Process to melt bond fibers onto three-dimensional formed film to achieve a cloth-like texture and the film produced thereby
AssigneeTredegar Film Products Corporation
InventorPaul E. Thomas
Life of this patent
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Abstract
A composite material having improved cloth-like texture and fluid transfer properties is disclosed. In one embodiment, the composite material has a polymeric film with a plurality of apertured protuberances and a plurality of loose fibers coupled to the polymeric film, including at least a portion of the sidewalls of the protuberances. In another embodiment, the composite material has a polymeric film with first and second layers, a plurality of apertured protuberances extending through both layers, and a plurality of loose fibers coupled to the first layer and to at least a portion of the sidewalls of the protuberances.
Claims31
A composite material comprising:
- a polymeric film having a first side defining a planar surface, a second side having a plurality of three-dimensional structures extending outwardly from said second side, and a plurality of apertures, each of said apertures having an inlet on the first side and said apertures extending through the composite material and having at least a portion of each aperture defined by a sidewall extending from the first side of the polymeric film through one of said three-dimensional structures extending outwardly from the second side of the polymeric film;
- and
- a plurality of individual loose microfibers coupled substantially only to said first side of said polymeric film and to at least a portion of each of said sidewalls of the apertures extending through the polymeric film with a substantial portion of the inlet to the apertures not bridged by the microfibers and remaining open for the passage of fluid therethrough;
- wherein a majority of the individual loose microfibers have at least one end extending from said polymeric film.
A composite material comprising:
- a polymeric film having:
- a first layer having a first side, a second side, and a first melt temperature;
- a second layer having a first side defining a planar surface, a second side having a plurality of three-dimensional structures extending outwardly therefrom, said second layer having a second melt temperature higher than said first melt temperature, and said first side of said second layer being coupled to said second side of said first layer;
- a plurality of apertures extending through the composite material from said first side of said first layer through said second side of said second layer, each of said apertures being at least partially defined by a sidewall extending from the first side of said second layer through one side of said three-dimensional structures of said second layer, each of said apertures having an inlet on the first side;
- and
- a plurality of individual loose microfibers coupled substantially only to said first side of said first layer and to at least a portion of said sidewalls of the apertures, with a substantial portion of the inlet to the apertures not bridged by the microfibers and remaining open for the passage of fluid therethrough;
- wherein a majority of the individual loose microfibers have at least one end outwardly extending from said polymeric film.
Dependencies are inferred from the claim text.