Laminate web comprising an apertured layer and method for manufacture thereof

• US 20030028165A1
• Filed: 06/14/2002
• Published: 02/06/2003
• Est. Priority Date: 12/21/1999
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Strube, John B, Benson, Douglas H, Curro, John J
• Granted Patent: US 7,037,569 B2
• Time in Patent Office: Days
• US Class Current: 604/378
• CPC Class Codes: A47L 1/15 Cloths, sponges, pads, or the like, e.g. containing cleaning agents
• CPC Class Codes: A47L 13/17 containing cleaning agents A47L13/19 takes precedence ; chemical compositions C11D17/049
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/15707 Mechanical treatment, e.g. notching, twisting, compressing, shaping
• CPC Class Codes: A61F 13/15756 Applying tabs, strips, tapes, loops; Knotting the ends of pads
• CPC Class Codes: A61F 13/512 characterised by its apertures, e.g. perforations
• CPC Class Codes: A61F 13/5146 having apertures of perforations
• CPC Class Codes: A61F 13/51478 being a laminate, e.g. multi-layered or with several layers
• CPC Class Codes: A61F 13/53 characterised by the absorbing medium A61F13/20 takes precedence
• CPC Class Codes: A61F 13/536 having discontinuous areas of compression
• CPC Class Codes: A61F 13/537 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer A61F13/538 takes precedence
• CPC Class Codes: A61F 13/539 characterised by the connection of the absorbent layers with each other or with the outer layers
• CPC Class Codes: A61F 13/8405 Additives, e.g. for odour, disinfectant or pH control
• CPC Class Codes: A61K 8/0208 Tissues; Wipes; Patches
• CPC Class Codes: A61Q 19/00 Preparations for care of the skin
• CPC Class Codes: A61Q 19/10 Washing or bathing preparations
• CPC Class Codes: B08B 1/143 Wipes
• CPC Class Codes: B26F 1/20 with tools carried by a rotating drum or similar support B26F1/22 takes precedence
• CPC Class Codes: B26F 1/24 Perforating by needles or pins
• CPC Class Codes: B29C 2793/0045 Perforating
• CPC Class Codes: B29C 55/023 : using multilayered plates or sheets
• CPC Class Codes: B29C 55/18 : by squeezing between surfaces, e.g. rollers
• CPC Class Codes: B29C 59/007 : Forming single grooves or ribs, e.g. tear lines, weak spots by moulding B29C37/0057; folding lines B29C53/06; in metal articles B21D17/00; by cutting B26D3/08
• CPC Class Codes: B29C 59/04 : using rollers or endless belts
• CPC Class Codes: B29C 65/02 : by heating, with or without pressure
• CPC Class Codes: B29C 65/08 : using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/18 : using heated tools
• CPC Class Codes: B29C 65/7437 : the tool being a perforating tool perforating as mechanical pre-treatment B29C66/02242
• CPC Class Codes: B29C 66/1122 : Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/21 : said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/436 : Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats joining through openings B29C66/304
• CPC Class Codes: B29C 66/45 : Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/4722 : Fixing strips to surfaces other than edge faces fixing strips to edge faces B29C63/0026
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/723 : being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/7294 : Non woven mats, e.g. felt
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/81433 : being toothed, i.e. comprising several teeth or pins comprising a single tooth B29C66/81429, or being patterned
• CPC Class Codes: B29C 66/83411 : Roller, cylinder or drum types B29C66/83431 takes precedence; rollers, cylinders or drums moving relative to and tangentially to the parts to be joined B29C66/8362
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/83511 : jaws mounted on rollers, cylinders or drums
• CPC Class Codes: B29K 2001/00 : Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/04 : Polymers of ethylene
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/10 : Polymers of propylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2105/0854 : in the form of a non-woven mat
• CPC Class Codes: B29K 2995/0068 : Permeability to liquids; Adsorption
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2031/4878 : Diapers, napkins
• CPC Class Codes: B29L 2031/737 : Articles provided with holes, e.g. grids, sieves nets B29L2028/00
• CPC Class Codes: B29L 2031/7374 : Slotted
• CPC Class Codes: B32B 15/04 : comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 2037/0092 : in which absence of adhesives is explicitly presented as an advantage
• CPC Class Codes: B32B 2038/0028 : Stretching, elongating
• CPC Class Codes: B32B 2038/047 : Perforating
• CPC Class Codes: B32B 2305/18 : Fabrics, textiles
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2307/202 : Conductive
• CPC Class Codes: B32B 2307/204 : Di-electric
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/0076 : characterised in that the layers are not bonded on the totality of their surfaces
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/0012 : Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: B32B 38/04 : Punching, slitting or perforating
• 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 7/04 : Interconnection of layers
• CPC Class Codes: B65D 75/30 : Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
• CPC Class Codes: C11D 17/049 : Cleaning or scouring pads; Wipes
• CPC Class Codes: H01B 7/0838 : Parallel wires, sandwiched between two insulating layers
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24562 : Interlaminar spaces
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 442/647 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/656 : Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
• CPC Class Codes: Y10T 442/668 : Separate nonwoven fabric layers comprise chemically different strand or fiber material
• CPC Class Codes: Y10T 442/671 : Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/69 : Autogenously bonded nonwoven fabric
• CPC Class Codes: Y10T 442/693 : Including a paper layer

Abstract

A laminate web comprising a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second nonwovens. The third material is apertured in regions adjacent the bond sites, such that the first and second nonwoven webs are joined through the apertures. In one embodiment an apertured laminate web is disclosed, having a first extensible web having a first elongation to break, and a second extensible web joined to the first extensible web at a plurality of bond sites, the second extensible web having elongation to break. A third web material is disposed between the first and second nonwovens, the third web material having a third elongation to break which is less than both of the first or second elongations to break. In a further embodiment, an apertured laminate web is disclosed, having first and second extensible webs being joined at a plurality of discrete bond sites and a third material disposed between the first and second nonwoven webs. The first and second nonwoven webs are in fluid communication via the apertures and have distinct regions being differentiated by at least one property selected from the group consisting of basis weight, fiber orientation, thickness, and density.

Claims

1. A non-apertured laminate web comprising:

a) a first web;

b) a second web joined to said first web in a face to face relationship at a plurality of discrete bond sites, the first and second webs forming an interior region therebetween;

c) a third material being disposed between said first and second webs, said third material being differentiated from said first or second web by at least one material property selected from thermal properties, elongation properties, elastic properties, or conductive properties; and

d) said third material being apertured in regions coincident said bond sites, such that said first and second webs are joined through said apertures and wherein said third material is involved in said discrete bond sites and substantially fills said interior region.

2. The laminate web of claim 1, wherein said laminate is joined by bonds in the absence of adhesive.

3. The laminate web of claim 1, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 3:

1.

4. The laminate web of claim 1, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 10:

1.

5. The laminate web of claim 1, wherein said first or second web comprises a nonwoven.

6. The laminate web of claim 1, wherein said third material comprises cellulosic tissue paper.

7. The laminate web of claim 1, wherein said third material comprises metal foil.

8. The laminate web of claim 1, wherein said third material is a polymeric film.

9. The laminate web of claim 1, wherein said third material is open cell foam.

10. A laminate web having a plurality of apertures, said laminate web comprising:

a) a first extensible web having a first elongation to break;

b) a second extensible web joined to said first extensible web at a plurality of bond sites, said second extensible web having a second elongation to break; and

c) a third web material being disposed between said first and second webs, said third web material having a third elongation to break which is less than both of said first or second elongations to break.

11. The laminate web of claim 10, wherein said laminate is joined by bonds in the absence of adhesive.

12. The laminate web of claim 10, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 3:

1.

13. The laminate web of claim 10, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 10:

1.

14. The laminate web of claim 10, wherein said first or second extensible web comprises a nonwoven.

15. The laminate web of claim 10, wherein said third web material comprises cellulosic tissue paper.

16. The laminate web of claim 10, wherein said third web material is conductive.

17. The laminate web of claim 10, wherein said third web material comprises metal foil.

18. The laminate web of claim 10, wherein said third web material is an open cell foam.

19. A laminate web having a plurality of apertures, said laminate web comprising:

a) first and second extensible webs being joined at a plurality of discrete bond sites;

b) a third material disposed between said first and second nonwoven webs; and

c) the first and second extensible webs being in fluid communication via the apertures and having distinct regions being differentiated by at least one property selected from the group consisting of basis weight, fiber orientation, thickness, and density.

20. The laminate web of claim 19, wherein said laminate is joined by bonds in the absence of adhesive.

21. The laminate web of claim 19, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 3:

1.

22. The laminate web of claim 19, wherein said bond sites are discrete thermal bonds having an aspect ratio of at least 10:

1.

23. The laminate web of claim 19, wherein said first or second extensible web comprises a nonwoven.

24. The laminate web of claim 19, wherein said third material comprises cellulosic tissue paper.

25. The laminate web of claim 19, wherein said third material comprises metal foil.

26. The laminate web of claim 19, wherein said third material is a polymeric film.

27. The laminate web of claim 19, wherein said third material is an open cell foam.

28. A disposable absorbent article comprising a laminate web having a plurality of apertures, said laminate web comprising:

a) first and second extensible webs being joined at a plurality of discrete bond sites;

b) a third material disposed between said first and second nonwoven webs; and

c) said first and second extensible webs being in fluid communication via the apertures and having distinct regions being differentiated by at least one property selected from the group consisting of basis weight, fiber orientation, thickness, and density.

29. The laminate web of claim 28, wherein said first or second extensible web comprises a nonwoven.

30. The laminate web of claim 28, wherein said third material comprises absorbent gelling material.

31. A method for forming a laminate web comprising the steps of:

(a) providing first and second web materials comprising thermoplastic material;

(b) providing at least one third web material;

(c) providing a thermal point bonder having a plurality of protuberances;

(d) guiding said third web material between said first and second web materials in a face-to-face layered relationship to said thermal point bonder;

(e) displacing said third web material with said protuberances at discrete, spaced apart locations to form apertures in said third material; and

(f) thermally point bonding said first and second outer web materials to form bond sites at discrete, spaced apart locations coincident with said protuberances, thereby forming a bonded laminate.

32. The method of claim 31, wherein said third web material is provided in an unapertured condition.

33. The method of claim 31, wherein said third web material is involved in said thermal point bonding about a perimeter of a said bond sites.

34. A method for forming an apertured laminate web comprising the steps of:

(a) providing first and second web materials comprising thermoplastic material;

(b) providing at least one third web material;

(c) providing a thermal point bonder having a plurality of protuberances;

(d) providing a stretching means;

(e) guiding said third web material between said first and second web materials in a face-to-face layered relationship to said thermal point bonder;

(f) displacing said third web material with said protuberances at discrete, spaced apart locations to form apertures in said third material;

(g) thermally point bonding said first and second outer web materials at discrete, spaced apart locations corresponding to said protuberances, thereby forming a bonded laminate; and

(g) stretching said bonded laminate to form the apertured laminate web.

35. The method of claim 34, wherein said first and second web materials comprise nonwoven fibers.

36. The method of claim 34, wherein said third web material has an elongation to break which is less than both of said first or second web materials.

37. The method of claim 34, wherein said third web material has an elongation to break which is greater than both of said first or second web materials.

38. The method of claim 34, wherein said thermal point bonder comprises a patterned calendar roller.

39. The method of claim 34, wherein said stretching means comprises incremental stretching.

40. The method of claim 34, wherein said protuberances of said thermal point bonder have an aspect ratio of between about 3 and 20.

41. The method of claim 34, wherein said protuberances of said thermal point bonder have an aspect ratio of 10.