Methods and apparatus for intermittent rotary ultrasonic bonding system

A process for securing layers of a substrate web comprising:

• (a) outputting ultrasonic energy from a rotary ultrasonic horn having a first outer radial surface extending about at least a substantial portion of a circumference thereof;
• (b) receiving the substrate web to be worked by ultrasonic energy at a substrate web receiving surface of an anvil roll the substrate web receiving surface cooperating with the ultrasonic horn to form a close relationship comprising a nip between the ultrasonic horn and the anvil roll for passage of the substrate web therethrough;
• and
• (c) positioning the first outer radial surface of the ultrasonic horn in engaging contact with the substrate web receiving surface of the anvil roll, thereby to bond the layers of the substrate web passing through the nip;
• and
• (d) periodically displacing the first outer radial surface of the ultrasonic horn from the engaging contact with the anvil roll, thus creating a physical gap between the ultrasonic horn and the substrate web on the anvil roll, and subsequently returning the ultrasonic horn to the anvil roll, and thereby re-establishing the engaging contact with the anvil roll.

An ultrasonic system, comprising:

• (a) an ultrasonic horn having a first outer radial surface extending about at least a substantial portion of a circumference thereof, said ultrasonic horn outputting ultrasonic energy;
• (b) an anvil roll having a second outer radial surface extending about at least a substantial portion of a circumference thereof, said anvil roll having a substrate receiving surface for receiving a substrate web to be worked by ultrasonic energy, said substrate receiving surface cooperating with said ultrasonic horn to form a close relationship comprising a nip between said ultrasonic horn and said anvil roll for passage of the substrate web therethrough;
• and
• (c) actuator apparatus arranged to interact with said ultrasonic horn and said anvil roll, and, during operation of said ultrasonic system, to assist in positioning the first outer radial surface of said ultrasonic horn substantially in engaging contact with said anvil roll, thereby to bond the substrate web passing the first outer radial surface, said actuator apparatus periodically displacing the first outer radial surface of said ultrasonic horn from the engaging contact with said anvil roll, thus creating a physical gap between said ultrasonic horn and the substrate web on said anvil roll, and subsequently returning said ultrasonic horn to said anvil roll, and thereby re-establishing the engaging contact with said anvil roll.

An ultrasonic system, comprising:

• (a) a rotary ultrasonic horn having a length, and a first central axis of rotation along the length of said ultrasonic horn, said rotary ultrasonic horn outputting ultrasonic energy;
• (b) an anvil roll having an outer radial surface comprising a substrate-moving surface, said anvil roll cooperating with said rotary ultrasonic horn to form a close relationship comprising a nip between said rotary ultrasonic horn and said anvil roll at the substrate-receiving surface;
• and
• (c) cam apparatus arranged to interact with said ultrasonic horn and said anvil roll, said cam apparatus periodically displacing said ultrasonic horn and said anvil roll from engaging contact with each other, thus creating a physical gap between said ultrasonic horn and the combination of the substrate web and said anvil roll,
• such that said ultrasonic horn intermittently bonds a substrate web traversing in the nip between said ultrasonic horn and said anvil roll.

An ultrasonic system, comprising:

• (a) a rotary ultrasonic horn having a first central axis of rotation;
• (b) an anvil roll cooperating with said rotary ultrasonic horn to form a close relationship comprising a nip between said rotary ultrasonic horn and said anvil roll;
• and
• (c) actuator apparatus arranged to move at least one of said ultrasonic horn and said anvil roll with respect to each other, said actuator apparatus periodically moving one of said ultrasonic horn and said anvil roll away from the other of said ultrasonic horn and said anvil roll, and thus creating a physical separation between said ultrasonic horn and the combination of said anvil roll and any substrate web on said anvil roll, and returning said ultrasonic horn and said anvil roll into engaging contact with each other, with such substrate web therebetween, such that said ultrasonic system intermittently bonds such substrate web as such substrate web traverses the nip between said ultrasonic horn and said anvil roll, and does not bond such substrate web when said ultrasonic horn and said anvil roll are thus separated from each other,
• the physical separation between said ultrasonic horn and the combination of such substrate web and said anvil roll, and the approach velocity of one of said ultrasonic horn and said anvil roll, controlled by said actuator apparatus, in a direction toward the other of said ultrasonic horn and said anvil roll, being such as to avoid harmful impact loading of one of said ultrasonic horn and said anvil roll against the other of said ultrasonic horn and said anvil roll.

An ultrasonic system, comprising:

• (a) an ultrasonic horn outputting ultrasonic energy;
• and
• (b) an anvil roll receiving a substrate web to be worked by ultrasonic energy, said anvil roll cooperating with said ultrasonic horn to form a close relationship comprising a nip between said ultrasonic horn and said anvil roll for passage of such substrate web therethrough;
• and
• (c) actuator apparatus arranged to interact with said ultrasonic horn and said anvil roll, and, during operation of said ultrasonic system, to assist in positioning said ultrasonic horn and said anvil roll in loading position with respect to each other such that the ultrasonic energy bonds the substrate web, said actuator apparatus periodically moving one of said ultrasonic horn and said anvil roll a distance away from the other of said ultrasonic horn and said anvil roll, the distance causing a physical separation of from about 0.2 millimeter to about 2 millimeters between said ultrasonic horn, and the substrate web on said anvil roll.