Method for making a bulked web
First Claim
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1. A method of producing a bulked web comprising the steps of:
- a) providing a web;
b) feeding the web in a first direction;
c) subjecting the web to incremental stretching in a direction perpendicular to said first direction to provide a bulky web;
d) gathering the bulky web wherein the bulky web has a first bulk dimension before gathering and a second bulk dimension after gathering, the bulk dimensions being substantially equal; and
e) stabilizing the bulky web to provide a stabilized bulked web.
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Abstract
A method for making a bulky web. A web is fed in a first direction. The web is subjected to incremental stretching in a direction perpendicular to the first direction to provide a bulky web. The bulky web is then stabilized to provide a stabilized bulked web, Optionally, the bulky web may be gathered after it has been subjected to incremental stretching.
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Citations
15 Claims
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1. A method of producing a bulked web comprising the steps of:
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a) providing a web;
b) feeding the web in a first direction;
c) subjecting the web to incremental stretching in a direction perpendicular to said first direction to provide a bulky web;
d) gathering the bulky web wherein the bulky web has a first bulk dimension before gathering and a second bulk dimension after gathering, the bulk dimensions being substantially equal; and
e) stabilizing the bulky web to provide a stabilized bulked web. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
f) winding the stabilized bulked web onto a take-up roll.
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6. The method of claim 1 further comprising the additional step of:
f) festooning the stabilized bulked web into a box.
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7. The method of claim 1 wherein said stabilization comprises feeding the web through a nip formed by a pair of patterned compression rollers.
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8. The method of claim 7 wherein said patterned compression rollers provide a continuous compression stabilization embossment across the entire width of the web.
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9. The method of claim 1 wherein step c) comprises subjecting the web to incremental stretching in a direction parallel to said first direction.
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10. The method of claim 9 wherein said incremental stretching comprises feeding the web through a nip formed by a pair of incremental stretching rollers.
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11. The method of claim 10 wherein each said incremental stretching roller comprises a plurality of teeth and a plurality of grooves.
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12. The method of claim 1 wherein said web is a nonwoven web selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.
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13. The method of claim 12 wherein said fibers comprise a polymer selected from the group consisting of polyolefins, polyesters, and polyamides.
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14. The method of claim 13 wherein said polyolefin is selected from the group consisting of one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
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15. The method of claim 14 wherein said web is a composite material comprising a mixture of fibers and one or more other materials selected from the group consisting of wood pulp, staple fibers, particulates, and super-absorbent materials.
Specification