# US 10,500,826 B2 · Method of making nonwoven material having discrete three-dimensional deformations with wide base openings

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- Number: US 10,500,826 B2
- Document ID: US10500826B2
- Status: Granted
- Kind: B2
- Application number: 14/844,457
- Filed: 2015-09-03
- Published: 2016-03-17
- Granted: 2019-12-10
- Earliest claimed: 2014-09-12
- Assignees: The Procter & Gamble Company
- Applicants: The Procter & Gamble Company
- Inventors: John Brian Strube; Jill Marlene Orr; James Terry Knapmeyer; Rodrigo Rosati; Adrien Grenier
- Web page: https://patentgrep.com/patent/US10500826B2

## CPC

- B32B 38/04: Punching, slitting or perforating
- 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}
- A61F 13/51104: {the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections}
- A61F 13/512: characterised by its apertures, e.g. perforations
- B29C 65/56: using mechanical means {or mechanical connections, e.g. form-fits}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- 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}
- B29C 66/438: {Joining sheets for making hollow-walled, channelled structures or multi-tubular articles}
- B29C 66/45: {Joining of substantially the whole surface of the articles (methods or apparatus for laminating B32B37/00)}
- B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)}
- B29C 66/7294: {Non woven mats, e.g. felt}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/83413: {cooperating rollers, cylinders or drums}
- B32B 3/28: 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)
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/142: {Variation across the area of the layer}
- B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 38/06: Embossing
- D04H 1/44: the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H 1/45: by forming intermeshing loops or stitches from some of the fibres
- D04H 1/492: by fluid jet (D04H1/49 takes precedence)
- D04H 1/54: by welding together the fibres, e.g. by partially melting or dissolving (in combination with needling D04H1/485)
- D04H 1/558: in combination with mechanical or physical treatments other than embossing
- D04H 1/559: the fibres being within layered webs
- D04H 13/001: {Making non-woven fabrics from staple fibres, filaments or yarns, bonded to at least one web-like material, e.g. woven, knitted non-woven fabric, paper, leather, during consolidation}
- B29C 43/46: Rollers
- B29C 59/02: by mechanical means, e.g. pressing {(B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627)}
- B29C 59/022: {characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor}
- B29C 59/04: using rollers or endless belts
- B29C 59/046: {for layered or coated substantially flat surfaces}
- B29C 65/02: by heating, with or without pressure
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 65/7894: {of continuously moving sheets or webs}
- B29C 2043/461: {the rollers having specific surface features}
- B29C 2043/463: {corrugated, patterned or embossed surface}
- B29C 2059/023: {Microembossing}
- B29L 2031/4878: {Diapers, napkins}
- B32B 2038/042: {Punching}
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/04: Cellulosic plastic fibres, e.g. rayon
- B32B 2262/06: Vegetal fibres
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/08: Animal fibres, e.g. hair, wool, silk
- B32B 2262/12: Conjugate fibres, e.g. core/sheath or side-by-side
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2305/20: in the form of a non-woven mat
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2432/00: Cleaning articles, e.g. mops or wipes
- B32B 2555/02: Diapers or napkins
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A method of forming deformations in a nonwoven web includes the steps of: a) providing a precursor nonwoven web; b) providing a pair of forming members which include: a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements; and a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and may completely surround, the plan view periphery of the male elements; and c) mechanically deforming the precursor nonwoven web with the forming members by placing the precursor nonwoven web between the forming members. The method forms a nonwoven web having a generally planar first region and a plurality of discrete deformations. The deformations form protrusions that extend outward from the first surface of the nonwoven web and a base opening adjacent to the second surface of the nonwoven web. The maximum interior width of the cap portion of the protrusions is wider than the width of the base opening.

## Claims

### Claim 1

A method of forming deformations in a nonwoven web, the method comprising the steps of:
a) providing a precursor nonwoven web, the precursor web comprising a nonwoven material comprising fibers, the precursor web having a first surface, a second surface, thermal point bonds, and a thickness;
b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, the forming members comprising:
a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the surface of the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements, wherein the male elements have a plan view periphery, and a height; and
a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and completely surrounds, the plan view periphery of the male elements, and the recesses have a depth;
c) placing the precursor nonwoven web between the forming members, wherein the second surface of the precursor nonwoven web is placed in contact with the first forming member, and mechanically deforming the precursor nonwoven web with the forming members, wherein the precursor nonwoven web is formed into a nonwoven web comprising a generally planar first region and a plurality of discrete integral second regions that comprise deformations, the deformations forming protrusions extending outward from the first surface of the nonwoven web, and openings formed in the second surface of the nonwoven web, the protrusions being comprised of the fibers, wherein the protrusions comprise a base proximate the first surface of the nonwoven web, an opposed distal end extending outward in the Z-direction from the base, side walls between the base and the distal end of the protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein the side walls have interior surfaces, wherein the interior surfaces of the side walls define a base opening at the base of the protrusion, wherein the interior surfaces of the side walls surround the base opening, wherein the cap has a portion with a maximum interior width, and the base opening has a width, wherein the maximum interior width of the cap of the protrusions is greater than the width of the base opening; and
d) pressure bonding at least a portion of the fibers together in the first region of the nonwoven web outside the base of at least some of the protrusions.

### Claim 2 (depends on 1)

The method of claim 1, wherein the sides of the male forming elements intersect with the top of the male forming elements at a non-radiused edge.

### Claim 3 (depends on 1)

The method of claim 1, wherein at least one of the male elements and the second forming member have at least two discrete surface texture elements thereon.

### Claim 4 (depends on 3)

The method of claim 3, wherein the male forming elements are not heated.

### Claim 5 (depends on 1)

The method of claim 1, wherein the depth of the recesses is greater than the height of the male forming elements.

### Claim 6 (depends on 5)

The method of claim 5, wherein a depth of engagement ranges from at least about 1.5 mm to about 5 mm.

### Claim 7 (depends on 5)

The method of claim 5, wherein a clearance ranges from about 0.13 mm to about 1.3 mm.

### Claim 8 (depends on 1)

The method of claim 1, wherein the recesses in the second forming member have a larger plan view periphery than the plan view periphery of the male forming elements.

### Claim 9 (depends on 1)

The method of claim 1, wherein the precursor nonwoven web comprises two or more layers of nonwoven material, each of which is comprised of fibers.

### Claim 10 (depends on 9)

The method of claim 9, wherein the step (c) nests the layers together in a protrusion.

### Claim 11 (depends on 9)

The method of claim 9, wherein the step (c) thins at least a portion of the fibers in at least one of the layers.

### Claim 12 (depends on 1)

The method of claim 1, wherein the step (c) forms bulbous protrusions in the web.

### Claim 13 (depends on 1)

The method of claim 1, comprising:
prior to the bonding step, providing a second nonwoven web; and
bonding the second nonwoven web to the precursor nonwoven web during the bonding step.

### Claim 14 (depends on 1)

The method of claim 1, wherein the bonded fibers in the first region are discrete.

### Claim 15 (depends on 1)

The method of claim 1, wherein the bonded fibers in the first region completely surround the deformations.

### Claim 16

A method of forming deformations in a nonwoven web, the method comprising the steps of:
a) providing a precursor nonwoven web, the precursor web comprising a nonwoven material comprising fibers, the precursor web having a first surface, a second surface, thermal point bonds, and a thickness;
b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, the forming members comprising:
a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the surface of the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements, wherein the male elements have a plan view periphery, and a height; and
a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and completely surrounds, the plan view periphery of the male elements, and the recesses have a depth;
c) placing the precursor nonwoven web between the forming members, wherein the second surface of the precursor nonwoven web is placed in contact with the first forming member, and mechanically deforming the precursor nonwoven web with the forming members, wherein the precursor nonwoven web is formed into a nonwoven web comprising a generally planar first region and a plurality of discrete integral second regions that comprise deformations, the deformations forming protrusions extending outward from the first surface of the nonwoven web, and openings formed in the second surface of the nonwoven web, the protrusions being comprised of the fibers, wherein the protrusions comprise a base proximate the first surface of the nonwoven web, an opposed distal end extending outward in the Z-direction from the base, side walls between the base and the distal end of the protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein the side walls have interior surfaces, wherein the interior surfaces of the side walls define a base opening at the base of the protrusion, wherein the side walls fully surround the base opening, wherein the cap has a portion with a maximum interior width, and the base opening has a width, wherein the maximum interior width of the cap of the protrusions is greater than the width of the base opening; and
d) pressure bonding at least a portion of the fibers together in the first region of the nonwoven web outside the base of at least some of the protrusions.

### Claim 17

A method of forming deformations in a nonwoven web, the method comprising the steps of:
a) providing a precursor nonwoven web, the precursor web comprising a nonwoven material comprising fibers, the precursor web having a first surface, a second surface, thermal point bonds, and a thickness;
b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, the forming members comprising:
a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the surface of the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements, wherein the male elements have a plan view periphery, and a height; and
a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and completely surrounds, the plan view periphery of the male elements, and the recesses have a depth;
c) placing the precursor nonwoven web between the forming members, wherein the second surface of the precursor nonwoven web is placed in contact with the first forming member, and mechanically deforming the precursor nonwoven web with the forming members, wherein the precursor nonwoven web is formed into a nonwoven web comprising a generally planar first region and a plurality of discrete integral second regions that comprise deformations, the deformations forming protrusions extending outward from the first surface of the nonwoven web, and openings formed in the second surface of the nonwoven web, the protrusions being comprised of the fibers, wherein the protrusions comprise a base proximate the first surface of the nonwoven web, an opposed distal end extending outward in the Z-direction from the base, side walls between the base and the distal end of the protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein the side walls have interior surfaces, wherein the interior surfaces of the side walls define a base opening at the base of the protrusion, wherein the interior surfaces of the side walls surround the base opening and form an enclosed shape, wherein the cap has a portion with a maximum interior width, and the base opening has a width, wherein the maximum interior width of the cap of the protrusions is greater than the width of the base opening; and
d) pressure bonding at least a portion of the fibers together in the first region of the nonwoven web outside the base of at least some of the protrusions.