Apparatuses and Methods for Bonding Substrates

A method for forming a seam, the method comprising the steps of:

• rotating a drum about an axis of rotation, the drum comprising a fluid nozzle and a press member, the press member having an outer surface;
• rotating an anvil roll about an axis of rotation adjacent to the drum, the anvil roll having a compliant outer circumferential surface, the anvil roll and the drum forming a nip there between;
• advancing a first substrate layer in a machine direction onto the drum, the first substrate layer having an inner surface and an outer surface, wherein the outer surface of the first substrate layer is adjacent the drum;
• advancing a second substrate layer in the machine direction, the second substrate layer having an inner surface and an outer surface, wherein the first substrate layer is between the second substrate layer and the drum, wherein the first and second substrate layers have a combined, uncompressed caliper;
• wrapping the first and second substrate layers around a portion of the drum;
• heating a fluid to a temperature sufficient to at least partially melt the first and second substrate layers;
• moving the fluid nozzle radially outward relative to the axis of rotation of the drum;
• directing a jet of the heated fluid onto the first and second substrate layers;
• partially melting the first and second substrate layers;
• retracting the fluid nozzle radially inward relative to the axis of rotation of the drum;
• shifting the press member radially outward relative to the axis of rotation of the drum;
• advancing the first and second substrate layers through the nip;
• and
• compressing the first and second substrate layers between the press member and the anvil roll and deforming the compliant outer circumferential surface of the anvil roll.