APPARATUS AND METHODS FOR FORMING LAMINATES CONTAINING ADDITIVE MATTER

• US 20140155853A1
• Filed: 11/08/2013
• Published: 06/05/2014
• Est. Priority Date: 11/09/2012
• Status: Abandoned Application

• Current Assignee: Curt G. Joa, Inc.
• Original Assignee: Curt G. Joa, Inc.
• Inventors: HANDZIAK, PERRY
• Application Number:
  US14/075,494
• Publication Number:
  US 20140155853A1
• Time in Patent Office: Days
• US Class Current: 604/369
• CPC Class Codes: A61F 13/15658 Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
• CPC Class Codes: A61F 13/5323 having absorbent material located in discrete regions, e.g. pockets
• CPC Class Codes: A61F 2013/530481 having superabsorbent materials, i.e. highly absorbent polymer gel materials
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2264/025 Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/04 characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

Discrete or continuous products are disclosed including formation of laminates containing an additive matter. Such additive matters comprise gels, superabsorbent polymers, particulate additives and the like. Pulp-free absorbent cores for use in disposable products such as diapers and sanitary napkins can be formed by the methods and apparatus of the present invention. Additive matter is carried between two layers in void spaces in a scrim layer to form a laminate.

Claims

1. A laminate comprising:

a first material layer;

a second material layer having a plurality of void spaces carried by said first material layer;

an additive material carried in said void spaces;

and a third material layer coupled to said first and second layers to form a laminated material.

2. A laminate according to claim 1, said second material layer comprising a scrim material.

3. A laminate according to claim 2, said scrim material selected from the group of bonded, unbounded, woven, polymer, non-polymer, and textile.

4. A laminate according to claim 2, said scrim material formed as woven netting.

5. A laminate according to claim 2, said scrim material containing a wicking component.

6. A laminate according to claim 1, said void spaces comprising at least one of square and round voids.

7. A laminate according to claim 1, said additive comprising super absorbent polymer.

8. A laminate according to claim 1, said additive comprising cellulosic fluff.

9. A laminate according to claim 1, said additive comprising a mixture of super absorbent polymer and cellulosic fluff.

10. A laminate according to claim 1, said additive comprising a fluid.

11. A laminate according to claim 1, said additive material carried in selected void spaces to define a pattern of additive material.

12. A laminate according to claim 1, said first and said second material layers comprising nonwoven material.

13. A laminate according to claim 1, said laminate further comprising said first material layer, said second material layer having a plurality of void spaces, a fourth layer comprising intermediate web layer overlying said second material layer, a fifth layer comprising an additional material layer having a plurality of void spaces overlying said intermediate web layer, additive material carried in said void spaces of said fifth layer, and said third material layer overlying said fifth layer.

14. A method of forming a laminate comprising:

supplying a first material layer;

supplying a second material layer carried by said first material layer, said second material layer comprising a plurality of void spaces;

coupling said first material to said second material layer;

supplying an additive material to said void spaces of said second material layer;

supplying a third material layer and coupling said third material layer to said first and second material layers to create a laminated material.

15. A method according to claim 14, said first and said second material layers comprising nonwoven material.

16. A method according to claim 14, said additive material supplied by at least one of vibration, gravity, ultrasonic agitation, and vacuum to said first material layer through said void spaces.

17. A method according to claim 14, said additive material comprising at least one of a gel or liquid.

18. A method according to claim 17, said additive material supplied by a dispensing nozzle.

19. A method according to claim 14, said additive material supplied intermittently.

20. A method according to claim 14, said method further comprising stretching said second material in at least one of a cross machine direction or a machine direction prior to coupling said first material to said second material layer.

21. A method according to claim 14, said coupling steps accomplished by at least one of adhesives, heat, heat-activated adhesive, ultrasonic, RF energy activation, microwave activation, UV activation, and pressure.