Tip bonded formed laminates of film

Patent metadata

Field	Value
Publication number	US-11020932-B2
Application number	US-201816022794-A
Country	US
Kind code	B2
Filing date	Jun 29, 2018
Priority date	Jun 30, 2017
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

Tip bonded formed laminates, and methods for making tip bonded formed laminates, are made from multiple layers of formed substrates made from films which are bonded together at the tips of their formed protrusions. Tip bonded laminates can be designed with greater resistance to bending, improved resilience to compression, and can be patterned for directionally oriented responses to tensile loads. Also, tip bonded formed laminates made from multiple layers of formed substrates can use their layered structure to provide better aesthetics as well as better physical properties such as improved puncture resistance. Tip bonded formed laminates can be configured with thicker portions and designed patterns, which are appealing to consumers. A tip bonded formed laminate can be made from two or more formed substrates and can be used instead of a single, thick, unformed, substrate, so the laminate can use about the same amount of material, while still providing surprising functional benefits. Tip bonded formed laminates can provide these benefits without relying on more expensive polymers and/or high concentrations of additives and offer significant improvements at a reasonable cost, when compared with unformed, single layer substrates.

First claim

What is claimed is:

1. A laminate comprising:
a first film having a first plurality of integrally connected, incrementally stretched, elongated corrugations disposed side-by-side, each having:
a first inward facing trough, which has a first trough smallest thickness;
a first outward facing crest, which has a first crest smallest thickness; and
a first intermediate portion disposed between the first trough and the first crest,
wherein the first intermediate portion has a first intermediate smallest thickness,
which is less than the first crest smallest thickness;

a second film having a second plurality of integrally connected, incrementally stretched, elongated corrugations disposed side-by-side, each having:
a second inward facing trough, which has a second trough smallest thickness;
a second outward facing crest, which has a second crest smallest thickness; and
a second intermediate portion disposed between the second trough and the second crest, wherein the second intermediate portion has a second intermediate thickness, which is less than the second crest smallest thickness; and

a plurality of attachment areas, wherein each of the attachment areas is directly connected to a trough of a corrugation from the first plurality and to a trough of a corrugation from the second plurality;
wherein the first intermediate smallest thickness is less than the first trough smallest thickness, and wherein the second intermediate smallest thickness is less than the second trough smallest thickness.

2. The laminate of claim 1 , wherein each of the corrugations from the first plurality is directly connected to only one of the corrugations from the second plurality.

3. The laminate of claim 2 , wherein each of the corrugations from the second plurality is directly connected to only one of the corrugations from the first plurality.

4. The laminate of claim 1 , wherein:
the corrugations of the first plurality are discrete corrugations; and
the corrugations of the second plurality are discrete corrugations.

5. The laminate of claim 1 , wherein:
the corrugations of the first plurality are discrete corrugations; and
the corrugations of the second plurality are continuous corrugations.

6. The laminate of claim 1 , wherein:
the corrugations of the first plurality are continuous corrugations; and
the corrugations of the second plurality are continuous corrugations.

7. The laminate of claim 1 , wherein the first plurality is only connected to the second plurality by the plurality of attachment areas.

8. The laminate of claim 1 , wherein each of the attachment areas is substantially continuous along a trough of a corrugation from the first plurality.

9. The laminate of claim 8 , wherein each of the attachment areas is substantially continuous along a trough of a corrugation from the second plurality.

10. The laminate of claim 1 , wherein:
the first plurality connects to a first uncorrugated portion of the first film at a first transition;
the second plurality connects to a second uncorrugated portion of the second film at a second transition that is offset from the first transition.

11. The laminate of claim 1 , wherein:
the first plurality connects to a first uncorrugated portion of the first film at a first transition;
the second plurality connects to a second uncorrugated portion of the second film at a second transition that is adjacent to the first transition.

12. The laminate of claim 1 , wherein for at least some of the corrugations of the first plurality, a ratio of an amplitude of the corrugation to a wavelength of the corrugation is from 0.7 to 5.

13. The laminate of claim 12 , wherein for substantially all of the corrugations of the first plurality, the ratio of the amplitude to the wavelength is from 1 to 3.

14. The laminate of claim 12 , wherein for at least some of the corrugations of the first plurality, the amplitude is from 1 to 10 millimeters.

15. The laminate of claim 14 , wherein for substantially all of the corrugations of the first plurality, the amplitude is from 1 to 4 millimeters.

16. The laminate of claim 12 , wherein for at least some of the corrugations of the first plurality, a ratio of the wavelength to an overall width of an attachment area for the corrugation is from 10 to 50.

17. The laminate of claim 16 , wherein for at least some of the corrugations of the first plurality, the overall width of the attachment area is from 0.2 to 1 millimeters.

18. A disposable wearable absorbent article comprising the laminate of claim 1 .

19. A disposable bag comprising the laminate of claim 1 .

Assignees

• Procter & Gamble

Inventors

• Peck Daniel Charles
• Strube John Brian
• Waldron Matthew William

Classifications

• B31B2170/30

  having corrugated or pleated walls · CPC title

• B31B2170/20

  having multi-layered walls, e.g. laminated or lined · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B29C66/1312

  Single flange to flange joints, the parts to be joined being rigid (the parts to be joined being flexible B29C66/133) · CPC title

• B32B38/0012

  Mechanical treatment, e.g. roughening, deforming, stretching · CPC title