Method and apparatus for making an adhesive cleaning sheet

A continuous process for selectively applying pressure-sensitive adhesive to specific recessed regions of a nonwoven web, comprising the steps of:

• (a) applying an elongated bead of pressure-sensitive adhesive to the outer surface of a rotating adhesive transfer roll;
• (b) spreading the pressure-sensitive adhesive to substantially evenly distribute the pressure-sensitive adhesive on the outer surface of the adhesive transfer roll, thereby forming a substantially continuous and uniform layer of adhesive having a substantially constant thickness on the outer surface of the adhesive transfer roll;
• (c) rotating the adhesively coated outer surface of the adhesive transfer roll into contact with a female pattern forming roll having raised surface regions and recessed surface regions, thereby to transfer adhesive from the adhesively coated outer surface of the adhesive transfer roll to the raised surface regions of the female pattern forming roll without transferring adhesive to the bottom of the recessed surface regions;
• (d) disconnecting any adhesive joining the adhesive transfer roll and the female pattern forming roll;
• (e) rotating the adhesively coated raised surface regions of the female pattern forming roll to mesh with a mating male pattern forming roll;
• (f) conveying a generally planar nonwoven web of material between the male and female pattern forming rolls, thereby simultaneously forming a contoured web having peaks and valleys and transferring adhesive to the valleys without transferring adhesive to the peaks;
• and
• (g) disconnecting any adhesive joining the web and the female pattern forming roll.

A continuous process of forming a cleaning sheet having peaks and valleys with pressure-sensitive adhesive selectively applied to only the valleys from a generally planar web of nonwoven material, comprising the steps of:

• (a) applying an elongated bead of pressure-sensitive adhesive to the outer surface of a rotating adhesive transfer roll;
• (b) spreading the pressure-sensitive adhesive to substantially evenly distribute the pressure-sensitive adhesive on the outer surface of the adhesive transfer roll, thereby forming a substantially continuous and uniform layer of adhesive having a substantially constant thickness on the outer surface of the adhesive transfer roll;
• (c) rotating the adhesively coated outer surface of the adhesive transfer roll into contact with a female pattern forming roll having raised surface regions and recessed surface regions, thereby to transfer adhesive from the adhesively coated outer surface of the adhesive transfer roll to the raised surface regions of the female pattern forming roll without transferring adhesive to the bottom of the recessed surface regions;
• (d) disconnecting any adhesive joining the adhesive transfer roll and the female pattern forming roll;
• (e) rotating the adhesively coated raised surface regions of the female pattern forming roll to mesh with a mating male pattern forming roll;
• (f) conveying the nonwoven web of material between the male and female pattern forming rolls, thereby simultaneously forming a contoured web having peaks and valleys and transferring adhesive to the valleys without transferring adhesive to the peaks;
• and
• (g) disconnecting any adhesive joining the web and the female pattern forming roll.

An apparatus for selectively applying adhesive to a web, comprising:

• (a) an adhesive transfer roll having an outer surface;
• (b) an adhesive applicator arranged to apply an elongated bead of pressure-sensitive adhesive to the outer surface of said adhesive transfer roll;
• (c) a female pattern forming roll having a raised surface region and recessed regions arranged to contact said adhesive transfer roll and thereby transfer adhesive from the adhesively coated outer surface of the adhesive transfer roll to the raised surface region of the female pattern forming roll;
• (d) an adhesive separating element arranged adjacent the adhesive transfer roll and the female pattern forming roll to separate any adhesive joining the adhesive transfer roll and the female pattern forming roll;
• (e) a male pattern forming roll arranged in mating relation with said female pattern forming roll, said male pattern forming roll having protrusions that mesh with said female pattern forming roll recessed regions;
• (f) a conveyor for conveying a generally planar nonwoven web of material between said male and female pattern forming rolls;
• and
• (g) an adhesive separating element arranged adjacent the adhesive web and the female pattern forming roll to separate any adhesive joining the web and the female pattern forming roll.