Continuous solid state web coating process and webs produced thereby

• US 6,355,330 B1
• Filed: 07/20/1999
• Issued: 03/12/2002
• Est. Priority Date: 03/07/1997
• Status: Expired due to Term

• Current Assignee: KX Technologies, LLC (Berkshire Hathaway Incorporated)
• Original Assignee: Koslow Tech Corp
• Inventors: Kendrick, Richard D., Spilkin, Gordon, Koslow, Evan E.
• Primary Examiner(s): LAM, CATHY FONG FONG
• Application Number:
  US09/358,183
• Time in Patent Office: 966 Days
• Field of Search: 428/114, 604/355, 604/356, 604/358, 604/259, 604/360, 604/366
• US Class Current: 428/114
• 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 13/531 having a homogeneous composition through the thickness of the pad A61F13/538, A61F13/539 take precedence
• CPC Class Codes: A61F 13/8405 Additives, e.g. for odour, disinfectant or pH control
• CPC Class Codes: A61F 2013/530489 being randomly mixed in with other material
• CPC Class Codes: A61F 2013/530554 and being fixed to a web
• CPC Class Codes: A61F 2013/530671 being mixed with mineral or inert material, e.g. "introfying particles"
• CPC Class Codes: A61L 15/18 containing inorganic materials
• CPC Class Codes: A61L 15/20 containing organic materials
• CPC Class Codes: A61L 15/32 Proteins, polypeptides; Degradation products or derivatives thereof, e.g. albumin, collagen, fibrin, gelatin A61L15/225 takes precedence
• CPC Class Codes: A61L 15/46 Deodorants or malodour counteractants, e.g. to inhibit the formation of ammonia or bacteria
• CPC Class Codes: A61L 2300/102 Metals or metal compounds, e.g. salts such as bicarbonates, carbonates, oxides, zeolites, silicates
• CPC Class Codes: A61L 2300/104 Silver, e.g. silver sulfadiazine
• CPC Class Codes: A61L 2300/108 Elemental carbon, e.g. charcoal
• CPC Class Codes: A61L 2300/202 with halogen atoms, e.g. triclosan, povidone-iodine
• CPC Class Codes: A61L 2300/208 Quaternary ammonium compounds
• CPC Class Codes: A61L 2300/404 Biocides, antimicrobial agents, antiseptic agents
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/28011 Other properties, e.g. density, crush strength
• CPC Class Codes: B01J 20/28016 Particle form
• CPC Class Codes: B01J 20/2803 Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/28033 : Membrane, sheet, cloth, pad, lamellar or mat
• CPC Class Codes: B01J 20/28047 : Gels
• CPC Class Codes: B01J 20/28085 : being more than 50 nm, i.e. macropores
• CPC Class Codes: B05D 1/28 : performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
• CPC Class Codes: B05D 1/30 : performed by gravity only, i.e. flow coating
• CPC Class Codes: B05D 3/12 : by mechanical means
• CPC Class Codes: B05D 5/06 : to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B32B 2255/02 : on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/28 : Multiple coating on one surface
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2305/30 : Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• 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 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D06M 11/485 : Oxides or hydroxides of manganese; Manganates permanganates D06M11/50
• CPC Class Codes: D06M 11/74 : with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: D06M 11/76 : with carbon oxides or carbonates D06M11/75 takes precedence; with percarbonic acids or their salts D06M11/50; with urea D06M13/432
• CPC Class Codes: D06M 11/79 : with silicon dioxide, silicic acids or their salts
• CPC Class Codes: D06M 13/46 : Compounds containing quaternary nitrogen atoms hydrazinium compounds D06M13/338; betaines, sulfo-betaines D06M13/342
• CPC Class Codes: D06M 15/15 : Proteins or derivatives thereof
• CPC Class Codes: D06M 15/227 : of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
• CPC Class Codes: D06M 15/333 : of vinyl acetate; Polyvinylalcohol
• CPC Class Codes: D06M 16/00 : Biochemical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. enzymatic
• CPC Class Codes: D06M 23/08 : Processes in which the treating agent is applied in powder or granular form adhesives for multi-layer textile fabrics D06M17/00
• CPC Class Codes: D06N 3/0056 : characterised by the compounding ingredients of the macro-molecular coating D06N3/005 takes precedence
• CPC Class Codes: D06N 3/0063 : Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• CPC Class Codes: D06N 3/0093 : by applying resin powders; by sintering
• CPC Class Codes: D06N 3/045 : with polyolefin or polystyrene (co-)polymers
• CPC Class Codes: D21H 19/58 : Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
• CPC Class Codes: D21H 21/14 : characterised by function or properties in or on the paper D21H19/66, D21H27/02 take precedence
• CPC Class Codes: D21H 21/36 : Biocidal agents, e.g. fungicidal, bactericidal, insecticidal agents
• CPC Class Codes: D21H 23/64 : the material being non-fluent at the moment of transfer, e.g. in form of preformed, at least partially hardened coating
• CPC Class Codes: D21H 25/06 : of impregnated or coated paper D21H25/08 takes precedence
• CPC Class Codes: D21H 27/08 : Filter paper self-supporting filtering material B01D39/14; making on paper-making machines D21F11/14
• CPC Class Codes: Y10T 428/24132 : including grain, strips, or filamentary elements in different layers or components parallel

Abstract

One or more particulate active agents are fused to the surface of a substrate web by mixing the particulate agents with a particulate binder having a particle size not exceeding an average diameter of approximately 40 microns and coating the composite mixture onto the surface of the substrate. Thereafter; the coated substrate is heated to a temperature equal to or greater than the Vicat softening temperature of the binder and compressed within the nip of a pair of pressure rolls to achieve fusion. If desired, a top layer may be placed upon the coated composite prior to the compression step. Also disclosed are various products manufactured by the process.

Claims

1. A first substrate web having a first surface upon which is deposited a particulate iodinated resin and particles of a thermoplastic binder fused to both of said particulate resin and said first surface, wherein at least one of said substrate, said particulate iodinated resin, and said particles of a thermoplastic binder is treated with an antibacterial agent.

2. The web of claim 1 comprising, in addition, a second substrate web having a second surface spaced from said first substrate web and fused to said thermoplastic binder.

3. The substrate web of claim 1, wherein said antibacterial agent is selected from the group consisting of:

a quaternary amine, a milk protein, triclosan, a silver impregnated zeolite, activated carbon, and mixtures thereof.

4. A composite structure comprising a first substrate having a first surface upon which is deposited particulate carbon and particles of a thermoplastic binder fused to both of said particulate carbon and said first surface, wherein at least one of said substrate, said particulate carbon, and said particles of a thermoplastic binder is treated with an antibacterial agent.

5. The web of claim 4 comprising, in addition, a second substrate web having a second surface spaced from said first surface and fused to said thermoplastic binder.

6. The composite structure of claim 4, wherein said antibacterial agent is selected from the group consisting of:

a quaternary amine, a milk protein, triclosan, a silver impregnated zeolite, activated carbon, and mixtures thereof.

7. A first substrate web having a first surface upon which is deposited particulate sodium bicarbonate and particles of a thermoplastic binder fused to both of said particulate sodium bicarbonate and said first surface, wherein at least one of said substrate, said particulate sodium bicarbonate, and said particles of a thermoplastic binder is treated with an antibacterial agent.

8. The web of claim 7 comprising, in addition, a second substrate web having a second surface spaced from said first surface and fused to said thermoplastic binder.

9. The substrate web of claim 7, wherein said antibacterial agent is selected from the group consisting of:

a quaternary amine, a milk protein, triclosan, a silver impregnated zeolite, activated carbon, and mixtures thereof.

10. A first substrate web having a first surface upon which is deposited particulate manganese oxide and particles of a thermoplastic binder fused to both of said particulate manganese oxide and said first surface, wherein at least one of said substrate, said particulate manganese oxide, and said particles of a thermoplastic binder is treated with an antibacterial agent.

11. The web of claim 10 comprising, in addition, a second substrate web having a second surface spaced from said first surface and fused to said thermoplastic binder.

12. The substrate web of claim 10, wherein said antibacterial agent is selected from the group consisting of:

a quaternary amine, a milk protein, triclosan, a silver impregnated zeolite, activated carbon, and mixtures thereof.

13. A composite structure comprising a first substrate having a first surface upon which is deposited a particulate liquid absorbent and particles of a thermoplastic binder fused to both said particulate liquid absorbent and said first surface, wherein at least one of said substrate, said particulate liquid absorbent, and said particles of a thermoplastic binder is treated with an antibacterial agent.

14. The web of claim 13 comprising, in addition, a second substrate web having a second surface spaced from said first surface and fused to said thermoplastic binder.

15. The composite structure of claim 13, wherein said antibacterial agent is selected from the group consisting of:

a quaternary amine, a milk protein, triclosan, a silver impregnated zeolite, activated carbon, and mixtures thereof.