Forming belt for shaped nonwoven

Patent metadata

Field	Value
Publication number	US-10190244-B2
Application number	US-201615221625-A
Country	US
Kind code	B2
Filing date	Jul 28, 2016
Priority date	Jul 31, 2015
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

A forming belt for use in making a nonwoven substrate. The forming belt includes a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use. A plurality of discrete belt patterns can be ordered in sequential relationship with respect to the longitudinal direction. At least a majority of the plurality of discrete belt patterns can include a discrete belt pattern overall area, a first forming zone having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface and a second forming zone having a second pattern of three-dimensional raised elements extending outwardly from the plane of the first surface. The first forming zone can have a first air permeability value and the second forming zone can have a second air permeability value. The first air permeability value can be different from the second air permeability value.

First claim

What is claimed is:

1. A forming belt for use in making a nonwoven substrate, the forming belt comprising:
a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use; and
at least three discrete belt patterns ordered in sequential relationship with respect to the longitudinal direction, each of the plurality of discrete belt patterns comprising:
a discrete belt pattern overall area;
a first forming zone having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface; and
a second forming zone having a second pattern of three-dimensional raised elements extending outwardly from the plane of the first surface;
wherein the first forming zone has a first air permeability value;
wherein the second forming zone has a second air permeability value;
wherein the first air permeability value is different from the second air permeability value;

wherein the first pattern of three-dimensional raised elements on a first discrete belt pattern is different from both the first pattern of three-dimensional raised elements on a second discrete belt pattern and the first pattern of three-dimensional raised elements on a third discrete belt pattern.

2. The forming belt of claim 1 , wherein the air permeability value varies, in one of the forming zones, in at least a cross direction of the first surface.

3. The forming belt of claim 1 , wherein the first air permeability value is different from the second air permeability value by a factor of 1.2.

4. The forming belt of claim 1 , wherein the first air permeability value is different from the second air permeability value by a factor of 2.

5. The forming belt of claim 1 , wherein the discrete belt pattern overall area of each discrete belt pattern are from 150 cm 2 to 500 cm 2 .

6. The forming belt of claim 1 , further comprising a third forming zone, the third forming zone having a third pattern of three-dimensional features extending outwardly from the plane of the first surface, the third forming zone having a third air permeability value.

7. A forming belt for use in making a nonwoven substrate, the forming belt comprising:
a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use; and
a first and second discrete belt pattern, the first and second discrete belt patterns ordered in sequential relationship with respect to the longitudinal direction, each of the discrete belt patterns having a discrete belt pattern overall area, a first forming zone having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface, and a second forming zone having a second pattern of three-dimensional raised elements extending outwardly from the plane of the first surface, wherein for both the first and second discrete belt patterns the first forming zone has a first air permeability value and the second forming zone has a second air permeability value, and the first air permeability value is different from the second air permeability value, and the first discrete belt pattern has a visual appearance different from the second discrete belt pattern, wherein the first pattern of three-dimensional raised elements on the first discrete belt pattern is different from the first pattern of three-dimensional raised elements on the second discrete belt pattern.

8. The forming belt of claim 7 , wherein the air permeability value of either of the first or second discrete belt patterns varies in a cross direction of the first surface.

9. The forming belt of claim 7 , wherein the first air permeability value of the first discrete belt pattern is different from the second air permeability value by a factor of 1.2.

10. The forming belt of claim 7 , wherein the first air permeability value of the first discrete belt pattern is different from the second air permeability value by a factor of 2.

11. The forming belt of claim 7 , wherein the discrete belt pattern overall areas of each discrete belt pattern arc from 150 cm 2 to 500 cm 2 .

12. The forming belt of claim 7 , each discrete belt pattern further comprising a third forming zone, the third forming zone having a pattern of three-dimensional features extending outwardly from the plane of the first surface, the third forming zone having a third air permeability value.

13. An endless forming belt for use in making a nonwoven substrate, the forming belt comprising:
a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use;
at least three discrete belt patterns ordered in sequential relationship with respect to the longitudinal direction, each of the plurality of discrete belt patterns having a discrete belt pattern length, a first forming zone and a second forming zone, wherein the first forming zone has a first air permeability value and the second forming zone has a second air permeability value, and the first air permeability value is different from the second air permeability value; and wherein the sum of the discrete belt pattern lengths equals the length of the endless forming belt, as measured parallel to the axis parallel to the longitudinal direction;
wherein a first pattern of three-dimensional raised elements on a first discrete belt pattern is different from both a first pattern of three-dimensional, raised elements on a second discrete belt pattern and a first pattern of three-dimensional raised elements on a third discrete belt pattern.

14. The forming belt of claim 13 , wherein the air permeability varies in a cross direction of the first surface.

15. The forming belt of claim 13 , wherein the first air permeability value is different from the second air permeability value by a factor of 1.2.

16. The forming belt of claim 13 , wherein the first air permeability value is different from the second air permeability value by a factor of 2.

17. The forming belt of claim 13 , wherein the discrete belt patterns have a width, the length and width determining an overall area, and the overall areas of each discrete belt pattern are from 150 cm 2 to 500 cm 2 .

18. The forming belt of claim 13 , further comprising a third forming zone, the third forming zone having a third pattern of three-dimensional features extending outwardly from the plane of the first surface, the third forming zone having a third air permeability value.

19. The forming belt of claim 13 , having a reinforcing element of woven filaments on which the three-dimensional raised elements are cured.

Assignees

• Procter & Gamble

Inventors

• Ashraf Arman
• Rasch David Mark

Classifications

• A61F13/51305

  having areas of different permeability · CPC title

• D04H3/07 Primary

  otherwise than in a plane, e.g. in a tubular way · CPC title

• A61F13/51394

  creating a visual effect, e.g. having a printed or coloured topsheet, printed or coloured sub-layer but being visible from the topsheet, other than embossing for purposes of bonding, wicking, acquisition, leakage-prevention · CPC title

• D04H3/16

  with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion · CPC title

• D04H3/14

  with bonds between thermoplastic yarns or filaments produced by welding · CPC title