Method for producing an effervescent laminate structure

• US 20050067095A1
• Filed: 09/24/2004
• Published: 03/31/2005
• Est. Priority Date: 09/26/2003
• Status: Abandoned Application

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Meyers, Gary Earl, Cilley, Timothy John Walter, Hasenoehrl, Erik John, McAtee, David Michael
• Application Number:
  US10/949,833
• Publication Number:
  US 20050067095A1
• Time in Patent Office: Days
• US Class Current: 156/276
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2432/00 Cleaning articles, e.g. mops, wipes personal care B32B2555/00
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties

Abstract

A method for producing a laminate structure includes providing a first layer comprising a substrate, forming an intermediate layer of an effervescent composition and a bonding agent on the first layer, applying a second layer onto the intermediate layer to form a multilayered structure, and bonding the multilayered structure to produce a laminate structure, wherein at least one of the first and second layers is permeable to liquids.

Claims

1. A method for producing a laminate structure comprising:

a.) providing a first layer comprising a substrate;

b.) forming an intermediate layer on said first layer wherein said intermediate layer comprises an effervescent composition and a bonding agent;

c.) applying a second layer onto said intermediate layer to form a multilayered structure;

bonding said multilayered structure to produce a laminate structure comprising the first layer bonded to the second layer with the intermediate layer disposed therebetween, wherein at least one of the first and second layers is permeable to liquids.

2. The method of claim 1 wherein the effervescent composition has a pH from about 2.5 to about 9.0.

3. The method of claim 1 wherein the effervescent composition comprises solid alkaline and acidic materials.

4. The method of claim 3 wherein the alkaline material is selected from the group consisting of anhydrous salts of carbonates and bicarbonates;

alkaline peroxides and azides and mixtures thereof.

5. The method of claim 4 wherein the alkaline material is selected from the group consisting of sodium bicarbonate, potassium bicarbonate, sodium carbonate, potassium carbonate and mixtures thereof.

6. The method of claim 3 wherein said alkaline material has a total particle size of less than about 500 mesh.

7. The method of claim 3 wherein the acidic material is selected from the group consisting of C₂ to C₂₀ organic mono- and poly-carboxylic acids;

C₂ to C₂₀ organophosphorus acids;

C₂ to C₂₀ organosulfur acids, toluene sulfonic acid;

peroxides, lactones and mixtures thereof.

8. The method of claim 7 wherein the acidic material is selected from the group consisting of adipic, glutaric, succinic, tartaric, malic, maleic, lactic, salicylic, citric acids and mixtures thereof.

9. The method of claim 3 wherein said acid material has a total particle size of about 300 mesh.

10. The method of claim 3, wherein the ratio of said acidic material to said alkaline material is from about 20:

70 to about 70;

20.

11. The method of claim 1 wherein said laminate structure optionally comprises a powdered surfactant.

12. A method according to claim 11, wherein said structure generates greater than or equal to about 25 ml Average Lather Volume.

13. The method of claim 1 wherein the first and second layers extend beyond the intermediate layer laterally forming longitudinal edge portions and the method further comprises the step of applying longitudinal lines of adhesive material to the longitudinal edge portions of the first layer and bonding together the first and second layers along each of the edge portions.

14. The method of claim 1 wherein the first and second layers are the same or different and each of the first and second layers independently comprises a material selected from the group consisting of woven fabric, non-woven fabric, synthetic film, tissue paper and combinations thereof.

15. The method of claim 14 wherein the material has a basis weight of between about 1 g/m² and about 150 g/m².

16. The method of claim 1 wherein the intermediate layer is formed on the first layer at a coat weight of from about 50 g/m² to about 600 g/m².

17. The method of claim 16 wherein the intermediate layer is formed on the first layer at a coat weight of from about 300 g/m² to about 500 g/m².

18. The method of claim 1 wherein the bonding agent is selected from the group consisting of polypropylene, polyethylene, ethylene vinyl acetate and mixtures thereof.

19. The method of claim 18 wherein the bonding agent is present in an amount of from about 10 g/m² to about 120 g/m².

20. The method of claim 1 wherein the bonding agent has a melt flow index (M.F.I.) of at least about 25 g/10 min.

21. The method of claim 1 wherein the intermediate layer is formed by depositing a blend of the effervescent composition and the bonding agent on the first layer.

22. The method of claim 1 wherein the intermediate layer is formed by separately depositing the effervescent composition and the bonding agent on the first layer.

23. The method of claim 13 wherein said method further comprises:

e.) longitudinally slitting said laminate structure to produce narrow webs.

24. The method of claim 23 further comprising winding the narrow webs into rolls.

25. The method of claim 3 wherein the effervescent composition comprises from about 1 to about 80% of an alkaline material and from about 0.5% to about 80% of an acidic material based on the total weight of the effervescent composition.

26. A laminate article comprising a laminate structure produced in accordance with the method of claim 1.

27. A laminate article according to claim 26 in the form of an article for cleaning surfaces wherein the surfaces are selected from the group consisting of skin, hair, teeth, counters, sinks, tubs, fixtures, toilet bowls, and combinations thereof.

28. A method of producing a laminate structure comprising the following steps:

(a) providing a first layer of fibrous material,

(b) providing a second layer of fibrous material of a width such that it can contact the first layer along respective longitudinal edge portions,

(c) distributing a mixture of particles of effervescent material as well as bonding agent on the first layer of fibrous material to form an intermediate layer, the mixture being distributed in a manner such that the longitudinal edge portions of the first layer are left free,

(d) applying lines of adhesive to the longitudinal edge portions of the first layer, and

(e) combining the first layer, the intermediate layer and the second layer in a layered structure by the application of heat and pressure to melt the bonding agent so as to bond the first layer, the intermediate layer and the second layer with the lines of adhesive;

(f) bonding the first and second layers together along the longitudinal edge portions.

29. A method according to claim 28 wherein the lines of adhesive are applied in the form of substantially continuous lines.

30. A method for producing a laminate structure comprising:

a.) providing a first layer comprising a substrate;

b.) forming an intermediate layer on said first layer wherein said intermediate layer comprises a powdered surfactant and a bonding agent;

c.) applying a second layer onto said intermediate layer to form a multilayered structure;

bonding said multilayered structure to produce a laminate structure comprising the first layer bonded to the second layer with the intermediate layer disposed therebetween, wherein at least one of the first and second layers is permeable to liquids.

31. A method according to claim 30, wherein the structure generates greater than or equal to about 25 ml Average Lather Volume.