Methods of winding substrates having three-dimensional features
AssigneeThe Procter & Gamble Company
InventorsGueltekin Erdem, Nadezhda Kurbatova, Joseph Hung Lam, Sudhanshu Gupta
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Abstract
The present disclosure provides methods of winding substrates comprising three-dimensional features about a core to form a spool so that at least a majority of the three-dimensional features in one wrap of a lane of the spool are at least partially nested with a majority of the three-dimensional features in another adjacent wrap in the same lane of the spool. By at least partially nesting these three-dimensional features in adjacent wraps of a lane of the spool, the three-dimensional features may be at least mostly maintained in the substrates without significant compression during winding and storage of the spool.
Claims23
A method of winding a substrate comprising a nonwoven on a core to create a spool of the substrate, wherein the substrate comprises a plurality of three-dimensional features, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:
- spirally winding a plurality of wraps of the substrate about the core to at least partially form a first lane, wherein a majority of the three-dimensional features in at least some of the wraps of the first lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap in the first lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a second lane;
- spirally winding a plurality of wraps of the substrate about the core to at least partially form the second lane, wherein a majority of the three-dimensional features in at least some of the wraps of the second lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the second lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a third lane;
- spirally winding a plurality of wraps of the substrate about the core to at least partially form the third lane, wherein a majority of the three-dimensional features in at least some of the wraps of the third lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the third lane;
- and
- applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.
A method of winding a three-dimensional substrate on a core to create a spool of the three-dimensional substrate, wherein the three-dimensional substrate comprises a plurality of projections on a first side of the substrate that form a plurality of recesses on a second side of the substrate, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form a first lane, wherein a majority of the projections in at least some of the wraps of the first lane are at least partially nested with a majority of the recesses in an adjacent wrap in the first lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a second lane, wherein the first lane is positioned more proximal to the first end than the second lane;
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the second lane, wherein a majority of the projections in at least some of the wraps of the second lane are at least partially nested with a majority of the recesses in an adjacent wrap of the second lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a third lane, wherein the third lane is positioned more proximal to the second end than the second lane;
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the third lane, wherein a majority of the projections in at least some of the wraps of the third lane are at least partially nested with a majority of the recesses in an adjacent wrap of the third lane;
- and applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.
A method of winding a three-dimensional substrate on a core to create a spool of the three-dimensional substrate, wherein the three-dimensional substrate comprises a plurality of projections on a first side of the substrate that form a plurality of recesses on a second side of the substrate, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form a first lane, wherein a majority of the projections in at least some of the wraps of the first lane are at least partially nested with a majority of the recesses in an adjacent wrap in the first lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a second lane, wherein the first lane is positioned more proximal to the first end than the second lane;
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the second lane, wherein a majority of the projections in at least some of the wraps of the second lane are at least partially nested with a majority of the recesses in an adjacent wrap of the second lane;
- helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a third lane, wherein the third lane is positioned more proximal to the second end than the second lane;
- spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the third lane, wherein a majority of the projections in at least some of the wraps of the third lane are at least partially nested with a majority of the recesses in an adjacent wrap of the third lane;
- wherein the helically winding comprises less than 35% of the spool;
- and applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.
Dependencies are inferred from the claim text.