COMPOSITE WEBS AND METHODS OF MANUFACTURING SAME
First Claim
1. A method for forming a composite web in a continuous process, the method comprising:
- delivering molten polymeric composition onto an outer surface of a forming tool, wherein the molten polymeric composition enters a plurality of depressions formed into the outer surface, and wherein a skin layer of molten polymeric composition extends between the plurality of depressions over the outer surface of the forming tool;
forming a structured web on the forming tool by solidifying the molten polymeric composition in the skin layer and within the plurality of discrete depressions on the forming tool, wherein the structured web comprises a plurality of structures formed in the shape of the plurality of depressions and a skin layer interconnecting the plurality of structures; and
removing the formed structured web from the forming tool while the structured web is in a relaxed state on the forming tool, wherein the removing comprises adhering the skin layer and the plurality of structures to a first major surface of a carrier web using adhesive exposed on the first major surface of the carrier web;
wherein the carrier web and the structured web adhered thereto form a composite web comprising an indefinite length.
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Abstract
Composite webs having a structured web attached to a carrier web and methods of manufacturing the composite webs are disclosed. The structured web may include a plurality of structures that protrude from the structured web. The methods may involve delivering a molten polymeric composition onto the outer surface of a forming tool that includes a plurality of depressions formed in the outer surface. The molten polymer enters depressions in the outer surface of the forming tool and is solidified therein such that a plurality of structures are formed in the shape of the depressions. A skin layer of the polymeric composition may extend between the depressions, such that the structured web formed on the forming tool includes a skin layer connecting the structures. The structured web is removed from the forming tool after solidification of the polymeric composition by adhering the structured web to a carrier web using adhesive located between the carrier web and structured web.
61 Citations
36 Claims
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1. A method for forming a composite web in a continuous process, the method comprising:
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delivering molten polymeric composition onto an outer surface of a forming tool, wherein the molten polymeric composition enters a plurality of depressions formed into the outer surface, and wherein a skin layer of molten polymeric composition extends between the plurality of depressions over the outer surface of the forming tool; forming a structured web on the forming tool by solidifying the molten polymeric composition in the skin layer and within the plurality of discrete depressions on the forming tool, wherein the structured web comprises a plurality of structures formed in the shape of the plurality of depressions and a skin layer interconnecting the plurality of structures; and removing the formed structured web from the forming tool while the structured web is in a relaxed state on the forming tool, wherein the removing comprises adhering the skin layer and the plurality of structures to a first major surface of a carrier web using adhesive exposed on the first major surface of the carrier web; wherein the carrier web and the structured web adhered thereto form a composite web comprising an indefinite length. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. An elastic composite web comprising:
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an extensible carrier web; a structured web adhesively attached to a first major surface of the carrier web by adhesive located between the first major surface of the carrier web and the structured web, the structured web comprising a skin layer interconnecting a plurality of structures; wherein the structures of the plurality of structures exhibit elastic behavior; wherein the plurality of structures are in a selected arrangement on the first major surface of the carrier; and wherein the structured web is in a relaxed state on the first major surface of the carrier web. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30)
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31. A composite web comprising:
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a carrier web; a structured web adhesively attached to a first major surface of the carrier web by adhesive located between the first major surface of the carrier web and the structured web, the structured web comprising a skin layer interconnecting a plurality of structures; wherein the plurality of structures comprise a thickness of 1 millimeter or less and the skin layer comprises a thickness of 50 micrometers or less; wherein the plurality of structures are in a selected arrangement on the first major surface of the carrier; and wherein the structured web is in a relaxed state on the first major surface of the carrier web. - View Dependent Claims (32, 33, 34, 35, 36)
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Specification