Apparatuses and methods for making absorbent articles with elastomeric laminates

Abstract

The present disclosure relates to methods and apparatuses for making elastomeric laminates with deactivated regions that may be used as components of absorbent articles. The methods and apparatuses may be configured with a pattern roll and a pressing surface adjacent the pattern roll. The pattern roll may include a bonding surface and a protuberance. As the pattern roll rotates, first and second substrates are welded together between the bonding surface and the pressing surface to create bonds between the first and second substrates. As the pattern roll continues to rotate, the first and second substrates and one or more stretched elastic strands are compressed between the pressing surface and the protuberance to sever the one or more stretched elastic strands to create deactivated regions in the elastomeric laminate. The processes and apparatuses may be configured to help prevent ends of the severed elastic strands from retracting in an uncontrolled fashion.

What is claimed is: 
     
         1 . An apparatus for making an elastomeric substrate, the apparatus comprising:
 a pattern roll adapted to rotate about an axis of rotation extending axially in a cross direction, the pattern roll comprising:
 a bonding surface positioned at a first radial distance R 1  from the axis of rotation; 
 discrete first channels in the bonding surface, wherein the discrete first channels are spaced apart from each other circumferentially and in the cross direction, the first channels comprising a first width W 1  extending axially along the axis of rotation and comprising a first depth D 1  extending radially inward from the bonding surface; and 
 a protuberance extending axially along the axis of rotation between two of the discrete first channels, wherein the protuberance extends radially outward from the axis of rotation to a second radial distance R 2  wherein R 2 >(R 1 −D 1 ); and 
   an ultrasonic horn comprising an energy transfer surface; the ultrasonic horn positioned adjacent the pattern roll to define a nip between the pattern roll and the energy transfer surface.   
     
     
         2 . The apparatus of  claim 1 , further comprising: a discrete second channel in the bonding surface, wherein the discrete second channel comprises a second width W 2  extending axially along the axis of rotation and comprising a second depth D 2  extending radially inward from the bonding surface; and wherein the second width W 2  is greater than the first width W 1  and/or the second depth D 2  is greater than the first depth D 1 . 
     
     
         3 . The apparatus of  claim 1 , wherein the discrete second channel is aligned axially with two discrete first channels and the discrete second channel is positioned circumferentially between the two discrete first channels. 
     
     
         4 . The apparatus of  claim 1 , wherein the discrete second channel is aligned axially with at least one discrete first channel and wherein the discrete second channel is positioned circumferentially between the one discrete first channel and the protuberance. 
     
     
         5 . The apparatus of  claim 1 , wherein the protuberance is defined by a portion of the bonding surface.