Apparatus and system for fabricating an elastic nonwoven material
An apparatus for fabricating an elastic nonwoven material generally includes a rotary ultrasonic horn and a rotary anvil positionable in close proximity to the ultrasonic horn. The anvil has a face with a width and a circumferential axis. The face has a plurality of ridges each of which defines a plurality of interspaced lands and notches.
1. An apparatus for fabricating an elastic nonwoven material, said apparatus comprising:
a first bonding module; and
a second bonding module positionable in close proximity to the first bonding module, wherein one of the first bonding module and the second bonding module has a face with a width and a circumferential axis, the face having a plurality of ridges extending non-linearly across the circumferential axis such that each of the plurality of ridges has a curvilinear axis and extends substantially arcuately relative to the circumferential axis, each of the plurality of ridges are parallel to each other and define a plurality of interspaced lands and notches.
2. The apparatus of claim 1 , wherein the notches are oriented substantially parallel to the circumferential axis.
3. The apparatus of claim 1 , wherein the ridges extend across substantially the entire width of the face.
4. The apparatus of claim 1 , wherein all pairs of adjacent ridges on the face are substantially equally spaced apart from one another along the circumferential axis.
5. The apparatus of claim 1 , wherein an adjacent pair of ridges has a spacing measured along the circumferential axis of between about 0.10 inches and about 1.00 inches.
6. The apparatus of claim 1 , wherein all of the notches on the face are substantially the same size.
7. The apparatus of claim 1 , wherein the other one of the first bonding module and the second bonding module has a face with a contour that is substantially continuous.
8. The apparatus of claim 1 , wherein the face has a first circumferential region with ridges defining notches of a first size, and a second circumferential region with ridges defining notches of a second size different than the first size.
9. The apparatus of claim 1 , wherein the face has a first widthwise region in which the ridges define notches of a first size, and a second widthwise region in which the ridges defining notches of a second size different than the first size.
10. A first bonding module positionable in close proximity to a second bonding module for fabricating an elastic nonwoven material, the first bonding module comprising a face with a width and a circumferential axis, the face having a plurality of ridges extending non-linearly across the circumferential axis such that each of the plurality of ridges has a curvilinear axis and extends substantially arcuately relative to the circumferential axis, each of the plurality of ridges are parallel to each other and define a plurality of interspaced lands and notches.
11. The first bonding module of claim 10 , wherein the notches are oriented substantially parallel to the circumferential axis.
12. The first bonding module of claim 10 , wherein the ridges extend across substantially the entire width of the face.
13. The first bonding module of claim 10 , wherein all pairs of adjacent ridges on the face are substantially equally spaced apart from one another along the circumferential axis.
14. The first bonding module of claim 10 , wherein an adjacent pair of ridges has a spacing measured along the circumferential axis of between about 0.10 inches and about 1.00 inches.
15. The first bonding module of claim 10 , wherein all of the notches on the face are substantially the same size.
16. The first bonding module of claim 10 , wherein the face has a first circumferential region with ridges defining notches of a first size, and a second circumferential region with ridges defining notches of a second size different than the first size.
17. The first bonding module of claim 10 , wherein the face has a first widthwise region in which the ridges define notches of a first size, and a second widthwise region in which the ridges defining notches of a second size different than the first size.
18. A system for fabricating an elastic nonwoven material, said system comprising:
a bonding apparatus comprising:
a first bonding module; and
a second bonding module positionable in close proximity to the first bonding module, wherein one of the first bonding module and the second bonding module has a face with a width and a circumferential axis, the face having a plurality of ridges extending non-linearly across the circumferential axis such that each of the plurality of ridges has a curvilinear axis and extends substantially arcuately relative to the circumferential axis, each of the plurality of ridges are parallel to each other and define a plurality of interspaced lands and notches; and
a supply station configured to:
supply a non-woven fabric to at least one of the first bonding module face and the second bonding module face; and
supply a plurality of elastic strands to a surface of the non-woven fabric.
19. The system of claim 18 , wherein the notches are oriented substantially parallel to the circumferential axis.
20. The system of claim 18 , wherein the ridges extend across substantially the entire width of the face.