Apparatus and method for application of discrete material segments to running web material

An apparatus for applying discrete segments to a continuous web, the apparatus comprising:

• a roller rotating to translate a first continuous web along a roller surface of the roller, the first continuous web comprising one or more layers;
• a vacuum anvil rotating to translate a second continuous web along an anvil surface of the vacuum anvil, the roller and vacuum anvil adjacent to one another at a first location;
• at least one cutting element selectively positionable adjacent the roller and that interacts with the roller to cut the first continuous web into a plurality of discrete segments;
• and
• a bonding device operable with the vacuum anvil to bond each of the plurality of discrete segments to the second continuous web at a second location downstream from the first location in a machine direction in which the plurality of discrete segments and the second continuous web are translated;
• wherein the roller rotates to translate the plurality of discrete segments to the first location, after being cut by the interaction of the at least one cutting element and the roller;
• and
• wherein the vacuum anvil generates a vacuum pressure at the anvil surface to cause each of the plurality of discrete segments to transfer from the roller onto the second continuous web at the first location and to be held in place on the second continuous web;
• and
• wherein the vacuum anvil comprises:
• a plurality of vacuum holes formed in the anvil surface through which the vacuum pressure is communicated;
• and
• a plurality of raised protrusions extending out from the anvil surface and that interact with the bonding device to form a pattern of bonds between the second continuous web and respective discrete segments of the plurality of discrete segments.