# US 2014/0155853 A1 · Apparatus and methods for forming laminates containing additive matter > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0155853 A1 - Document ID: US20140155853A1 - Status: Published application - Kind: A1 - Application number: 14/075,494 - Filed: 2013-11-08 - Published: 2014-06-05 - Earliest claimed: 2012-11-09 - Assignees: Curt G. Joa, Inc. - Inventors: PERRY HANDZIAK - Web page: https://patentgrep.com/patent/US20140155853A1 ## CPC - 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} - 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 5/024: {Woven fabric} - B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points} - B32B 5/04: characterised by a layer being specifically extensible by reason of its structure or arrangement {, e.g. by reason of the chemical nature of the fibres or filaments} - 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 7/12: using interposed adhesives or interposed materials with bonding properties - A61F 2013/530481: {having superabsorbent materials, i.e. highly absorbent polymer gel materials} - B32B 2262/062: Cellulose fibres, e.g. cotton - B32B 2264/025: Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers - B32B 2307/728: Hydrophilic - B32B 2555/02: Diapers or napkins - Y10T 156/10: Methods of surface bonding and/or assembly therefor - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Discrete or continuous products are disclosed including formation of laminates containing an additive matter. Such additive matters comprise gels, superabsorbent polymers, particulate additives and the like. Pulp-free absorbent cores for use in disposable products such as diapers and sanitary napkins can be formed by the methods and apparatus of the present invention. Additive matter is carried between two layers in void spaces in a scrim layer to form a laminate. ## Claims ### Claim 1 A laminate comprising: a first material layer; a second material layer having a plurality of void spaces carried by said first material layer; an additive material carried in said void spaces; and a third material layer coupled to said first and second layers to form a laminated material. ### Claim 2 (depends on 1) A laminate according to claim 1, said second material layer comprising a scrim material. ### Claim 3 (depends on 2) A laminate according to claim 2, said scrim material selected from the group of bonded, unbounded, woven, polymer, non-polymer, and textile. ### Claim 4 (depends on 2) A laminate according to claim 2, said scrim material formed as woven netting. ### Claim 5 (depends on 2) A laminate according to claim 2, said scrim material containing a wicking component. ### Claim 6 (depends on 1) A laminate according to claim 1, said void spaces comprising at least one of square and round voids. ### Claim 7 (depends on 1) A laminate according to claim 1, said additive comprising super absorbent polymer. ### Claim 8 (depends on 1) A laminate according to claim 1, said additive comprising cellulosic fluff. ### Claim 9 (depends on 1) A laminate according to claim 1, said additive comprising a mixture of super absorbent polymer and cellulosic fluff. ### Claim 10 (depends on 1) A laminate according to claim 1, said additive comprising a fluid. ### Claim 11 (depends on 1) A laminate according to claim 1, said additive material carried in selected void spaces to define a pattern of additive material. ### Claim 12 (depends on 1) A laminate according to claim 1, said first and said second material layers comprising nonwoven material. ### Claim 13 (depends on 1) A laminate according to claim 1, said laminate further comprising said first material layer, said second material layer having a plurality of void spaces, a fourth layer comprising intermediate web layer overlying said second material layer, a fifth layer comprising an additional material layer having a plurality of void spaces overlying said intermediate web layer, additive material carried in said void spaces of said fifth layer, and said third material layer overlying said fifth layer. ### Claim 14 A method of forming a laminate comprising: supplying a first material layer; supplying a second material layer carried by said first material layer, said second material layer comprising a plurality of void spaces; coupling said first material to said second material layer; supplying an additive material to said void spaces of said second material layer; supplying a third material layer and coupling said third material layer to said first and second material layers to create a laminated material. ### Claim 15 (depends on 14) A method according to claim 14, said first and said second material layers comprising nonwoven material. ### Claim 16 (depends on 14) A method according to claim 14, said additive material supplied by at least one of vibration, gravity, ultrasonic agitation, and vacuum to said first material layer through said void spaces. ### Claim 17 (depends on 14) A method according to claim 14, said additive material comprising at least one of a gel or liquid. ### Claim 18 (depends on 17) A method according to claim 17, said additive material supplied by a dispensing nozzle. ### Claim 19 (depends on 14) A method according to claim 14, said additive material supplied intermittently. ### Claim 20 (depends on 14) A method according to claim 14, said method further comprising stretching said second material in at least one of a cross machine direction or a machine direction prior to coupling said first material to said second material layer. ### Claim 21 (depends on 14) A method according to claim 14, said coupling steps accomplished by at least one of adhesives, heat, heat-activated adhesive, ultrasonic, RF energy activation, microwave activation, UV activation, and pressure.