A system for ultrasonic bonding of elastic includes a rotating roll. The rotating roll has an exterior surface. A removable shell layer is attached to the external surface. The removable shell layer includes one or more patterned segments. The patterned segments include a shell channels formed through the removable shell layer to form a pattern.

Apparatus and methods are provided to allow for creation of an elastic laminate. Non-stretched elastic can be laid at peaks over a nonwoven layer contained in valleys and atop peaks. Stretched elastic can be laid over tented nonwoven to create nonwoven tunnels when a second nonwoven is laid atop the first nonwoven and elastic, and the tunnels resist un-stretching of stretched elastic strands by frictional or obstruction forces. An elastic assembly or structure comprising a first and second layer of material bonded at spaced apart bond sites is disclosed, with a plurality of elastic strands disposed in a non-linear manner between said first and second layer of material, so that said strands meander in a cross-machine direction and traverse a machine direction line, restraining movement of the strands by frictional forces between the strands and the non-woven layers.

An elastic nonwoven material includes a first non-woven fabric including a plurality of rows. Each row has a plurality of adjacent bonds formed therein. The elastic nonwoven material also includes a first elastic strand entrapped between a first pair of adjacent bonds within a first row of the plurality of rows, and a second elastic strand entrapped between a second pair of adjacent bonds within the first row. A third pair of adjacent bonds within the first row is free of elastic material therebetween and is located between the first pair of adjacent bonds and the second pair of adjacent bonds.

A composite web including: a first continuous web; at least one molded segment having at least one protrusion and a base portion at least partly delimiting the protrusion, the molded segment being obtained from a second continuous web; the molded segment being joined to the first continuous web by the base portion, the first continuous web and the molded segment delimiting at least one cavity at the protrusion.

An elastic film stretchable structure in which an elastic film is stacked between a first sheet layer having air permeability and a second sheet layer having air permeability, the first sheet layer and the second sheet layer are bonded through bonding holes penetrating the elastic film at a number of sheet bonded portions arranged at intervals. A region having the elastic film stretchable structure has a stretchable region that is stretchable in a stretchable direction, and the stretchable region is contracted in the stretchable direction by a contraction force of the elastic film and is extensible in the stretchable direction, and vent holes are formed on the elastic film at sites where the elastic film does not overlap with the sheet bonded portions.

An elastic resin material having a thermoplastic elastic resin as a main component is heated and melted, and the elastic resin material is discharged in a film or a linear shape from a discharge mechanism to form a film-shape or a linear-shape intermediate product. At a temperature above the temperature region at which the elastic resin material elastically deforms, extending is performed until the thickness or width of the film-shape intermediate product or the thickness of the linear-shape intermediate product assumes a prescribed value; with a cooling roller, the intermediate product is cooled to the temperature region at which the elastic resin material elastically deforms, and the intermediate product is hardened, forming a film-shape or linear-shape elastic member. The elastic member is stretched with a stretch roller to a prescribed stretching ratio, and the stretched elastic member is laminated on and bonded to a first base material sheet.

A three dimensional tape that may be used as a top sheet and a backsheet for a sanitary product, particularly a baby diaper or a sanitary pad. The three dimensional tape allows manufacturing of comparatively thinner, fluffless sanitary products with an improved comfort for the user. Manufacturing of the tape may be accomplished in-line, thereby dispensing with all of the logistics burden from outsourced products, and all of the environmental impact the logistics come with.

A disposable wearable article includes an elastic film stretchable structure in which an elastic film is laminated between a first sheet layer and a second sheet layer. The first sheet layer and the second sheet layer are bonded to each other through holes passing through the elastic film with many bonded portions arranged at intervals. A region having the elastic film stretchable structure includes a stretchable region that elastically stretches and contracts together with the elastic film. The stretchable region includes a plurality of elastic films disposed so as to have an overlapping portion. The number of laminated layers of the elastic film in a region located in an intermediate portion of the stretchable region in an orthogonal direction (XD) orthogonal to a stretchable direction (ED) is different from that in each of second regions adjacent to both sides of the first region.

An elastic sheet stretchable structure in which a first sheet layer and a second sheet layer are bonded through joint holes penetrating an elastic film at a plurality of sheet joined portions arranged at intervals is included. Joined portion groups in the stretchable region are in a relationship of intersecting a stretchable direction line at respective positions in an orthogonal direction or in a relationship of not intersecting the stretchable direction line at a separation width of 0.5 mm or less in the orthogonal direction of the stretchable direction line. The joined portion groups are in a relationship of not intersecting an oblique line at a predetermined separation width in the orthogonal direction in an oblique line group of oblique lines q in the orthogonal direction intersecting the stretchable direction line within an angle range γ of 45 degrees or less.

An absorbent article and method of making the absorbent article are disclosed. The absorbent article having a topsheet, a backsheet, and an absorbent core structure having one or more layers wherein at least one layer is a heterogeneous mass layer, wherein the topsheet and the heterogeneous mass are integrated such that they reside in the same X-Y plane.