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US6969441B2 Expired / Lapsed US ⏱️ 0.0 years remaining

Method and apparatus for producing laminated articles

Assignee: Kimberly Clark Worldwide Inc
•
Filing: 2001-05-14
•
Granted: 2005-11-29
•
Expires: 2021-05-14
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Abstract

Abstract In the invention, a method is provided for producing a composite nonwoven fabric. A polymer is extruded into heated continuous filaments, possibly elastic, from the die head to a first chilled roller, wherein the extruder is configured to provide the continuous filaments to the chilled roller in a canted direction that is at a tangent or angle to the surface of the first chilled roller. The filaments are conveyed in a downward direction by way of chilled rollers to a nip. In a next step, the nonwoven web is sprayed with an adhesive and is laminated on the continuous filaments in the nip to form a composite nonwoven fabric. The continuous filaments move vertically downward approximately in line with the lamination process, facilitating automatic re-threading of filaments when they are broken or interrupted in their travel downward onto the chilled rolls.

Inventors

  • 👤 Howard M. Welch
  • 👤 Charles J. Morell
  • 👤 Michael C. Cook
  • 👤 James R. Fitts, Jr.
  • 👤 Donald V. Willitts
  • 👤 Marion C. Morris
  • 👤 Ronald H. Wideman
  • 👤 John A. Brewer
  • 👤 Mark M. Mleziva
  • 👤 Kenneth M. Salter
  • 👤 Raymond J. May
  • 👤 Lavada Boggs
  • 👤 Leslie D. Dobbins

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-11-01 03:51
CPC Classifications
B; B32; B32B; B32B37/00; B32B37/14; B32B37/144; B29; B29C; B29C48/00; B29C48/03; B29C48/05; B29C48/07; B29C48/25; B29C48/30; B29C48/345; B29C48/88; B29C48/911; B29C48/9135; B29C48/914; B29C48/915; B29C48/9155; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/50; B29C70/504; B32B5/00; B32B5/22; B32B5/24; B32B5/26; D; D01; D01D; D01D5/00; D01D5/12; D01D5/16; D02; D02J; D02J1/00; D02J1/22; D04; D04H; D04H3/00; D04H3/08; D04H3/16; B32B2305/00; B32B2305/10; B32B2305/20; B32B37/12; B32B37/15; B32B37/153

Claims Analysis

Total Claims: 19
Claim 1
Independent Claim 269 words
A method for producing a composite nonwoven fabric in a vertical plane, comprising: a) providing an extruder having a plurality of die heads, a vertically-arranged series of first and second chilled rollers, and a set of nip rollers, the extruder being located above the vertically-arranged series of first and second chilled rollers, the first chilled roller being positioned vertically below the extruder so that extruded filaments from the extruder flow directly to the first chilled roller, the second chilled roller being positioned vertically below the first chilled roller and located before the set of nip rollers so that the extruded continuous filaments flow directly from the first chilled roller to the second chilled roller and then directly to a nip formed by the set of nip rollers, b) extruding heated continuous filaments from the die heads of the extruder directly to the first chilled roller, wherein the extruder is further configured to provide the continuous filaments to the first chilled roller in a canted direction that is tangent to the surface of the first chilled roller, c) conveying the continuous filaments directly from the first chilled roller to the second chilled roller, d) quenching and stretching simultaneously the continuous filaments to form stretched continuous filaments, e) conveying the stretched continuous filaments directly from the second chilled roller to the nip, f) providing at least one nonwoven web, g) applying an adhesive on the surface of the one nonwoven web and then providing said one nonwoven web to the nip, and h) laminating the stretched continuous filaments with the nonwoven web in the nip to form a composite nonwoven fabric.
Claim 2
Independent Claim 269 words
A method for producing a composite nonwoven fabric in a vertical plane, comprising: a) providing an extruder having a plurality of die heads, a vertically-arranged series of first and second chilled rollers, and a set of nip rollers, the extruder being located above the vertically-arranged series of first and second chilled rollers, the first chilled roller being positioned vertically below the extruder so that extruded filaments from the extruder flow directly to the first chilled roller, the second chilled roller being positioned vertically below the first chilled roller and located before the set of nip rollers so that the extruded continuous filaments flow directly from the first chilled roller to the second chilled roller and then directly to a nip formed by the set of nip rollers, b) extruding heated continuous filaments from the die heads of the extruder directly to the first chilled roller, wherein the extruder is further configured to provide the continuous filaments to the first chilled roller in a canted direction that is tangent to the surface of the first chilled roller, c) conveying the continuous filaments directly from the first chilled roller to the second chilled roller, d) quenching and stretching simultaneously the continuous filaments to form stretched continuous filaments, e) conveying the stretched continuous filaments directly from the second chilled roller to the nip, f) providing at least one nonwoven web, g) applying an adhesive on the surface of the one nonwoven web and then providing said one nonwoven web to the nip, and h) laminating the stretched continuous filaments with the nonwoven web in the nip to form a composite nonwoven fabric.
Claim 3
Dependent Claim 11 words
The method of claim 1 wherein the continuous filaments are elasticized.
Claim 4
Dependent Claim 12 words
The method of claim 1 wherein the composite nonwoven fabric is elasticized.
Claim 5
Dependent Claim 19 words
The method of claim 1 wherein the continuous filaments move vertically downward approximately in line with the lamination process.
Claim 6
Dependent Claim 17 words
The method of claim 1 wherein upon breakage of a continuous filament, the filament is automatically re-threaded.
Claim 7
Dependent Claim 24 words
The method of claim 1 comprising the further step of relaxing said composite nonwoven fabric by a take-up roll running at a differential speed.
Claim 8
Dependent Claim 28 words
The method of claim 1 comprising the further step of providing a second nonwoven web and laminating the second nonwoven web to the continuous filaments in the nip.
Claim 9
Dependent Claim 31 words
The method of claim 7 comprising the further step of applying an adhesive on the surface of the second nonwoven web prior to laminating the second nonwoven web at the nip.
Claim 10
Dependent Claim 22 words
The method of claim 1 wherein the speed ratio of the nip rolls relative to the first chilled roller can be varied.
Claim 11
Dependent Claim 26 words
The method of claim 9 wherein the speed ratio of the nip rolls relative to the first chilled roller is between about 2:1 and about 8:1.
Claim 12
Dependent Claim 26 words
The method of claim 9 wherein the speed ratio of the nip rolls relative to the first chilled roller is between about 4:1 and about 6:1.
Claim 13
Independent Claim 180 words
An apparatus for producing a composite nonwoven fabric, comprising: a) an extruder having a plurality of die heads for extruding heated continuous filaments, b) a vertically-arranged series of first and second chilled rollers, wherein the first chilled roller is positioned vertically below the extruder so that extruded filaments from the extruder flow directly to the first chilled roller in a canted direction that is tangent to the surface of the first chilled roller and the second chilled roller is positioned vertically below the first chilled roller so that the extruded continuous filaments flow directly from the first chilled roller to the second chilled roller, c) a nip comprising at least two nip rollers, said nip being positioned vertically with respect to the first chilled roller in order to receive the heated continuous filaments directly from the second chilled roller, d) a roller mechanism for providing a first web to said nip to be laminated with the continuous filaments so as to form a continuous filament laminate, and e) a mechanism for carrying the continuous filament laminate away from the nip.
Claim 14
Independent Claim 180 words
An apparatus for producing a composite nonwoven fabric, comprising: a) an extruder having a plurality of die heads for extruding heated continuous filaments, b) a vertically-arranged series of first and second chilled rollers, wherein the first chilled roller is positioned vertically below the extruder so that extruded filaments from the extruder flow directly to the first chilled roller in a canted direction that is tangent to the surface of the first chilled roller and the second chilled roller is positioned vertically below the first chilled roller so that the extruded continuous filaments flow directly from the first chilled roller to the second chilled roller, c) a nip comprising at least two nip rollers, said nip being positioned vertically with respect to the first chilled roller in order to receive the heated continuous filaments directly from the second chilled roller, d) a roller mechanism for providing a first web to said nip to be laminated with the continuous filaments so as to form a continuous filament laminate, and e) a mechanism for carrying the continuous filament laminate away from the nip.
Claim 15
Dependent Claim 26 words
The apparatus of claim 12 further comprising an adhesive applicator for applying adhesive to the first web prior to providing the first web to the nip.
Claim 16
Dependent Claim 26 words
The apparatus of claim 13 further comprising an adhesive applicator for applying adhesive to the second web prior to providing the second web to the nip.
Claim 17
Dependent Claim 24 words
The apparatus of claim 14 wherein the adhesive applicator for the second web applies the adhesive by spraying the adhesive onto the second web.
Claim 18
Dependent Claim 20 words
The apparatus of claim 13 wherein the adhesive applicator applies the adhesive by spraying the adhesive onto the first web.
Claim 19
Dependent Claim 37 words
The apparatus of claim 12 further comprising a roller mechanism for providing a second web to said nip to be laminated with the continuous filaments and the first web so as to form a continuous filament laminate.

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USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 2008-11-28 2009-05-30 2009-11-29 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 2012-11-28 2013-05-30 2013-11-29 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 2016-11-28 2017-05-30 2017-11-29 $7700.00 Window Closed / Lapsed

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