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  Bidirectional stretch material and laminate made therefrom applications thereof, and methods of making sameUSPTO Application #: 20070117481Title: Bidirectional stretch material and laminate made therefrom applications thereof, and methods of making same Abstract: A method of producing a stretch material includes the steps of extruding a thermoplastic film (20); passing the extruded film through a nip of two rolls (30, 35) having first and second roll surfaces, where the first roll surface includes a raised closed shape pattern and the second roll surface is a flat anvil surface; forming a pattern in the film with the rolls, while chilling the film, such that there are thicker and thinner areas in the film, corresponding to the pattern on the first roll surface; and passing the patterned film under tension, by a heated air stream (45), whereby the polymer in the thinner patterned areas is removed, thereby creating a netting material. A bidirectional stretch laminate is produced by bonding a necked nonwoven material (75) to the netting material while the netting material is being stretched (under tension). (end of abstract)
Agent: Kimberly-clark Worldwide, Inc. - Neenah, WI, US Inventors: Byron P. Day, David C. Strack USPTO Applicaton #: 20070117481 - Class: 442050000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Scrim (e.g., Open Net Or Mesh, Gauze, Loose Or Open Weave Or Knit, Etc.), Nonwoven Scrim The Patent Description & Claims data below is from USPTO Patent Application 20070117481. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATIONS [0001] This Application is a continuation-in-part of and claims priority from Attorney Docket Number 18,169.1--U.S. Patent Application bearing Express Mailing Number EV413564267US filed Dec. 17, 2003 for Stretchable Film Laminates and Methods and Apparatus for Making Stretchable Film Laminates in the names of Leslie Warren Collier, IV, Susan Elaine Shawver, Bryon Paul Day, Raymond Jeffrey May, James Russell Fitts, Jr., Michael Tod Morman, Monica Varriale, Matthew Boyd Lake, David Michael Matela, Gregory Todd Sudduth, Randall James Palmer, Charles John Morell, Prasad Shrikrishna Potnis, Rasha Wafik Zaki Guirguis, Cristian M. Neculescu, and Peiguang Zhou. The foregoing application is incorporated by reference herein in its entirety. FIELD OF THE INVENTION [0002] The present invention relates to bidirectional stretch film and netting fabric materials and methods of making the same. BACKGROUND OF THE INVENTION [0003] Nonwoven and film-based fabric materials have been heretofore utilized as base materials in a variety of personal care products (such as infant, child, elder, and feminine care products) as well as in workwear, outerwear and even outdoor protective covering materials. For instance, nonwoven materials have been used as base materials for diaper and training pant liners, outercovers, and absorbent components. Such materials have likewise been used as components for surgical drapes and gowns, surgical masks, and protective covers such as grill, car and boat covers, as well as veterinary care products. While a variety of nonwoven and film-based materials have been conceived for use with such products, there is still a need for materials that provide for bidirectional stretch properties, and that will allow for fluid transfer. By bidirectional stretch, it is meant that such materials are capable of elongation/extensibility in at least two different directions, and in some circumstances, stretch and recovery (elastic in nature) in at least the two different directions. There is a further need for such materials which demonstrate corrugated surface topography for a cloth-like feel. [0004] There is a further need for such bidirectional stretch materials that can be readily produced in-line without complicated manufacturing steps. There is also a further need for laminates which incorporate such materials and methods of making such materials. [0005] Heretofore it is known to produce scrim and netting-type fabric materials from polymer resins. Such materials have found applications in a wide array of products, such as in containment products, such as produce bags, and as separation layers. Such materials offer the possibility of bidirectional stretch as a result of their particular structural geometry. The nature of flexible netting allows for "give" in multiple directions, and in some instances directions perpendicular to each other. However, while such materials have been produced through a number of processes, there is still a need for in-line manufacturing processes for such netting materials, that allow them to be easily/rapidly produced and laminated to various other nonwoven materials, for a variety of end product uses. It is to such needs that the current invention is directed. SUMMARY OF THE INVENTION [0006] A method of producing a laminate material includes the steps of extruding or providing a thermoplastic film; forming a pattern of shapes defined by thin and thick areas in the film; exposing the film to heat while the film is under tension, such that the heat causes polymer within the film to flow from the thin areas to the thick areas, thereby creating a pattern of open spaces within the film; and bonding the film to at least one nonwoven material, whereby a netting and nonwoven material laminate is formed. [0007] A method of producing a bidirectional stretch material is also provided which includes the steps of extruding or providing a thermoplastic film; forming a pattern of closed shapes within the film, such that there are thicker and thinner areas in the film, corresponding to the pattern; and bonding the patterned film to a sheet material that is extensible in at least two directions so as to create a film and nonwoven material laminate with bidirectional stretch. [0008] A method of producing a stretch material also includes the steps of extruding or providing a thermoplastic film; forming a pattern of closed shapes within the film, such that there are thicker and thinner areas in the film, corresponding to the pattern; exposing the patterned film to heat while the film is under tension, such that the heat causes polymer within the film to flow from the thin areas to the thick areas, thereby creating a pattern of open spaces within the film; such that a netting material is formed; and bonding the netting material to a sheet material, while the netting is being stretched or is under tension. In one embodiment of the method, the sheet material is a nonwoven web. In a further embodiment of the method, the nonwoven web is a necked nonwoven web. [0009] A method of producing a stretch material also includes the steps of extruding a thermoplastic film; passing the extruded film through a nip of two rolls having first and second roll surfaces, where the first roll surface includes a raised closed shape pattern and the second roll surface is a flat anvil surface; forming a pattern in the film with the rolls, while chilling the film, such that there are thicker and thinner areas in the film, corresponding to the pattern on the first roll surface; and passing the patterned film under tension, by a heated air stream, whereby the polymer in the thinner patterned areas is removed, thereby creating a netting material. A bidirectional stretch laminate is produced by bonding a necked nonwoven material to the netting material while the netting material is being stretched (under tension). [0010] A method of producing a stretch material includes the steps of extruding or providing a thermoplastic film; forming a pattern of closed shapes within the film, such that there are thicker and thinner areas in the film, corresponding to the pattern; and bonding the patterned film to a sheet material that is extensible in at least one direction so as to create a film and nonwoven material laminate with stretch in at least one direction. [0011] Materials may also be produced which include a topographied film and nonwoven laminate, or alternatively, a netting and nonwoven material laminate. Such topographied film, netting and laminates may be nonextensible, extensible in one direction, extensible to two directions, elastic in one direction, or elastic in two directions, depending on the product needs. Such laminates may be corrugated to provide cloth-like texture. Films, netting materials and laminates of the above constructions and produced by the above methods are all considered to be within the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: [0013] FIG. 1 illustrates a method of making the materials of the invention. [0014] FIG. 2 illustrates a perspective/cross sectional view of film material made in accordance with the invention. [0015] FIG. 2A illustrates a perspective/cross-sectional view of laminate material made in accordance with the invention. [0016] FIG. 3A illustrates an alternative embodiment of a pattern roll that may be used to make material (also shown) with a plain/flat anvil roll, in accordance with the invention. [0017] FIG. 3B illustrates an alternative embodiment of a pattern roll that may be used to make material with a plain anvil roll, in accordance with the invention. [0018] FIG. 3C illustrates an alternative embodiment of a pattern roll that may be used to make material with a plain anvil roll, in accordance with the invention. [0019] FIG. 3D illustrates an alternative embodiment of a pattern roll that may be used to make material, in accordance with the invention. Continue reading... Full patent description for Bidirectional stretch material and laminate made therefrom applications thereof, and methods of making same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Bidirectional stretch material and laminate made therefrom applications thereof, and methods of making same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. 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