Pre-strained laminates and methods for making the same

Patent metadata

Field	Value
Publication number	US-2016136003-A1
Application number	US-201514933039-A
Country	US
Kind code	A1
Filing date	Nov 5, 2015
Priority date	Nov 6, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

A method of forming a three-dimensional laminate for an absorbent article is provided. The method comprises providing a first nonwoven layer, providing a second nonwoven layer, and applying a pre-strain force to the first nonwoven layer or to the second nonwoven layer. The method comprises joining the first nonwoven layer to the second nonwoven layer while the first nonwoven layer or the second nonwoven layer is in a pre-strained condition, and releasing the pre-strain force to form the three-dimensional laminate.

First claim

What is claimed is:

1 . A method of forming a three-dimensional laminate for an absorbent article, the method comprising:
providing a first nonwoven layer; providing a second nonwoven layer; applying a pre-strain force to the first nonwoven layer or to the second nonwoven layer; joining the first nonwoven layer to the second nonwoven layer while the first nonwoven layer or the second nonwoven layer is in a pre-strained condition; and releasing the pre-strain force to form the three-dimensional laminate.

2 . The method of claim 1 , wherein the first nonwoven layer or the second nonwoven layer has a plurality of apertures defined therein.

3 . The method of claim 2 , wherein the apertures are non-homogenous apertures.

4 . The method of claim 1 , wherein the first nonwoven layer or the second nonwoven layer comprises a plurality of overbonds.

5 . The method of claim 1 , wherein the joining step comprises overbonding a plurality of overbonds into the first and second nonwoven layers.

6 . The method of claim 5 , comprising stretching the first and second nonwoven layers substantially in a cross-machine direction to cause at least some of the overbonds to at least partially rupture and at least partially form apertures in the first and second nonwoven layers.

7 . The method of claim 6 , wherein the stretching step occurs before or after the releasing step.

8 . The method of claim 1 , wherein the laminate is free of elastic strands or elastic films.

9 . The method of claim 1 , comprising:
providing a third layer; and joining the third layer to the first nonwoven layer or to the second nonwoven layer.

10 . The method of claim 1 , comprising:
applying a pigmented patterned adhesive or an ink to the first nonwoven layer or to the second nonwoven layer.

11 . The method of claim 1 , wherein the pre-strain force is applied substantially in a machine direction, and wherein the pre-strain force causes the first nonwoven layer or the second nonwoven layer to elongate by at least 5%.

12 . The method of claim 5 , wherein the plurality of overbonds comprise a first overbond, a second overbond, and a third overbond, and wherein the first, second, and third overbonds are all different in size, shape, or orientation.

13 . The method of claim 5 , wherein the plurality of overbonds comprise a first overbond having a first central longitudinal axis extending in a first direction, a second overbond having a second central longitudinal axis extending in a second direction, and a third overbond having a third central longitudinal axis extending in a third direction, and wherein the first direction, the second direction, and the third direction are all different.

14 . The method of claim 13 , wherein the first direction, the second direction, and the third direction are all at least 10 degrees from each other.

15 . The method of claim 13 , wherein the first direction, the second direction, and the third direction are all at least 15 degrees from each other.

16 . A method of forming a three-dimensional laminate for an absorbent article, the method comprising:
providing a first layer; providing a separate, second layer; applying a pre-strain force to the first layer or to the second layer; overbonding the first layer and the second layer while the first layer or the second layer is in a pre-strained condition to join the first layer and the second layer; and releasing the pre-strain force to form the three-dimensional laminate.

17 . The method of claim 16 , comprising stretching the first and second nonwoven layers to cause at least some of the overbonds to at least partially rupture and at least partially form apertures in the first and second layers.

18 . The method of claim 17 , wherein stretching is substantially in a cross-machine direction.

19 . The method of claim 18 , wherein the pre-strain force is applied substantially in a machine direction.

20 . A method of forming a three-dimensional laminate for an absorbent article, the method comprising:
providing a nonwoven first layer; providing a separate, nonwoven second layer; applying a pre-strain force substantially in the machine direction to the first nonwoven layer or to the second nonwoven layer; overbonding the first layer and the second layer while the first layer or the second layer is in a pre-strained condition to join the first layer and the second layer; stretching the first and second nonwoven layers in a substantially cross-machine direction to cause at least some of the overbonds to at least partially rupture and at least partially form apertures in the first and second nonwoven layers; and releasing the pre-strain force to form the three-dimensional laminate; wherein the three-dimensional laminate is free of elastic strands or elastic films.

21 . The method of claim 20 , wherein the releasing step is performed before the stretching step.

Assignees

• Procter & Gamble

Inventors

• Mullane Timothy Ian
• Arora Kelyn Anne
• Orr Jill Marlene
• Roe Donald Carroll
• Strube John Brian

Classifications

• D04H3/147

  Composite yarns or filaments · CPC title

• B32B2250/20

  All layers being fibrous or filamentary · CPC title

• D04H3/14

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

• Y10T428/24793

  Comprising discontinuous or differential impregnation or bond · CPC title

• B32B3/06

  for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking} · CPC title