`
`(12) United States Patent (cid:9)
`(12) United States Patent
`Eaton et al. (cid:9)
`Eaton et al.
`
`(54) COMPOSITE WEBS WITH REINFORCING
`(54) COMPOSITE WEBS WITH REINFORCING
`POLYMERIC REGIONS AND ELASTIC
`POLYMERIC REGIONS AND ELASTIC
`POLYMERIC REGIONS
`POLYMERIC REGIONS
`
`(75) Inventors: Bradley W. Eaton, Woodbury, MN
`(75)
`Inventors: Bradley W. Eaton, Woodbury, MN
`(US); Byron M. Jackson, Forest Lake,
`(US); Byron M. Jackson, Forest Lake,
`MN (US); Leigh E. Wood, Woodbury,
`MN (US); Leigh E. Wood, Woodbury,
`MN (US); Scott J. Tuman, Woodbury,
`MN (US); Scott J. Tuman, Woodbury,
`MN (US)
`MN (US)
`
`(73) Assignee: 3M Innovative Properties Company,
`(73) Assignee: 3M Innovative Properties Company,
`St. Paul, MN (US)
`St. Paul, MN (US)
`
`( * ) Notice:
`( * ) Notice:
`
`(21) Appl. No.: 10/012,698
`(21) Appl. No.: 10/012,698
`
`(22) Filed: (cid:9)
`(22) Filed:
`
`(65) (cid:9)
`(65)
`
`US 2003/0087098 Al May 8, 2003
`US 2003/0087098 Al May 8, 2003
`
`(cid:9) (cid:9)(cid:9) (cid:9)
`
`US006875710B2
`
`11111111111111101111111111111
`
`1811.1711il!!1101011111111110111111
`
`US006875710B2
`
`(to) Patent No.: (cid:9)
`(io) Patent No.:
`(45) Date of Patent: (cid:9)
`(45) Date of Patent:
`
`US 6,875,710 B2
`US 6,875,710 B2
`Apr. 5, 2005
`Apr. 5, 2005
`
`5,503,076 A
`5,503,076 A
`5,843,057 A
`5,843,057 A
`6,638,605 B1
`6,638,605 B1
`2002/0115972 Al
`2002/0115972 Al
`2003/0085485 Al
`2003/0085485 Al
`2003/0087059 Al
`2003/0087059 Al
`2003/0088220 Al
`2003/0088220 Al
`2003/0088228 Al
`2003/0088228 Al
`2003/0091807 Al
`2003/0091807 Al
`2003/0111166 Al
`2003/0111166 Al
`
`4/1996 Yeo
`4/1996
`Yeo
`12/1998 McCormack
`McCormack
`12/1998
`10/2003 Ankuda, Jr. et al.
`Ankuda, Jr. et al.
`10/2003
`8/2002 Dabi et al.
`Dabi et al.
`8/2002
`5/2003 Seidel et al.
`5/2003
`Seidel et al.
`5/2003 Jackson et al.
`5/2003
`Jackson et al.
`5/2003 Molander et al.
`5/2003
`Molander et al.
`5/2003 Desai et al.
`5/2003
`Desai et al.
`5/2003 Desai et al.
`5/2003
`Desai et al.
`6/2003 Uitenbroek et al.
`Uitenbroek et al.
`6/2003
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`
`EP
`EP
`EP
`EP
`FR
`ER
`WO
`WO
`
`0 189 351 A2
`0 189 351 A2
`0 189 351 B1
`0 189 351 B1
`1117251
`1117251
`WO 00/07532
`WO 00/07532
`
`7/1986
`7/1986
`3/1991
`3/1991
`5/1956
`5/1956
`2/2000
`2/2000
`
`Primary Examiner—Terrel Morris
`Primary Examiner—Terrel Morris
`Assistant Examiner—Lynda Salvatore
`Assistant Examiner—Lynda Salvatore
`(74) Attorney, Agent, or Firm—Gary L. Griswold; Kevin
`(74) Attorney, Agent, or Firm—Gary L. Griswold; Kevin
`W. Raasch; William J. Bond
`W. Raasch; William J. Bond
`
`(57) (cid:9)
`(57)
`
`ABSTRACT
`ABSTRACT
`
`Methods of manufacturing composite webs including a
`Methods of manufacturing composite webs including a
`substrate with one or more reinforcing discrete polymeric
`substrate with one or more reinforcing discrete polymeric
`regions located on or within the composite web arc dis-
`regions located on or within the composite web are dis
`closed. Molten nonelastomeric thermoplastic material of the
`closed. Molten nonelastomeric thermoplastic material of the
`discrete polymeric region is forced against the substrate by
`discrete polymeric region is forced against the substrate by
`a transfer roll. If the substrate is porous, fibrous, etc., a
`a transfer roll. If the substrate is porous,
`fibrous, etc., a
`portion of the nonelastomeric thermoplastic composition
`portion of the nonelastomeric thermoplastic composition
`may infiltrate the substrate and/or encapsulate fibers of the
`may infiltrate the substrate and/or encapsulate fibers of the
`substrate. The composite webs also include elastomeric
`substrate. The composite webs also include elastomeric
`thermoplastic material in discrete polymeric regions on or
`thermoplastic material in discrete polymeric regions on or
`within the composite web.
`within the composite web.
`
`16 Claims, 14 Drawing Sheets
`16 Claims, 14 Drawing Sheets
`
`Subject to any disclaimer, the term of this
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 320 days.
`U.S.C. 154(b) by 320 days.
`
`Nov. 5, 2001
`Nov. 5, 2001
`
`Prior Publication Data
`Prior Publication Data
`
`(51)
`(51)
`
`Int. C1.7
`Int. CI.7 (cid:9)
`
`(52) U.S. Cl.
`(52) U.S. CI(cid:9)
`
` B32B 27/04; B32B 27/12;
`B32B 27/04; B32B 27/12;
`B32B 3/06; B32B 3/10; B32B 3/28
`B32B 3/06; B32B 3/10; B32B 3/28
` 442/66; 428/134; 428/136;
`442/66; 428/134; 428/136;
`428/137; 428/100; 428/141; 428/167
`428/137; 428/100; 428/141; 428/167
`(58) Field of Search (cid:9)
`442/66; 428/134,
`(58) Field of Search (cid:9)
`442/66; 428/134,
`428/136, 137, 141, 100, 167
`428/136, 137, 141, 100, 167
`
`(56) (cid:9)
`(56)
`
`References Cited
`References Cited
`
`U.S. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
`
`5,230,851 A (cid:9)
`5,230,851 A
`5,458,590 A (cid:9)
`5.458.590 A
`
`7/1993 Thomas
`7/1993 Thomas
`10/1995 Schleinz et al.
`10/1995 Schleinz et al.
`
`tIO ^ /
`I
`—Jk (cid:9) AW -X-VVVYN NV\ VnVNXA
`
`_
`
`Petitioner - Owens Corning
`Ex. 1005, p. 1 of 32
`
`(cid:9)
`(cid:9)
`(cid:9)
`

`

`U.S. Patent
`U.S. Patent (cid:9)
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 1 of 14
`Sheet 1 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
`
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`Petitioner - Owens Corning
`Ex. 1005, p. 2 of 32
`
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 2 of 14
`Sheet 2 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 3 of 32
`
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 3 of 14
`Sheet 3 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
`
`Petitioner - Owens Corning
`Ex. 1005, p. 4 of 32
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 4 of 14
`Sheet 4 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 5 of 32
`
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 5 of 14
`Sheet 5 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 6 of 32
`
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005 (cid:9)
`Apr. 5, 2005
`
`Sheet 6 of 14 (cid:9)
`Sheet 6 of 14
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`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 7 of 32
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`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 7 of 14
`Sheet 7 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 8 of 32
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`(cid:9)
`

`

`U.S. Patent
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 8 of 14
`Sheet 8 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 9 of 32
`
`(cid:9)
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 9 of 14
`Sheet 9 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 10 of 32
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5,2005
`Apr. 5, 2005
`
`Sheet 10 of 14
`Sheet 10 of 14 (cid:9)
`
`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 11 of 32
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 11 of 14
`Sheet 11 of 14 (cid:9)
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`US 6,875,710 B2
`US 6,875,710 B2
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`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 12 of 14
`Sheet 12 of 14 (cid:9)
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`Ex. 1005, p. 13 of 32
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`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 13 of 14
`Sheet 13 of 14 (cid:9)
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`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 14 of 32
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 5, 2005
`Apr. 5, 2005
`
`Sheet 14 of 14 (cid:9)
`Sheet 14 of 14
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`US 6,875,710 B2
`US 6,875,710 B2
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`Ex. 1005, p. 15 of 32
`
`(cid:9)
`

`

`US 6,875,710 B2
`US 6,875,710 B2
`
`1
`COMPOSITE WEBS WITH REINFORCING
`COMPOSITE WEBS WITH REINFORCING
`POLYMERIC REGIONS AND ELASTIC
`POLYMERIC REGIONS AND ELASTIC
`POLYMERIC REGIONS
`POLYMERIC REGIONS
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`
`The present invention relates to composite webs that
`The present
`invention relates to composite webs that
`include reinforcing discrete polymeric regions and elastic
`include reinforcing discrete polymeric regions and elastic
`discrete polymeric regions.
`discrete polymeric regions.
`
`BACKGROUND
`BACKGROUND
`
`The manufacture of articles formed of webs that require
`The manufacture of articles formed of webs that require
`some reinforcement to withstand forces experienced during
`some reinforcement to withstand forces experienced during
`use are known. In many cases, reinforcement is simply
`use are known.
`In many cases, reinforcement
`is simply
`provided over the entire substrate or web. Such approaches
`provided over the entire substrate or web. Such approaches
`can, however, add cost and weight to the web, as well as
`can, however, add cost and weight to the web, as well as
`stiffness over the entire surface of the web—even in those
`stiffness over the entire surface of the web—even in those
`areas that do not require reinforcement. Furthermore, rein-
`areas that do not require reinforcement. Furthermore, rein
`forcing layers that are coextensive with the web may also
`forcing layers that are coextensive with the web may also
`reduce its breathability.
`reduce its breathability.
`To address some of these issues, smaller pieces of rein-
`To address some of these issues, smaller pieces of rein
`forcing materials may be attached to a web or substrate in
`forcing materials may be attached to a web or substrate in
`selected areas that require reinforcement. The handling and
`selected areas that require reinforcement. The handling and
`attachment of such discrete pieces can, however, be
`attachment of such discrete pieces can, however, be
`problematic, by potentially reducing throughput, causing
`problematic, by potentially reducing throughput, causing
`waste (where the discrete pieces are not securely attached),
`waste (where the discrete pieces are not securely attached),
`requiring precise registration or location on the web, requir-
`requiring precise registration or location on the web, requir
`ing the use of adhesives or other bonding agents, etc. The
`ing the use of adhesives or other bonding agents, etc. The
`discrete pieces may also present relatively sharp that may be
`discrete pieces may also present relatively sharp that may be
`the source of irritation or discomfort. The irritation or
`the source of irritation or discomfort. The irritation or
`discomfort can be exacerbated because the reinforcing
`discomfort can be exacerbated because the reinforcing
`pieces are typically located on the surface of the substrate.
`pieces are typically located on the surface of the substrate.
`In addition to reinforcing substrates or webs, it may also
`In addition to reinforcing substrates or webs, it may also
`be desirable to manufacture articles that exhibit elasticity in
`be desirable to manufacture articles that exhibit elasticity in
`addition to reinforcing regions. The manufacture of articles
`addition to reinforcing regions. The manufacture of articles
`that exhibit elasticity, i.e., the ability to at least partially
`that exhibit elasticity,
`i.e.,
`the ability to at
`least partially
`recover their original shape after moderate elongation, may
`recover their original shape after moderate elongation, may
`be desired for a number of reasons. For example, elasticity
`be desired for a number of reasons. For example, elasticity
`may be useful in connection with fastening systems for
`may be useful
`in connection with fastening systems for
`items such as garments (e.g., diapers, training pants, gowns,
`items such as garments (e.g., diapers, training pants, gowns,
`etc.). Elasticity in garments can provide what may be
`etc.). Elasticity in garments can provide what may be
`referred to as dynamic fit, i.e., the ability to stretch and
`referred to as dynamic fit, i.e.,
`the ability to stretch and
`recover in response to movement by the wearer.
`recover in response to movement by the wearer.
`Elasticity may also be useful in connection with other
`Elasticity may also be useful
`in connection with other
`applications. For example, some fasteners may provide more
`applications. For example, some fasteners may provide more
`consistent attachment if the fastener is held in tension that
`consistent attachment if the fastener is held in tension that
`can be supplied by stretching the fastener and relying on the
`can be supplied by stretching the fastener and relying on the
`recovery forces to provide the desired tension. In other
`recovery forces to provide the desired tension.
`In other
`instances, elasticity may allow for easy adjustment of the
`instances, elasticity may allow for easy adjustment of the
`size or length of a fastener or other article.
`size or length of a fastener or other article.
`Although elasticity may be beneficial in a variety of
`Although elasticity may be beneficial
`in a variety of
`different applications, it may raise issues in manufacturing.
`different applications, it may raise issues in manufacturing.
`Many attempts to provide elasticity rely on separate elastic
`Many attempts to provide elasticity rely on separate elastic
`components that are, e.g., glued or sewn to a backing or
`components that are, e.g., glued or sewn to a backing or
`other nonelastic member to provide the desired elasticity.
`other nonelastic member to provide the desired elasticity.
`The manufacture of such composite articles may be prob-
`The manufacture of such composite articles may be prob
`lematic in that secure attachment of the elastic components
`lematic in that secure attachment of the elastic components
`may be difficult to achieve and/or maintain. Further, the cost
`may be difficult to achieve and/or maintain. Further, the cost
`and difficulty of providing and attaching separate elastic
`and difficulty of providing and attaching separate elastic
`components may be relatively high. The handling and
`components may be relatively high. The handling and
`attachment of separate elastic components can reduce
`attachment of separate elastic components can reduce
`throughput, cause additional waste (where the separate com-
`throughput, cause additional waste (where the separate com
`ponents are not securely attached), etc.
`ponents are not securely attached), etc.
`In other instances, an entire article may be constructed to
`In other instances, an entire article may be constructed to
`provide the desired elasticity. For example, many elastic
`provide the desired elasticitv. For example, manv elastic
`
`2
`fastening systems rely on the use of elastic laminate back-
`fastening systems rely on the use of elastic laminate back
`ings in which the elastic materials are provided in the form
`ings in which the elastic materials are provided in the form
`of a film that is coextensive with the backing. Such an
`of a film that
`is coextensive with the backing. Such an
`approach may add costs associated with providing a coex-
`approach may add costs associated with providing a coex
`tensive elastic layer or layers. Further, many elastic mate-
`tensive elastic layer or layers. Further, many elastic mate
`rials are not breathable. If the elastic laminate backings are
`rials are not breathable. If the elastic laminate backings are
`to be used in garments, it may be desirable to perforate the
`to be used in garments, it may be desirable to perforate the
`backing to improve its breathability. Such additional pro-
`backing to improve its breathability. Such additional pro
`cessing does, however, add to the cost of producing the
`cessing does, however, add to the cost of producing the
`elastic laminate backing. Another potential disadvantage of
`elastic laminate backing. Another potential disadvantage of
`elastic laminate backings is that it may be difficult to provide
`elastic laminate backings is that it may be difficult to provide
`any variability in the elastic recovery forces generated in
`any variability in the elastic recovery forces generated in
`different portions of the backing.
`different portions of the backing.
`
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`
`The present invention provides methods of manufacturing
`The present invention provides methods of manufacturing
`composite webs including a substrate with one or more
`composite webs including a substrate with one or more
`reinforcing discrete polymeric regions located on or within
`reinforcing discrete polymeric regions located on or within
`the composite web and one or more discrete elastic poly-
`the composite web and one or more discrete elastic poly
`meric regions located on or within the composite web.
`meric regions located on or within the composite web.
`One advantage of the methods of the present invention is
`One advantage of the methods of the present invention is
`the ability to transfer one or more discrete polymeric regions
`the ability to transfer one or more discrete polymeric regions
`onto a major surface of a substrate, where the thermoplastic
`onto a major surface of a substrate, where the thermoplastic
`material of the discrete polymeric region can be forced
`material of the discrete polymeric region can be forced
`against the substrate by a transfer roll. If the substrate is
`against the substrate by a transfer roll. If the substrate is
`porous, fibrous, etc., pressure may enhance attachment of
`porous, fibrous, etc., pressure may enhance attachment of
`the discrete polymeric regions to the substrates by forcing a
`the discrete polymeric regions to the substrates by forcing a
`portion of the thermoplastic composition to infiltrate the
`portion of the thermoplastic composition to infiltrate the
`substrate and/or encapsulate fibers of the substrate.
`substrate and/or encapsulate fibers of the substrate.
`Another advantage is the ability to control the shape,
`Another advantage is the ability to control
`the shape,
`spacing, and volume of the discrete polymeric regions. This
`spacing, and volume of the discrete polymeric regions. This
`may be particularly advantageous because these parameters
`may be particularly advantageous because these parameters
`(shape, spacing, and volume) can be fixed regardless of the
`(shape, spacing, and volume) can be fixed regardless of the
`line speed of the system.
`line speed of the system.
`Another advantage of the present invention may be found
`Another advantage of the present invention may be found
`in the composite depressions and their use, which may
`in the composite depressions and their use, which may
`improve the formation of reinforcing discrete polymeric
`improve the formation of reinforcing discrete polymeric
`regions in accordance with the present invention. The com-
`regions in accordance with the present invention. The com
`posite depressions may, e.g., improve the transfer of rela-
`posite depressions may, e.g., improve the transfer of rela
`tively large discrete polymeric regions onto the substrates as
`tively large discrete polymeric regions onto the substrates as
`well as the transfer of discrete polymeric regions that have
`well as the transfer of discrete polymeric regions that have
`a varying thickness.
`a varying thickness.
`Another advantage of the methods of the present inven-
`Another advantage of the methods of the present inven
`tion is the ability to provide one or more discrete polymeric
`tion is the ability to provide one or more discrete polymeric
`regions that extend for the length of the substrate (while not
`regions that extend for the length of the substrate (while not
`being formed over the width of the substrate, i.e., the
`being formed over
`the width of the substrate,
`i.e.,
`the
`discrete polymeric regions are not coextensive with the
`discrete polymeric regions are not coextensive with the
`major surface of the substrate).
`major surface of the substrate).
`Another advantage of the methods of the present inven-
`Another advantage of the methods of the present inven
`tion is the ability to provide different thermoplastic compo-
`tion is the ability to provide different thermoplastic compo
`sitions across the width of the substrate, such that some
`sitions across the width of the substrate, such that some
`discrete polymeric regions may be formed of one thermo-
`discrete polymeric regions may be formed of one thermo
`plastic composition, while other discrete polymeric regions
`plastic composition, while other discrete polymeric regions
`are formed of a different thermoplastic composition.
`are formed of a different thermoplastic composition.
`Yet another advantage of the methods of the present
`Yet another advantage of the methods of the present
`invention is the ability to provide one or more discrete
`invention is the ability to provide one or more discrete
`polymeric regions on both major surfaces of a substrate. The
`polymeric regions on both major surfaces of a substrate. The
`discrete polymeric regions on the opposing major surfaces
`discrete polymeric regions on the opposing major surfaces
`may be formed with the same or different features as desired.
`may be formed with the same or different features as desired.
`In one aspect, the present invention provides an elastic
`In one aspect, the present invention provides an elastic
`article including a substrate with first and second major
`article including a substrate with first and second major
`surfaces; one or more reinforcing discrete polymeric regions
`surfaces; one or more reinforcing discrete polymeric regions
`attached to the substrate, wherein each reinforcing discrete
`attached to the substrate, wherein each reinforcing discrete
`polymeric region of the one or more reinforcing discrete
`polymeric region of the one or more reinforcing discrete
`polymeric regions is formed of a nonelastomeric thermo-
`polymeric regions is formed of a nonelastomeric thermo
`plastic composition that infiltrates a portion of substrate; and
`plastic composition that infiltrates a portion of substrate; and
`
`5
`
`10
`to
`
`15
`15
`
`20
`20
`
`25
`25
`
`30
`50
`
`35
`55
`
`40
`40
`
`45
`45
`
`50
`50
`
`55
`55
`
`60
`
`65
`
`Petitioner - Owens Corning
`Ex. 1005, p. 16 of 32
`
`

`

`US 6,875,710 B2
`US 6,875,710 B2
`
`4
`3
`FIG. 2 is a plan view of a portion of a transfer roll that can
`one or more elastic elements attached to the substrate,
`FIG. 2 is a plan view of a portion of a transfer roll that can
`one or more elastic elements attached to the substrate,
`wherein each elastic element of the one or more elastic
`be used in manufacturing composite webs according to the
`wherein each elastic element of the one or more elastic
`be used in manufacturing composite webs according to the
`elements includes an elastic discrete polymeric region
`methods of the present invention.
`elements includes an elastic discrete polymeric region
`methods of the present invention.
`formed of an elastomeric thermoplastic composition that
`formed of an elastomeric thermoplastic composition that
`FIG. 3A is a cross-sectional view of the depression of
`FIG. 3A is a cross-sectional view of the depression of
`infiltrates a portion of the substrate.
`5
`infiltrates a portion of the substrate.
`5 FIG. 2, taken along line 3-3 in FIG. 2 at one point during
`FIG. 2, taken along line 3—3 in FIG. 2 at one point during
`In another aspect, the present invention provides a method
`In another aspect, the present invention provides a method
`formation of the depression.
`formation of the depression.
`for producing a composite web by providing a first substrate
`for producing a composite web by providing a first substrate
`FIG. 3B is a cross-sectional view of the depression of
`FIG. 3B is a cross-sectional view of the depression of
`having a first major surface and a second major surface,
`having a first major surface and a second major surface,
`FIG. 2, taken along line 3-3 in FIG. 2 at another point
`FIG. 2, taken along line 3—3 in FIG. 2 at another point
`wherein a plurality of discrete elastomeric polymeric regions
`wherein a plurality of discrete elastomeric polymeric regions
`during formation of the depression.
`during formation of the depression.
`formed of an elastomeric thermoplastic composition are
`formed of an elastomeric thermoplastic composition are 10
`10 (cid:9)
`FIG. 3C is a cross-sectional view of the depression of
`FIG. 3C is a cross-sectional view of the depression of
`located on the first major surface of the first substrate,
`located on the first major surface of the first substrate,
`FIG. 2, taken along line 3-3 in FIG. 2 during formation of
`FIG. 2, taken along line 3—3 in FIG. 2 during formation of
`wherein each discrete elastomeric polymeric region of the
`wherein each discrete elastomeric polymeric region of the
`the depression.
`the depression.
`plurality of discrete elastomeric polymeric regions infiltrates
`plurality of discrete elastomeric polymeric regions infiltrates
`FIG. 4 is a plan view of another depression on a portion
`the first major surface of the first substrate. The method
`FIG. 4 is a plan view of another depression on a portion
`the first major surface of the first substrate. The method
`of a transfer roll that can be used to manufacture reinforcing
`further includes providing a second substrate having a first
`of a transfer roll that can be used to manufacture reinforcing
`further includes providing a second substrate having a first
`major surface and a second major surface, a plurality of
`major surface and a second major surface, a plurality of 15
`is discrete polymeric regions on a composite web according to
`discrete polymeric regions on a composite web according to
`discrete nonelastomeric polymeric regions formed of a non-
`the methods of the present invention.
`discrete nonelastomeric polymeric regions formed of a non-
`the methods of the present invention.
`elastomeric thermoplastic composition located on the first
`elastomeric thermoplastic composition located on the first
`FIG. 5 is a cross-sectional view of the depression of FIG.
`FIG. 5 is a cross-sectional view of the depression of FIG.
`major surface of the second substrate, wherein each discrete
`major surface of the second substrate, wherein each discrete
`4, taken along line 5-5 in FIG. 4.
`4, taken along line 5—5 in FIG. 4.
`nonelastomeric polymeric region of the plurality of discrete
`nonelastomeric polymeric region of the plurality of discrete
`FIG. 6 is a plan view of another depression on a portion
`FIG. 6 is a plan view of another depression on a portion
`nonelastomeric polymeric regions infiltrates the first major
`20 (cid:9)
`nonelastomeric polymeric regions infiltrates the first major 20
`of a transfer roll that can be used to manufacture reinforcing
`of a transfer roll that can be used to manufacture reinforcing
`surface of the second substrate; and laminating the first
`surface of the second substrate; and laminating the first
`discrete polymeric regions on a composite web according to
`discrete polymeric regions on a composite web according to
`substrate to the second substrate.
`substrate to the second substrate.
`the methods of the present invention.
`the methods of the present invention.
`In another aspect, the present invention provides a method
`In another aspect, the present invention provides a method
`FIG. 7 is a cross-sectional view of a composite web
`FIG. 7 is a cross-sectional view of a composite web
`for producing a composite web by providing a substrate with
`for producing a composite web by providing a substrate with
`25 manufactured according to the methods of the present inven-
`manufactured according to the methods of the present inven
`a first major surface and a second major surface; and
`a first major surface and a second major surface; and 25
`tion including reinforcing discrete polymeric regions
`tion including reinforcing discrete polymeric regions
`forming a plurality of discrete elastomeric polymeric regions
`forming a plurality of discrete elastomeric polymeric regions
`between two substrates.
`between two substrates.
`formed of an elastomeric thermoplastic composition on the
`formed of an elastomeric thermoplastic composition on the
`FIG. 8 is a cross-sectional view of the composite web of
`FIG. 8 is a cross-sectional view of the composite web of
`first major surface of the substrate, wherein each discrete
`first major surface of the substrate, wherein each discrete
`FIG. 7, before attachment of the two substrates to form the
`FIG. 7, before attachment of the two substrates to form the
`elastomeric polymeric region of the plurality of discrete
`elastomeric polymeric region of the plurality of discrete
`30 composite web in accordance with the methods of the
`composite web in accordance with the methods of the
`elastomeric polymeric regions infiltrates the first major
`elastomeric polymeric regions infiltrates the first major 30
`present invention.
`present invention.
`surface of the substrate. The method further includes form-
`surface of the substrate. The method further includes form
`FIG. 9 is a plan view of one illustrative substrate with
`ing a plurality of discrete nonelastomeric polymeric regions
`FIG. 9 is a plan view of one illustrative substrate with
`ing a plurality of discrete nonelastomeric polymeric regions
`reinforcing discrete polymeric regions formed thereon that
`formed of a nonelastomeric thermoplastic composition
`reinforcing discrete polymeric regions formed thereon that
`formed of a nonelastomeric thermoplastic composition
`can be manufactured into a composite web according to the
`located on the first major surface or the second major surface
`can be manufactured into a composite web according to the
`located on the first major surface or the second major surface
`ls methods of the present invention.
`of the substrate, wherein each discrete nonelastomeric poly-
`methods of the present invention.
`of the substrate, wherein each discrete nonelastomeric poly- 35
`FIG. 10 is a cross-sectional view of another composite
`meric region of the plurality of discrete nonelastomeric
`FIG. 10 is a cross-sectional view of another composite
`meric region of the plurality of discrete nonelastomeric
`web with reinforcing discrete polymeric regions on both
`polymeric regions infiltrates the second substrate.
`web with reinforcing discrete polymeric regions on both
`polymeric regions infiltrates the second substrate.
`major surfaces of a substrate.
`In another aspect, the present invention provides a com-
`major surfaces of a substrate.
`In another aspect, the present invention provides a com
`FIG. 11 is a perspective view of one polymer transfer
`posite web that includes a substrate with first and second
`FIG. 11 is a perspective view of one polymer transfer
`posite web that includes a substrate with first and second
`40 process useful in providing discrete polymeric regions on a
`major surfaces; a plurality of nonelastomeric discrete poly-
`process useful in providing discrete polymeric regions on a
`major surfaces; a plurality of nonelastomeric discrete poly- 40
`substrate in accordance with the methods of the present
`meric regions attached to the substrate, wherein each non-
`substrate in accord