This invention relates to apparatus and methods for intermittently bonding a substrate web in fabricating a blank subassembly for an absorbent article. The invention comprises
ultrasonic bonding apparatus including an anvil roll, a substrate web thereon, and at least one rotary
ultrasonic horn. The substrate web can comprise at least first and second
layers of material. The rotary
ultrasonic horn, in combination with the anvil roll, ultrasonically bonds intermittent segments of the first and second
layers of the substrate web to each other. Such intermittent bonds can comprise end seals for the absorbent articles. The
ultrasonic horn and anvil roll are periodically separated from each other to provide the intermittent bonding of the substrate web. An
actuator apparatus periodically moves the anvil roll and ultrasonic horn from engaging contact with each other preventing
bond formation. The
actuator apparatus can include a
cam mechanism moving one of the anvil roll and ultrasonic horn from engaging contact with the other during rotation of the rotary ultrasonic horn. The
cam mechanism can create a physical gap between the ultrasonic horn and the anvil roll. The
cam mechanism moves either the ultrasonic horn and the anvil roll toward the other of the ultrasonic horn and anvil roll at a velocity of no more than about 80 millimeters / second to prevent bounce or
impact loading when the horn and anvil roll are in engaging contact. The anvil roll comprises a substrate-receiving surface generally moving the substrate web through the nip at a surface speed of at least 300 meters per minute. The ultrasonic
system generally creates bonds between the first and second
layers of the substrate web at least about 600 times per minute.