Kimberly-clark Worldwide, Inc.

Paul Gordon Klemp

Thomas David Ehlert

Patrick Sean McNichols

Timothy James Blenke

Tauhid Husain

Harold Norbert Heller

Barton Andrew Laughlin

Jeffrey Joseph Samida

John Ford Condron

Jack Lee Couillard

Daniel Hoo

Chinmay Suresh Betrabet

Robin Kurt Nason

Chris Lee Heikkinen

Jeffery R Cottingham

James Melvin Gaestel

Craig Steven Brennecke

Jeffrey Ray Cottingham

An ultrasonic processing method and apparatus ( ) can include a rotatable, ultrasonic horn member ( ) that is operatively joined to an isolation member ( ) which has high rigidity. Additionally, a rotatable anvil member ( ) can be cooperatively positioned to provide a selected horn-anvil gap ( ) between the anvil member ( ) and the horn member ( ). A transfer device ( ) can be configured to selectively adjust the horn-anvil gap ( ), and an automated drive ( ) can be operatively connected to the transfer device ( ) to selectively modify the horn-anvil gap ( ). A force sensor ( ) can be configured to detect a gap force at the horn-anvil gap ( ), and an electronic processor ( ) can be configured to employ an output from the force sensor ( ) to monitor the gap force, and provide a drive signal to the automated drive ( ) to thereby adjust the horn-anvil gap ( ).

Control of processing force and process gap in rigid rotary ultrasonic systems

An ultrasonic processing method and apparatus ( ) can include a rotatable, ultrasonic horn member ( ) that is operatively joined to an isolation member ( ) which has high rigidity. A rotatable anvil member ( ) can be cooperatively positioned to provide a selected horn-anvil gap ( ), and an automated drive ( ) can be connected to an actuator ( ), or other transfer device, to automatically adjust the horn-anvil gap ( ). An electronic processor ( ) can be configured to monitor an intermittent gap force detected from an output provided by a force sensor ( ), and can provide a drive signal to the automated drive ( ) to thereby adjust the horn-anvil gap ( ) to operatively maintain a target, gap force value.

Rotary ultrasonic bonder or processor capable of high speed intermittent processing

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.

Methods and apparatus for intermittent rotary ultrasonic bonding system

This invention relates to apparatus and methods for fabricating a web or consolidating web precursor material in fabricating a web. The invention comprises ultrasonic bonding apparatus including an anvil roll receiving web materials thereon and receiving first and second rotary ultrasonic horns. The rotary ultrasonic horns, in combination with the anvil roll, ultrasonically bond segments of e.g. first and second webs to each other. Third and fourth rotary ultrasonic horns spaced about the circumference of the anvil roll, in combination with the anvil roll, ultrasonically bond other segments of the webs to each other. The full widths of the webs can be ultrasonically bonded using the rotary ultrasonic horns. An outer surface of the anvil roll preferably carries a bonding pattern defining the locations where bonding of the webs occurs. Additional e.g. third and fourth webs can be bonded by the ultrasonic bonding apparatus. Such bonding can occur after first and second webs have been bonded to each other by first and second rotary ultrasonic horns. In some instances, the third and fourth rotary ultrasonic horns can ultrasonically bond portions of the first and second webs that have already been bonded together by one or both of the first and second rotary ultrasonic horns. In other embodiments, multiple repeat bonding of substantially the same segment of the web can occur. In still other embodiments, a batt of bondable material such as fibers can be consolidated by ultrasonic bonding with rotary ultrasonic horns to form a unitary web. The apparatus can operate at web speeds greater than 1000 feet minute.

Methods and apparatus for a full width ultrasonic bonding device

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Hortonville, WI, United States of America

Paul Gordon Klemp