# US 11,925,538 B2 · Apparatus and method of manufacturing an elastic composite structure for an absorbent sanitary product

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- Number: US 11,925,538 B2
- Document ID: US11925538B2
- Status: Granted
- Kind: B2
- Application number: 16/721,414
- Filed: 2019-12-19
- Published: 2020-07-09
- Granted: 2024-03-12
- Earliest claimed: 2019-01-07
- Assignees: Curt G. Joa, Inc.
- Applicants: Curt G. Joa, Inc.
- Inventors: Robert Earl Andrews; David Edward Schuette; Jeffrey Wayne Fritz; Justin Marshall Lafferty
- Web page: https://patentgrep.com/patent/US11925538B2

## CPC

- A61F 13/15593: {having elastic ribbons fixed thereto; Devices for applying the ribbons}
- A61F 13/15699: {Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs}
- A61F 13/15658: {Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof}
- A61F 13/4902: {characterised by the elastic material}
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 65/087: {using both a rotary sonotrode and a rotary anvil}
- B29C 65/7894: {of continuously moving sheets or webs}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/221: {being in the form of a sinusoidal wave (B29C66/2272 takes precedence)}
- B29C 66/433: {Casing-in, i.e. enclosing an element between two sheets by an outlined seam (for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261)}
- B29C 66/7294: {Non woven mats, e.g. felt}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/83511: {jaws mounted on rollers, cylinders or drums}
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B32B 37/20: involving the assembly of continuous webs only
- A61F 2013/15869: {with ultrasonic energy}
- A61F 2013/15991: {in making composite multi-layered product}
- B29K 2995/0046: Elastic
- B29L 2031/4878: {Diapers, napkins}
- B32B 2307/51: Elastic
- B32B 2555/02: Diapers or napkins
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

An apparatus and method for manufacturing an elastic composite structure for an absorbent sanitary product includes a bonding unit configured to bond a first web layer to a second web layer via a bond pattern that includes at least one bond line having at least one pair of adjacent bonds. The bonding unit secures an elastic thread within a passage defined by the at least one pair of adjacent bonds. The passage has a cross-sectional area smaller than a cross-sectional area of the elastic thread in a non-tensioned state.

## Claims

### Claim 1

An apparatus for manufacturing an elastic composite structure, the apparatus comprising:
at least one means for transporting a first web layer and a second web layer in a machine direction;
at least one means for transporting an elastic thread in the machine direction in a tensioned state; and
a bonding unit configured to:
bond the first web layer to the second web layer absent adhesive via a bond pattern comprising at least one bond line having at least one pair of adjacent bonds; and
anchor the elastic thread within a passage defined by the at least one pair of adjacent bonds, the passage having a cross-sectional area smaller than a cross-sectional area of the elastic thread in a non-tensioned state;
wherein the bonding unit comprises an ultrasonic bonding unit having a face with at least one welding line defined thereon, each welding line of the at least one welding line arranged to form the bond pattern;
wherein the at least one welding line comprises a notch positioned between a pair of projections;
wherein the notch has a cross-sectional area that is smaller than the cross-sectional area of the elastic thread in the non-tensioned state, and
wherein the notch has a stepped geometry.

### Claim 2 (depends on 1)

The apparatus of claim 1 wherein facing surfaces of the at least one pair of adjacent bonds are spaced apart at a distance greater than a strand diameter of the elastic thread in the non-tensioned state.

### Claim 3 (depends on 1)

The apparatus of claim 1 wherein the notch is v-shaped.

### Claim 4 (depends on 1)

The apparatus of claim 1 wherein facing edges of the at least one pair of adjacent bonds are spaced at a distance greater than a diameter of the at least one elastic thread in the non-tensioned state.

### Claim 5 (depends on 1)

The apparatus of claim 1 further comprising an ultrasonic bond between the first web layer and the second web layer.

### Claim 6 (depends on 1)

The apparatus of claim 1 wherein the at least one notch has one of a v-shaped geometry and a u-shaped geometry.