# US 11,432,969 B2 · Ultra thin laminate with particulates in dense packages

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- Number: US 11,432,969 B2
- Document ID: US11432969B2
- Status: Granted
- Kind: B2
- Application number: 14/583,511
- Filed: 2014-12-26
- Published: 2015-04-23
- Granted: 2022-09-06
- Earliest claimed: 2010-01-06
- Assignees: Eam Corporation
- Applicants: EAM Corporation
- Inventors: Paul M. Ducker; Steven S. Harlen
- Web page: https://patentgrep.com/patent/US11432969B2

## CPC

- 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 13/15658: {Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof}
- A61F 13/5323: {having absorbent material located in discrete regions, e.g. pockets}
- A61F 13/539: characterised by the connection of the absorbent layers with each other or with the outer layers
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- 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 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- 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 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 7/08: by mechanical means
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/14: next to a particulate layer
- B65D 65/40: Applications of laminates for particular packaging purposes {(B65D1/0215, B65D1/28, B65D3/22, B65D5/0281, B65D5/563, B65D9/30, B65D29/02, B65D31/02, B65D75/26, B65D77/2024, B65D81/1275, B65D81/3811, B65D81/3823, B65D81/3834, B65D81/3846, B65D81/3858, B65D81/3874, B65D81/3886, B65D81/3897 take precedence; laminates per se or laminated packages characterised by the composition or)}
- A61F 2013/530489: {being randomly mixed in with other material}
- A61F 2013/530496: {being fixed to fibres}
- A61F 2013/53051: {being only in particular parts or specially arranged}
- A61F 2013/53908: {with adhesive}
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2262/0207: Elastomeric fibres
- B32B 2262/0223: Vinyl resin fibres
- B32B 2262/0246: Acrylic resin fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide 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 2262/067: Wood fibres
- 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 2264/0207: Particles made of materials belonging to B32B25/00
- B32B 2264/0228: Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
- B32B 2264/0278: Polyester particles
- B32B 2264/06: Vegetal particles
- B32B 2307/514: Oriented
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2307/7265: Non-permeable
- B32B 2307/728: Hydrophilic
- B32B 2555/02: Diapers or napkins
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T 428/249924: Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention is directed to a method of forming a laminate absorbent structure, and a resulting package containing a single continuous running web of the laminate material. Notably, formation of the material is effected by blending a curtain of adhesive fibers with a curtain of particulate material, and depositing the mixture on a moving substrate, preferably provided in the form of a tissue layer. A second substrate, also preferably comprising a tissue layer, is applied on top of the deposited mixture, and pressure applied to form the laminated structure. Notably, attendant to packaging of the laminated material, adjacent layers of the material tend to nest into one another, to form a sandwich in which the density of the material in the package is more than 1.5 times the density of the material after its removal from the package.

## Claims

### Claim 1

A package containing a single continuous running web of laminated material within the package comprising adjacent layers of the laminated material, where the laminated material comprises a first layer of tissue laminated to a mixed layer of superabsorbent particulate mixed with adhesive fibers laminated to a second layer of tissue, to form a sandwich, in which the Material Density of the laminated material in the package is more than 1.5 times the Density of the laminated material after removing it from the package, where a mixture of the particulate and the adhesive fibers form a pressure sensitive three-dimensional lattice structure where the particulate is suspended within a matrix, where densification in the package is accomplished through interlocking and nesting of rough surfaces of adjacent tissue layers of the laminated material within the package, and where the mixed layer is free of cellulosic or synthetic fibrous additives.

### Claim 2 (depends on 1)

The package according to claim 1 where the package is a festooned package.

### Claim 3 (depends on 2)

The package according to claim 2, wherein the festooned package contains more than 2000 square meters.

### Claim 4 (depends on 1)

The package of claim 1, where a diameter of one or more lattice segments of the pressure sensitive three-dimensional lattice structure is between 0.02 millimeters and 0.08 millimeters.

### Claim 5 (depends on 1)

The package of claim 1, where the laminated material has a thickness of less than 1 millimeter.

### Claim 6 (depends on 1)

The package of claim 1, where the particulate comprises super absorbent particles (SAP), and where the particulate includes 98% SAP by weight.

### Claim 7 (depends on 1)

The package of claim 1, where the mixture of the particulate and the adhesive fibers covers approximately an entirety of a first surface of the first layer of tissue and a second surface of the second layer of tissue.

### Claim 8 (depends on 1)

The package of claim 1, where a first surface of the first layer of tissue has a first surface area that is less than a second surface area of a second surface of the second layer of tissue, and where the mixture of the particulate and the adhesive fibers covers approximately an entirety of the first surface and less than an entirety of the second surface.

### Claim 9 (depends on 1)

The package of claim 1, where the pressure sensitive three-dimensional lattice structure is configured to form one or more new bonds over time while the laminated material is within the package.

### Claim 10 (depends on 9)

The package of claim 9, where the one or more new bonds are formed without application of direct pressure to the laminated material.

### Claim 11 (depends on 1)

The package of claim 1, wherein the mixed layer consists essentially of the particulate and the adhesive fibers.

### Claim 12 (depends on 1)

The package of claim 1, wherein the mixed layer consists of the particulate and the adhesive fibers.

### Claim 13

A roll containing a continuous running web of laminated material comprising a first layer of tissue laminated to a layer of superabsorbent particulate mixed with adhesive fibers laminated to a second layer of tissue to form a sandwich, in which the Material Density of the laminated material in the roll is more than 3 times the Density of the laminated material when it is removed from the roll, where a mixture of the particulate and the adhesive fibers form a pressure sensitive three-dimensional lattice structure where the particulate is suspended within a matrix, where densification in the package is accomplished through interlocking and nesting of rough surfaces of adjacent tissue layers of the laminated material within the package, and where the mixed layer is free of cellulosic or synthetic fibrous additives.

### Claim 14 (depends on 13)

The roll according to claim 13 in which a Wind Layer Thickness of the web of laminated material is less than 0.3 mm.

### Claim 15 (depends on 13)

The roll according to claim 13 in which a Wind Layer Thickness of the web of laminated material is less than 0.27 mm.

### Claim 16 (depends on 13)

The roll according to claim 13, which contains more than 3000 lineal meters of material.