 1).

[0167] Referring now to FIG. 23, in examples utilizing bonding apparatus 422 having a coverage area 429, some or all of the adhesive anchor regions 50 shown in FIG. 22 may be omitted, with bonding apparatus 422 being employed to form intermittent anchoring bond patterns 50B, similar to those described with respect to FIGS. 14 and 14A, at select regions along the length of second and / or third pluralities of elastic strands 24, 28. It will be understood that the number and locations of intermittent anchoring bond pattern 50B in FIG. 23 are provided as examples only, and more or less intermittent anchoring bond patterns 50B may be formed by bonding apparatus 422 within a given product 10 depending on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the second and third pluralities of elastic strands 24, 28 in the final product 10 (for example within a deactivated region 313 of the product 10), and others.

[0168] In the example described with respect to FIG. 22, the second horn 420 interacts with a portion of the working surface 410 of the anvil 404 that includes bonding features similar to any of those shown in FIGS. 9A-9D that form constraining bonds 310. In other examples, such as that- 47 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 shown in FIG. 24, the second horn 420 interacts with a portion of the working surface 410 of the anvil 404 that includes bonding features that form a first bonding pattern 426A of anchoring bonds 308 and bonding features that form a second bonding pattern 430 of constraining bonds 310, with the second bonding pattern 430 following the curved path of the third plurality of elastic strands 28. In this example, the second bonding pattern 430 substantially covers the region between the uppermost of the third plurality of elastic strands 28 and the upper edge of the first bonding pattern 426, with uppermost referring to the relative arrangement of components shown in FIG. 24. In some aspects, the second and / or third pluralities of elastic strands 24, 28 are further secured between facing web layer 14, 26 at one or more optional discrete anchor regions 50 via adhesive material 32. For example, as shown in FIG. 24, the second and / or third plurality of elastic strands 24, 28 may be secured at optional anchor regions 50 that are located adjacent both side seam regions 44A, 44B, at inflection points of the curved path of strands 28, and / or and on opposing edges of the crotch portion 46 (FIG. 1). Alternatively, the portion of the working surface 410 of the anvil 404 corresponding to coverage area 428 includes intermittent anchoring bond patterns 50B of anchoring bonds that secure select regions of the second and / or third pluralities of elastic strands 24, 28 in position between facing web layers 14, 26 in the manner described above.

[0169] Referring now to FIGS. 25, 25A, and 25B, in examples utilizing bonding apparatus 422 having a coverage area 429, some or all of the adhesive anchor regions 50 shown in FIG. 24 may be omitted, with bonding apparatus 422 being employed to form intermittent anchoring bond patterns 50B, similar to those described with respect to FIGS. 14 and 14A, at select regions along the length of second and / or third pluralities of elastic strands 24, 28. It will be understood that the number and locations of intermittent anchoring bond pattern 50B in FIG. 25 are provided as examples only, and more or less intermittent anchoring bond pattern 50B may be formed by bonding apparatus 422 within a given product 10 depending on design specifications such as the curvature of the third plurality of elastic strands 28, locations of the cut ends of the second and third pluralities of elastic strands 24, 28 in the final product 10 (for example within a deactivated region 313 of the product 10), and others.

[0170] FIGS. 26 and 27 depict an alternative arrangement of the first and second bonding patterns 426A, 430 relative to that shown in FIG. 22. In these examples, the second bonding pattern 430 substantially follows the curvature of the third plurality of elastic strands 28. The coverage- 48 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 area 428 of the working surface 421 of second horn 420 of bonding apparatus 402 (FIG. 19) substantially spans the width of the third web layer 26 in the width direction W and interacts with the working surface 410 of the anvil 404 to form a pattern 430 of constraining bonds 310, of any of the types previously described herein, which substantially covers the location of the third plurality of elastic strands 28 in one or more regions within the elastic composite component 12. In some aspects, the second and / or third pluralities of elastic strands 24, 28 are further secured between facing web layer 14, 26 at one or more optional discrete anchor regions 50 via adhesive material 32, as shown in FIG. 26, and / or via anchoring bond pairs formed in intermittent anchoring bond patterns 50B, which may be formed via bond features located on anvil 404 or on downstream anvil 106 as described above and shown in FIG. 27. For example, the second and / or third plurality of elastic strands 24, 28 may be secured at optional anchor regions 50 that are located adjacent both side seam regions 44A, 44B, at inflection points of the curved path of strands 28, and / or and on opposing edges of the crotch portion 46 (FIG. 1).

[0171] The machine direction 58 dimension of coverage areas 300, 304, 312, 318, 320, 324, 328, 329, 424, 428, 429, as depicted in FIGS. 11, 12, 13, 14, 15, 16, 17, 18, 22, 23, 24, and 25, is intended to only be represented graphically only. The actual machine direction dimension of the coverage area may vary based on specific design parameters and should not be construed as limiting. Adjustments in the size and extent of the coverage area may be made in accordance with the requirements of the particular application without departing from the scope of the invention.

[0172] The described systems enable the anchoring of straight elastic strands and the constraining curved elastic strands within a product. As described above, this type of system is useful in high-volume assembly lines which may produce a variety of components or products (e.g., paper products, plastic products, disposable products, personal hygiene products, etc.) In particular, this type of system is compatible with a variety of different products and product sizes, thus reducing the amount of specialized equipment needed by manufacturers to meet customer demand. There are, however, many other applications for these types of feeding systems, including, for example, manufacturing processes related to houseware products, automotive and industrial products, food packaging, and many other products.

[0173] Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that- 49 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that the features described herein are applicable to all aspects of the embodiments described herein. Further, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. For example, although a specific ordered series of steps is described above, the order of these steps can be varied. For example, in some applications bonding web layers together and anchoring and / or constraining elastic strands to form an elastic composite component can be performed at alternate stages of the process.

[0174] Additionally, although multiple bonding apparatuses are illustrated in the systems above, it will be apparent that, in some applications, additional or fewer bonding apparatuses may be desirable, and aspects of the bonding apparatuses discussed above may be combined in a single bonding apparatuses if desired. Further, it is contemplated that a bonding apparatus can be configured to receive two or more products (e. ., two or more elastic composite components).

[0175] Thus, it will be appreciated by those skilled in the art that, while the disclosure has been described above in connection with particular non-limiting examples and examples, the disclosure is not necessarily so limited, and numerous other non-embodiments, examples, uses, modifications and departures from the non-limiting examples, examples and uses are intended to be encompassed by the claims attached hereto. The figures, similarly, depict selected configurations and are not intended to limit the scope of the present disclosure. The present disclosure is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0176] Various features and advantages of the invention are set forth in the following claims.- 50 - QB\94188861.1

Claims

PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 CLAIMSWe claim:

1. A system for bonding an elastic composite component, comprising:a first bonding apparatus including a first horn and a first anvil having a first anvil surface, the first anvil surface including an anchoring region defined by a plurality of non-linear continuous ridges; anda second bonding apparatus including a second horn and a second anvil having a second anvil surface, the second anvil surface including a constraining region defined by a plurality of discrete nodules that protrude outward from the second anvil surface;wherein at least one of the plurality of discrete nodules comprises a sidewall that is angled with respect to the second anvil surface at an angle selected to constrain an elastic strand in a selected trajectory.

2. The system of claim 1, wherein the second horn interacts with the plurality of discrete nodules of the second bonding apparatus to form a matrix of constraining bonds that are spaced apart at a distance greater than a distance between adjacent anchoring bonds formed when the first horn interacts with the anchoring region of the first bonding apparatus.

3. The system of claim 1, wherein the sidewall is angled at an acute angle with respect to the second anvil surface.

4. The system of claim 1, wherein the sidewall is angled at an obtuse angle with respect to the second anvil surface.

5. The system of claim 1, wherein the at least one of the plurality of discrete nodules further comprises a second sidewall that is at one of an acute angle an obtuse angle with respect to the second anvil surface, and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface.- 51 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 6. The system of claim 1, wherein the sidewall is angled at a right angle with respect to the second anvil surface.

7. The system of claim 1, wherein the at least one of the plurality of discrete nodules further comprises a second sidewall that is at a right angle with respect to the second anvil surface, and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface.

8. The system of claim 1, wherein each of the plurality of discrete nodules comprises a sidewall that is angled with respect to the anvil surface at an angle selected to maintain an elastic strand in a selected trajectory.

9. The system of claim 8, wherein the at least one of the plurality of discrete nodules further comprises a second sidewall that is at an obtuse angle or a right angle with respect to the second anvil surface, and a working surface that extends between the sidewall and the second sidewall in a direction substantially parallel to the second anvil surface.

10. The system of claim 1, further comprising:a first web infeed assembly to feed a first web layer in a machine direction toward the first bonding apparatus;a second web infeed assembly to feed a second web layer in the machine direction toward the first bonding apparatus; andat least one tensioning device to provide a first plurality of elastic strands between the first web layer and the second web layer; andwherein the anchoring region of the first anvil surface imparts a non-linear pattern of anchoring bonds on the first web layer, the second web layer, or both to anchor the first plurality of elastic strands between the first web layer and the second web layer.

11. The system of claim 10, further comprising:- 52 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 a third web infeed assembly to feed a third web layer in a machine direction toward the second bonding apparatus; andat least another tensioning device to feed a second plurality of elastic strands in the machine direction, the second plurality of elastic strands disposed between the third web layer and either the first web layer or the second web layer; andwherein the constraining region of the second anvil surface imparts a matrix of constraining bonds on the third web layer and at least one of the first web layer and the second web layer to constrain the second plurality of elastic strands between the third web layer and either the first web layer or the second web layer.

12. The system of claim 11, further comprising:a strand guide that maintains the first plurality of elastic strands in a substantially straight configuration; anda curved strand laydown guide that guides the second plurality of elastic strands in a curved laydown pattern.

13. A system for anchoring and constraining elastic strands within an elastic composite component, comprising:a first ultrasonic bonding apparatus including a first horn and a first anvil having a first anvil surface to impart a first bonding pattern on an elastic composite component to anchor a first plurality of elastic strands between a first web layer of the elastic composite component and a second web layer of the elastic composite component; anda second ultrasonic bonding apparatus including a second horn and a second anvil having a second anvil surface to impart a second bonding pattern on the elastic composite component to constrain a second plurality of elastic strands between a third web layer of the elastic composite component and either the first web layer or the second web layer;wherein the first anvil surface comprises a plurality of continuous ridges and the second anvil surface comprises a plurality of discrete nodules, each of the discrete nodules comprising a working surface located above the anvil surface and at least one sidewall extending between the second anvil surface and the working surface.- 53 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.0009414. The system of claim 13, wherein the at least one sidewall of each of the plurality of discrete nodules angles at an acute angle relative to the second anvil surface.

15. The system of claim 13, wherein the first ultrasonic bonding apparatus is upstream of the second ultrasonic bonding apparatus in a machine direction, and the second ultrasonic bonding apparatus is aligned relative to the first ultrasonic bonding apparatus such that the second bonding pattern overlaps the first bonding pattern in the elastic composite component.

16. The system of claim 13, wherein the plurality of continuous ridges are sinusoidal.

17. The system of claim 13, wherein a working surface of the plurality of continuous ridges is planar or grooved.

18. The system of claim 13, wherein a working surface of at least one of the first and second horns is grooved.

19. The system of claim 13, wherein the first plurality of elastic strands are straight elastic strands, and wherein the first bonding pattern is configured to anchor the straight elastic strands within the elastic composite component between facing bonds of a pair of anchoring bonds of the first bonding pattern; andwherein the second plurality of elastic strands are curved elastic strands, and wherein the second bonding pattern is configured to constrain the curved elastic strands within the elastic composite component within a matrix of constraining bonds; andwherein an unbonded interval between adjacent constraining bonds is greater than an unbonded interval between adjacent anchoring bonds of the first bonding pattern.

20. The system of claim 13, further comprising:an elastic strand guide that guides the first plurality of elastic strands onto the first web layer or the second web layer in a curved configuration; and- 54 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 a curved strand laydown guide that guides the second plurality of elastic strands onto the first web layer or the second web layer in a curved configuration, wherein the curved strand laydown guide is downstream of the first ultrasonic bonding apparatus and upstream of the second ultrasonic bonding apparatus in a machine direction.

21. The system of claim 20, wherein the curved strand laydown guide comprises one or more swinging arms or a crank and arm assembly.

22. The system of claim 13, wherein the first ultrasonic bonding apparatus is configured to join the first web layer of the elastic composite component and the second web layer of the elastic composite component; andwherein the second ultrasonic bonding apparatus is configured to join a third web layer to the joined first and second web layers.

23. The system of claim 13, further comprising a third ultrasonic bonding apparatus downstream of the first and second ultrasonic bonding apparatuses in a machine direction, the third ultrasonic bonding apparatus comprising at least one horn that cooperates with a working surface of at least one anvil having a third bonding pattern thereon, the third bonding pattern configured to form intermittent anchoring bond patterns in a machine direction and / or at locations adjacent at least one side seam region of the elastic composite component.

24. The system of claim 23, wherein the third ultrasonic bonding apparatus is aligned relative to the first ultrasonic bonding apparatus and / or the second ultrasonic bonding apparatus such that the third bonding pattern overlaps the first bonding pattern and / or the second bonding pattern on the elastic composite component.

25. The system of claim 13, further comprising a bonding apparatus comprising an adhesive applicator, the adhesive applicator being configured to create discrete anchor regions for the second plurality of elastic strands at locations adjacent at least one side seam region of the elastic composite component.- 55 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 26. A method of anchoring and constraining elastic strands within an elastic composite component, the method comprising:bonding, with a first bonding apparatus, a first web layer with a second web layer to anchor a first plurality of elastic strands in position relative to the first and second web layers and form a first intermediate product, the first bonding apparatus including a first horn and a first anvil having a first plurality of bonding features arranged on a surface thereof that interact with the first horn to form a first bonding pattern comprising pairs of anchoring bonds that anchor the first plurality of elastic strands;guiding a third web layer and a second plurality of elastic strands onto the first intermediate product; andbonding, with a second bonding apparatus positioned downstream from the first bonding apparatus, the third web layer with the first intermediate product to constrain the second plurality of elastic strands within a curved profile relative to the third web layer and the first intermediate product and form a second intermediate product, the second bonding apparatus including a second horn and a second anvil having a second plurality of bonding features arranged on a surface thereof that interact with the second horn to form a second bonding pattern comprising constraining bonds, wherein the constraining bonds are spaced apart at a distance greater than the pairs of anchoring bonds.

27. The method of claim 26, wherein the first bonding pattern is a non-linear bonding pattern.

28. The method of claim 26, wherein the second bonding pattern is a constraining dot bonding pattern.

29. The method of claim 26, further comprising bonding, with a third bonding apparatus, the second intermediate product to anchor the second plurality of elastic strands adjacent a deactivated region of the elastic composite component.- 56 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 30. The method of claim 26, further comprising bonding, with a third bonding apparatus, the second intermediate product to anchor cut ends of the second plurality of elastic strands.

31. The method of claim 26, further comprising bonding, with a third bonding apparatus, the second intermediate product to bond side seam regions of the second intermediate product.

32. The method of claim 31, wherein bonding the side seam regions of the second intermediate product includes anchoring ends of the first plurality of elastic strands, the second plurality of elastic strands, or both within the side seam regions.

33. The method of claim 26, wherein guiding the second plurality of elastic strands onto the elastic composite component includes placing the second plurality of elastic strands onto the elastic composite component in a curved configuration using a curved strand laydown guide.

34. The method of claim 26, further comprising forming the second bonding pattern to partially overlap the first bonding pattern.

35. An elastic composite component, comprising:a first web layer;a second web layer;a first plurality of elastic strands anchored between the first web layer and the second web layer by a first bonding pattern comprising a non-linear pattern of ultrasonic anchoring bonds; and a second plurality of elastic strands constrained between a third web layer and either the first web layer or the second web layer by a second bonding pattern comprising a matrix of ultrasonic constraining bonds; andwherein an unbonded interval between adjacent constraining bonds of the second bonding pattern is greater than an unbonded interval between adjacent anchoring bonds of the first bonding pattern.- 57 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.0009436. The elastic composite component of claim 35, wherein the first bonding pattern partially overlaps the second bonding pattern.

37. The elastic composite component of claim 35, wherein the first plurality of elastic strands are straight elastic strands that are anchored within the elastic composite component between facing bonds of a pair of anchoring bonds; andwherein the second plurality of elastic strands are curved elastic strands that are constrained in a curved path within the matrix of constraining bonds.

38. The elastic composite component of claim 35, wherein the second plurality of elastic strands are further secured within a leg region of the elastic composite component at a plurality of discrete anchor regions, the discrete anchor regions comprising one of an adhesive material and a plurality of ultrasonic anchoring bonds.

39. The elastic composite component of claim 38 wherein the discrete anchor regions are located adjacent at least one side seam region of the elastic composite component.

40. The elastic composite component of claim 38, wherein the discrete anchor regions are located adjacent a deactivated region of the elastic composite component.

41. The elastic composite component of claim 38, wherein the discrete anchor regions are located adjacent cut ends of the second plurality of elastic strands.

42. A system for bonding an elastic composite component, comprising:an anvil comprising a work surface, the work surface divided into an anchoring region comprising a plurality of continuous ridges configured to anchor an elastic strand, and a constraining region having a plurality of discrete nodules, each of the plurality of discrete nodules comprising a work surface and at least one sidewall extending from the work surface to a surface of the anvil, the plurality of discrete nodules configured to constrain an elastic strand;- 58 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 a first horn located to direct ultrasonic energy to at least a first portion of the anchoring region; anda second horn located downstream of the first horn to direct ultrasonic energy to the constraining region.

43. The system of claim 42, wherein at least one of the plurality of discrete nodules comprises a sidewall that is angled with respect to the surface of the anvil at an angle selected to constrain an elastic strand in a selected curved trajectory.

44. The system of claim 43, wherein the sidewall is angled at an acute angle with respect to the surface of the anvil.

45. The system of claim 42, further comprising:a first web infeed assembly and a second web infeed assembly to feed a first web layer a second web layer toward the anvil at a location upstream of the first horn in a machine direction;at least one tensioning device to provide a first plurality of elastic strands between the first web layer and the second web layer; anda third web infeed assembly to feed a third web layer toward the anvil at a location downstream of the first horn and upstream of the second horn in the machine direction; and at least another tensioning device to feed a second plurality of elastic strands in the machine direction, the second plurality of elastic strands disposed between the third web layer and either the first web layer or the second web layer.

46. The system of claim 45, wherein the plurality of continuous ridges impart a nonlinear pattern of anchoring bonds on the first web layer, the second web layer, or both to anchor the first plurality of elastic strands between the first web layer and the second web layer, and wherein the plurality of discrete nodules impart a constraining dot bonding pattern on the third web layer and at least one of the first web layer and the second web layer to constrain the second- 59 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 plurality of elastic strands between the third web layer and either the first web layer or the second web layer.

47. The system of claim 45, further comprising:a strand guide that maintains the first plurality of elastic strands in a substantially straight configuration; anda curved strand laydown guide that guides the second plurality of elastic strands in a curved laydown pattern.

48. The system of claim 42, wherein the second horn is located to direct ultrasonic energy to a second portion of the anchoring region.

49. A method of anchoring and constraining elastic strands within an elastic composite component, the method comprising:bonding a first web layer with a second web layer to form a first bonding pattern that anchors a first plurality of elastic strands in position relative to the first and second web layers and form a first intermediate product via interaction between a first horn and an anchoring region of a first anvil of a first bonding apparatus, the anchoring region comprising a plurality of continuous ridges;guiding a third web layer and a second plurality of elastic strands onto the first intermediate product at a location downstream of the first horn; andbonding the third web layer with the first intermediate product to form a second bonding pattern that constrains the second plurality of elastic strands within a curved profile relative to the third web layer and the first intermediate product and form a second intermediate product via interaction between a second horn and a constraining region of the first anvil of the first bonding apparatus, the constraining region having a plurality of discrete nodules, each of the plurality of discrete nodules comprising a work surface and at least one sidewall extending from the work surface to a surface of the anvil.- 60 - QB\94188861.1PCT Patent Application JOARef. 1000.339 PCT Attorney Docket No. 510169.00094 50. The method of claim 49, wherein the first bonding pattern is a non-linear bonding pattern.

51. The method of claim 49, wherein the second bonding pattern is a constraining dot bonding pattern.

52. The method of claim 49, further comprising bonding, with a second bonding apparatus, the second intermediate product to bond side seam regions of the second intermediate product.

53. The method of claim 49, further comprising bonding, with a second bonding apparatus, the second intermediate product to anchor the second plurality of elastic strands adjacent a deactivated region of the elastic composite component.

54. The method of claim 49, further comprising bonding, with a second bonding apparatus, the second intermediate product to anchor cut ends of the second plurality of elastic strands.

55. The method of claim 52, wherein bonding the side seam regions of the second intermediate product includes anchoring ends of the first plurality of elastic strands, the second plurality of elastic strands, or both within the side seam regions.

56. The method of claim 49, wherein guiding the second plurality of elastic strands onto the elastic composite component includes placing the second plurality of elastic strands onto the elastic composite component in a curved configuration using a curved strand laydown guide.

57. The method of claim 49, further comprising forming the second bonding pattern to partially overlap the first bonding pattern.- 61 - QB\94188861.1

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