........ . ..... .
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`~._.
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`ISSUE DATE
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`, ,.
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`APPLNUM F(UNG DATE
`
`: " EXAMINER ’
`
`I~°CONTINUING DATA VERIFI~.Di
`
`FAST FELT 2024, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`~.ST AVAILABLE COPY
`
`SEARCH
`
`Class Sub. Date Exmr.
`
`!
`
`SEARCH NOTES
`(List databases searched. Attach
`search strategy insid~ ,~
`Date Exmr
`
`INTERFERENCE SEARCHED
`Class Sub. Date !Exmr.
`
`FAST FELT 2024, pg. 2
`Owens Corning v. Fast Felt
`IPR2015-00650
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`CLASS. SUBCLASS
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`FAST FELT 2024, pg. 3
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`I E
`IN THE UNITED STATES PATENT AND T~AD M RK OFF C
`[~-12~0 ’ E A
`
`Appli~nt(s):
`
`No.:
`
`57190US002
`
`COMPOSITE WEBS WITH REINFORCING POLYMERIC REGIONS AND ELASTIC POLYMERIC REGIONS
`
`i~tant Commissioner for Patents
`Box PATENT APPLICATION
`D.C. 20231
`
`We are transmitting the following documents along with this Transmittal Sheet (which is submitted in triplicate):
`X.~ UTILrI’Y PATENT APPLICATION including:
`X Specification (47 consecutively numbered pgs, including 26claims on 7 consecutively numbered pgs and a ~l pg Abstract);
`X Drawings (~ figures on 1~4 sheets);
`
`__ A signed/unsigned Declaration and Power of Attorney ( _ pgs).
`Application Data Sheet (_ pgs).
`An itemized return postcard.
`An Assignment of the invention to ~ and Recordation Form Cover Sheet.
`A check in the amount of $40.00 to pay the Assignment Recording Fee.
`A certified copy of a _ application, Serial No. ~, filed , the right of priority of which is claimed under 35 U.S.C. § 119.
`Computer readable form of "Sequence Listing." Applicants state that the paper copy form of the "Sequence Listing" section of the
`present application, and the computer readable form submitted herewith, are the same.
`Other:~.
`
`***FILING FEE HAS BEEN DEFERRED HEREWITH***
`
`M~UETING, RAASCH & GEBHARDT, P.A.
`C~tomer Number: 268~ ~
`
`i!
`
`Name:
`Reg. No.:
`Direct Dial:
`Facsimile:
`
`Kevin W. Raasch
`35,651
`612-305-1218
`612-305-1228
`
`CERTIFICATE UNDER 37 CFR .~ 1.10:
`Date of Deposit: November 5, 2001
`"l~xpress Mail" mailing label number: EL 888 272 688 US
`I hereby certify that this paper or lee is being deposited with the United States Postal Service "Express Mail Post Office to Addressee"
`service under 37 CFR §1.10 on the date indicated above and is addressed to the Assistant Commissioner for Patents, ATTN: Box
`PATENT APPLICATION, Washington, D.C. 20231.
`
`By:
`Name:
`
`UNDER RULE 1.10)
`
`FAST FELT 2024, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`COMPOSITE WEBS WITH REINFORCING POLYMERIC REGIONS AND
`ELASTIC POLYMERIC REGIONS
`
`PATENT
`Docket No. 57190US002
`
`FIELD OF THE INVENTION
`
`The present invention relates to composite webs that include reinforcing
`
`10
`
`discrete polymeric regions and elastic discrete polymeric regions.
`
`BACKGROUND
`
`The manufacture of articles formed of webs that require some
`
`reinforcement to withstand forces experienced during use are known. In many
`
`15
`
`cases, reinforcement is simply provided over the entire substrate or web. Such
`
`approaches can, however, add cost and weight to the web, as well as stiffness
`
`over the entire surface of the web - even in those areas that do not require
`
`reinforcement. Furthermore, reinforcing layers that are coextensive with the
`
`web may also reduce its breathability.
`
`20
`
`To address some of these issues, smaller pieces of reinibrcing materials
`
`may be attached to a web or substrate in selected areas that require
`
`reinforcement. The handling and attachment of such discrete pieces can,
`
`however, be problematic, by potentially reducing throughput, causing waste
`
`(where the discrete pieces are not securely attached), requiring precise
`
`25
`
`registration or location on the web, requiring the use of adhesives or other
`
`bonding agents, etc. The discrete pieces may also present relatively sharp that
`
`may be the source of irritation or discomfort. The irritation or discomfort can be
`
`exacerbated because the reinforcing pieces are typically located on the surface of
`
`the substrate.
`
`30
`
`In addition to reintbrcing substrates or webs, it may also be desirable to
`
`manufacture articles that exhibit elasticity in addition to reinforcing regions.
`
`The manufacture of articles that exhibit elasticity, i.e., the ability to at least
`
`partially recover their original shape after moderate elongation, may be desired
`
`for a number of reasons. For example, elasticity may be useful in connection
`
`35 with fastening systems for items such as garments (e.g., diapers, training pants,
`
`gowns, etc.). Elasticity in garments can provide what may be referred to as
`1
`
`FAST FELT 2024, pg. 5
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

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`dynamic fit, i.e., the abitity to stretch and recover in response to movement by
`
`the wearer.
`
`Elasticity may also be useful in connection with other applications. For
`
`example, some fasteners may provide more consistent attachment if the fastener
`
`5
`
`is held in tension that can be supplied by stretching the fastener and relying on
`
`the recovery forces to provide the desired tension. In other instances, elasticity
`
`may allow for easy adjustment of the size or length of a fastener or other article.
`
`Although elasticity may be beneficial in a variety of different
`
`applications, it may raise issues in manufacturing. Many attempts to provide
`
`10
`
`elasticity, rely on separate elastic components that are, e.g., glued or sewn to a
`
`backing or other nonelastic member to provide the desired elasticity. The
`
`manufacture of such composite articles may be problematic in that secure
`
`attachment of the elastic components may be difficult to achieve and/or
`
`maintain° Further, the cost and difficulty of providing and attaching separate
`
`15
`
`elastic components may be relatively high. The handling and attachment of
`
`separate elastic COlnponents can reduce throughput, cause additional waste
`
`(where the separate components are not securely attached), etc.
`
`In other instances, an entire article may be constructed to provide the
`
`desired elasticity. For example, many elastic fastening systems rely on the use
`
`20
`
`of elastic laminate backings in which the elastic materials are provided in the
`
`form of a film that is coextensive with the backing. Such an approach may add
`
`costs associated with providing a coextensive elastic layer or layers. Further,
`
`many elastic materials are not breathable. If the elastic laminate backings are to
`
`be used in garments, it may be desirable to perforate the backing to improve its
`
`25
`
`breathability. Such additional processing does, however, add to the cost of
`
`producing the elastic laminate backing. Another potential disadvantage of
`
`elastic laminate backings is that it may be difficult to provide any variability in
`
`the elastic recovery forces generated in different portions of the backing.
`
`3O
`
`SUMMARY OF THE INVENTION
`
`The present invention provides methods of manufacturing composite
`
`webs including a substrate with one or more reinforcing discrete polymeric
`
`FAST FELT 2024, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

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`regions located on or within the composite web and one or more discrete elastic
`
`polymeric regions located on or within the composite web.
`
`One advantage of the methods of the present invention is the ability to
`
`transfer one or more discrete polymeric regions onto a major surface of a
`
`5
`
`substrate, where the thermoplastic material of the discrete polymeric region can
`
`be tbrced against the substrate by a transfer roll. If the substrate is porous,
`
`fibrous, etc., pressure may enhance attachment of the discrete polymeric regions
`
`to the substrates by forcing a portion of the thermoplastic composition to
`
`infiltrate the substrate and/or encapsulate fibers of the substrate.
`
`10
`
`Another advantage is the ability to control the shape, spacing, and
`
`volume of the discrete polymeric regions. This may be particularly
`
`advantageous because these parameters (shape, spacing, and volume) can be
`
`fixed regardless of the line speed of the system.
`
`Another advantage of the present invention may be found in the
`
`15
`
`composite depressions and their use, which may improve the formation of
`
`reinforcing discrete polymeric regions in accordance with the present invention.
`
`The composite depressions may, e.g., improve the transfer of relatively large
`
`discrete polymeric regions onto the substrates as well as the transfer of discrete
`
`polymeric regions that have a varying thickmess.
`
`20
`
`Another advantage of the methods of the present invention is the ability
`
`to provide one or more discrete polymeric regions that extend for the length of
`
`the substrate (while not being formed over the ~vidth of the substrate, i.e., the
`
`discrete polymeric regions are not coextensive with the major surface of the
`
`substrate).
`
`25
`
`Another advantage of the methods of the present invention is the ability
`
`to provide different thermoplastic compositions across t~e width of the substrate,
`
`such that some discrete polymeric regions may be formed of one thermoplastic
`
`composition, while other discrete polymeric regions are formed of a different
`
`thermoplastic composition.
`
`30
`
`Yet another advantage of the methods of the present invention is the
`
`ability to provide one or more discrete polymeric regions on both major surfaces
`
`of a substra[e. The discrete polymeric regions on the opposing major surfaces
`
`may be formed with the same or different features as desired.
`
`FAST FELT 2024, pg. 7
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

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`In one aspect, the present invention provides an elastic article including a
`
`substrate with first and second major surfaces; one or more reinforcing discrete
`
`polymeric regions attached to the substrate, wherein each reinforcing discrete
`
`polymeric region of the one or more reinforcing discrete polymeric regions is
`
`5
`
`formed of a nonelastomeric thermoplastic composition that infiltrates a portion
`
`of substrate; and one or more elastic elements attached to the substrate, wherein
`
`each elastic element of the one or more elastic elements includes an elastic
`
`discrete polymeric region formed of an elastomeric thermoplastic composition
`
`that infiltrates a portion of the substra~e.
`
`10
`
`In another aspect, the present invention provides a method for producing
`
`a composite web by providing a first substrate having a first major surface and a
`
`second major surface, wherein a plurality of discrete elastomeric polymeric
`
`regions formed of an elastomeric thermoplastic composition are located on the
`
`first major surface of the first substrate, wherein each discrete elastomeric
`
`! 5
`
`polymeric region of the plurality of discrete elastomeric polymeric regions
`
`infiltrates the first major surface of the first substrate. The method further
`
`includes providing a second substrate having a first major sin-face and a second
`
`major surface, a plurality of discrete nonelastomeric polymeric regions formed
`
`of a nonelastomeric thermoplastic composition located on the first major st~rface
`
`20
`
`of the second substrate, wherein each discrete nonelastomeric polymeric region
`
`of the plurality of discrete nonelastomeric polymeric regions infiltrates the first
`
`major surface of the second substrate; and laminating the first substrate to the
`
`second substrate.
`
`In another aspect, the present invention provides a method for producing
`
`25
`
`a composite web by providing a substrate with a first major surface and a second
`
`major surface; and forming a plurality of discrete elastomeric polymeric regions
`
`formed of an elastomeric thermoplastic composition on the first major surface of
`
`the substrate, wherein each discrete elastomeric polymeric region of the plurality
`
`of discrete elastomeric polymeric regions infiltrates the first major surface of the
`
`30
`
`substrate. The method further includes forming a plurality of discrete
`
`nonelastomeric polymeric regions ~brmed of a nonelastomeric thermoplastic
`
`composition located on the first major surface or the second major surface of the
`
`4
`
`FAST FELT 2024, pg. 8
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

`
`substrate, wherein each discrete nonelastomeric polymeric region of the plurality
`
`of discrete nonelastomeric polymeric regions infiltrates the second substrate.
`
`In another aspect, the present invention provides a composite web that
`
`includes a substrate with first and second major surfaces; a plurality of
`
`nonelastomeric discrete polymeric regions attached to the substrate, wherein
`
`each nonelastomeric discrete polymeric region of the plurality of nonelastomeric
`
`discrete polymeric regions is formed of a nonelastomeric thermoplastic
`
`composition that infiltrates a portion of substrate; a plurality of elastomeric
`
`discrete polymeric regions attached to the substrate, wherein each elastomeric
`
`10
`
`discrete polymeric region of the plurality of elastomeric discrete polymeric
`
`regions is formed of an elastomeric thermoplastic composition that infiltrates a
`
`portion of the substrate; and one or more lines of separation in the substrate. The
`
`one or more lines of separation define boundaries of a plurality of distinct
`
`articles in the composite web, and wherein each article of the plurality of articles
`
`15
`
`includes at least one nonelastomeric discrete polymeric region of the plurality of
`
`nonelastomeric discrete polymeric regions and at least one elastomeric discrete
`
`polymeric region of the plurality of elastomeric discrete polymeric regions.
`
`These and other features and advantages of methods according to the
`
`20
`
`present invention are described below in connection with various illustrative
`
`embodiments of the invention.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a cross-sectional view of one reinforcing discrete polymeric
`
`25
`
`region on a composite web manufactured according to the methods of the
`
`present invention.
`
`FIG. 2 is a plan view of a portion of a transfer roll that can be used in
`
`manufacturing composite webs according to the methods of the present
`
`invention.
`
`30
`
`FIG. 3A is a cross-sectional ~’iew of the depression of FIG. 2, taken along
`
`line 3-3 in FIG. 2 at one point during tbrmation of the depression.
`
`FIG. 3B is a cross-sectional view of the depression of FIG. 2, taken along
`
`line 3-3 in FIG. 2 at another point during formation of the depression.
`
`FAST FELT 2024, pg. 9
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`FIG. 3C is a cross-sectional view of the depression of FIG. 2, taken along
`
`line 3-3 in FIG. 2 during formation of the depression.
`
`FIG. 4 is a plan view of another depression on a portion of a transfer roll
`
`that can be used to manufacture reinforcing discrete polymeric regions on a
`
`5
`
`composite web according to the methods of the present invention.
`
`FIG. 5 is a cross-sectional view of the depression of FIG. 4, taken along
`
`line 5-5 in FIG. 4.
`
`FIG. 6 is a plan view of another depression on a portion of a transfer roll
`
`that can be used to manufacture reinforcing discrete polymeric regions on a
`
`10
`
`composite web according to the methods of the present invention.
`
`FIG. 7 is a cross-sectional vie~v of a composite web manufactured
`
`according to the methods of the present invention including reinforcing discrete
`
`polymeric regions between two substrates.
`
`FIG. 8 is a cross-sectional view of the composite web of FIG. 7, before
`
`15
`
`attachment of the two substrates to form the composite web in accordance with
`
`the methods of the present invention.
`
`FIG. 9 is a plan view of one illustrative substrate with reinforcing
`
`discrete polymeric regions formed thereon that can be manufactured i~to a
`
`composite web according to the methods of the present invention.
`
`20
`
`FIG. 10 is a cross-sectional view of another composite web with
`
`reinforcing discrete polymeric regions on both major surfaces of a substrate.
`
`FIG. 11 is a perspective view of one polymer transfer process useful in
`
`providing discrete polymeric regions on a substrate in accordance with the
`
`methods of the present invention.
`
`25
`
`FIG. 11A is an enlarged schematic diagram depicting the relationship
`
`between a doctor blade and a depression on a transfer roll used in connection
`
`with the present invention.
`
`FIG. 11B is an enlarged partial cross-sectional view depicting a
`
`conformable backup roll forcing a substrate against a transfer roll.
`
`30
`
`FiG. 11C is an enlarged partial cross-sectional view depicting a mating
`
`bac~lp roll including protrusions aligned with depressions in the transfer roll.
`
`FIG. 12 illustrates another transfer roll and polymer source useful in
`
`connection with zoned delive~-y systems and methods.
`
`6
`
`FAST FELT 2024, pg. 10
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`FIG. t3 is a plan view of one article formed in a composite web by
`
`providing reinforcing discrete polymeric regions on a substrate according to the
`
`methods of the present invention.
`
`FIG. 14 is a cross-sectional view of the article of FIG. 13 taken along line
`
`5
`
`14-14 in FIG. 13.
`
`FIG. 15 is a plan view of a portion of one composite web manufactured
`
`according to the present invention.
`
`FIG. 16 is a perspective view of one transfer roll that may be used to
`
`manufacture the composite web of FIG. 15.
`
`10
`
`FIG. 17 is a plan view of a portion of one composite web manufactured
`
`according to the present invention that includes discrete polymeric regions
`
`extending across the width of the substrate.
`
`FIG. 18 is a plan view of one article manufactured from a composite web
`
`including elastomeric and nonelastomeric discrete polymeric regions.
`
`15
`
`FIG. 19 is a cross-sectional view of the article of FIG. 18, taken a!ong
`
`line 19-19 in FIG. 18.
`
`FIG. 20 is a cross-sectional view of an article manufactured from a
`
`laminated composite web including elastomeric and nonelastomeric discrete
`
`polymeric regions.
`
`20
`
`FIG. 21 is a plan view of another article manufactured from a composite
`
`web including etastomeric and nonelastomeric discrete polymeric regions.
`
`FIG. 22 is a cross-sectional view of the article of FIG. 21 ,taken "along
`
`line 22-22 in FIG. 21.
`
`FIG. 23 is a cross-sectional view of the article of FIG. 21, taken along
`
`25 line 23-23 in FIG. 21.
`
`FIG. 24 is a plan view of one composite web according to the present
`
`invention, the composite web including lines of separation formed therein.
`
`FIG. 25 is a schematic diagram of oue system and method for
`
`manufacturing composite webs according to the present invention.
`
`30
`
`FIG. 26 is a schematic diagram of another system and method for
`
`manufacturing composite webs according to the present invention.
`
`7
`
`FAST FELT 2024, pg. 11
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS OF THE
`
`INVENTION
`
`As discussed above, the present invention provides methods and systems
`
`for producing composite webs that include a substrate with reinforcing discrete
`
`5
`
`polymeric regions located on the surface or within the composite web. Various
`
`different constructions will now be described to illustrate various embodiments
`
`of the composite webs that can be manufactured in accordance with the methods
`
`of the present invention. These illustrative consWoctions should not be
`
`considered to limit the methods of the present invention, which is to be limited
`
`10
`
`only by the claims that follow.
`
`FIG. 1 is a cross-sectional view of a portion of one composite web
`
`manufactured in accordance with the present invention. The composite web
`
`includes a substrate 10 with a first major surface 18 and a second major surface
`
`19. One or more reinforcing discrete polymeric regions 14 are located on the
`
`15
`
`first major surface 18 of the substrate 10, it being understood that the substrate
`
`may include more than one reinforcing discrete polymeric region as depicted in,
`
`e.g., FIGS. 7-12.
`
`It may be preferred that the reinforcing discrete poly~neric regions 14 of
`
`composite webs manufactured in accordance with the present invention each
`
`20
`
`include a varying thickness or height above the surface 18 of the substrate 10. It
`
`may be particularly preferred that the thickness variations be provided in the
`
`form of a thinner discrete polymeric region proximate the edges t 5 of the
`
`reinforcing discrete polymeric region 14.
`
`The combination of thicker central portions of the reinforcing discrete
`
`25
`
`polymeric region 14 and thinner edges 15 may provide advantages. The thinner
`
`edges 15 may be more flexible or softer, which may enhance comfort if the
`
`composite web including such discrete polymeric regions is iticorporated into a
`
`garment such as, e.g., a diaper, surgical gown, etc. At the same time, the thicker
`
`central portion of the reinforcing discrete polymeric region 14 may provide a
`
`30
`
`desired level of rigidity to the discrete polymeric re,on.
`
`The reinforcing discrete polymeric regions 14 may cover ,any desired
`
`portion of the surface t 8 of the substrate 10 on which they are positioned,
`
`although it will be understood that the discrete polymeric regions 14 will not
`
`8
`
`FAST FELT 2024, pg. 12
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`cover all of the surface of the substrate 10. Some variations in the percentage of
`
`surface area occupied by discrete polymeric regions may be as described in, for
`
`example, pending U.S. Patent Application Serial No. 09/257,447, entitled WEB
`
`HAVING DISCRETE STEM REGIONS, filed on Feb. 25, 1999 (published as
`
`5
`
`International Publication No. WO 00150229).
`
`Further, although the discrete polymeric regions 14 are depicted as being
`
`disconnected from each other, it should be understood that some composite webs
`
`manufactured with the systems and methods of the present invention may
`
`include a relatively thin skin layer of the thermoplastic composition used to form
`
`10
`
`the discrete polymeric regions. Such a skin layer may, in some instances,
`
`connect some or all of the discrete polymeric regions on the composite web. In
`
`any event, however, the amount of polymeric material in the skin layer will be
`
`insufficient to provide significant reinforcement of the substrate outside of the
`
`thicker discrete polymeric regions. If the composite web includes elastomeric
`
`15
`
`discrete polymeric regions as discussed in connection with FIGS. 18-26, the
`
`amount of elastomeric polymeric materiaI in any elastomeric skin layer will be
`
`insufficient to provide significant elasticity to the substrate outside of the thicker
`
`elastomeric discrete polymeric regions.
`
`The substrates used in connection with the composite webs of the present
`
`20
`
`invention may have a variety of constructions. For example, the substrates may
`
`be a woven material, nonwoven material, -knit material, paper, film, or any other
`
`continuous media that can be fed through a nip point. The substrates may have a
`
`wide variety of properties, such as extensibility, elasticity, flexibility,
`
`conformabiIity, breathability, porosity, stiffness, etc. Further, the substrates may
`
`25
`
`include pleats, corrugations or other deformations from a flat planar sheet
`
`configuration.
`
`In some instances, the substrates may exhibit some level of extensibility
`
`and also, in some instances, elasticity. Extensible webs that may be preferred
`
`may have an initial yield tensile force of at least about 50 gm!cm, preferably at
`
`30
`
`least about 100 grrdcm. Further, the extensible webs may preferably be
`
`extensible nonwoven webs.
`
`Suitable processes for making a nonwoven web that may be used in
`
`connection with the present invention include, but are not limited to, airlaying,
`
`FAST FELT 2024, pg. 13
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`spunbond, spunlace, bonded melt blown webs and bonded carded web formation
`
`processes. Spunbond nonwoven webs are made by extruding a molten
`
`thermoplastic, as filaments from a series of fine die orifices in a spinneret. The
`
`diameter of the extruded filaments is rapidly reduced under tension by, for
`
`5
`
`example, by non-eductive or eductive fluid-drawing or other known spunbond
`
`mechanisms, such as described in U.S. Patent Nos. 4, 340,563 (Appel et al.);
`
`3,692,618 (Dorschner et al.); 3,338,992 and 3,341,394 (Kinney); 3,276,944
`
`(Levy); 3,502,538 (Peterson); 3,502,763 (Hartman) and 3,542,615 (Dobo et al.).
`
`The spunbond web is preferably bonded (point or continuous bonding).
`
`10
`
`The nonwoven web layer may also be made from bonded carded webs.
`
`Carded webs are made from separated staple fibers, which fibers are sent
`
`through a combing or carding unit which separates and aligns the staple fibers in
`
`the machine direction so as to form a generally machine direction-oriented
`
`fibrous nonwoven web. However, randomizers can be used to reduce this
`
`15 machine direction orientation.
`
`Once the carded web has been formed, it is then bonded by one or more
`
`of several bonding methods to give it suitable tensile properties. One bonding
`
`method is powder bonding wherein a powdered adhesive is distributed through
`
`the web and then activated, usually by heating the web and adhesive with hot air.
`
`20 Another bonding method is pattern bonding wherein heated calender rolls or
`
`ultrasonic bonding equipment are used to bond the fibers together, usually in a
`
`localized bond pattern though the web can be bonded across its entire surface if
`
`so desired. Generally, the more the fibers of a web are bonded together, the
`
`greater the nonwoven web tensile properties.
`
`25
`
`Aiflaying is another process by which fibrous nonwoven webs useful in
`
`the present invention can be made. In the airlaying process, bundles of small
`
`fibers usually having lengths ranging between about 6 to about 19 millimeters
`
`are separated and entrained in an air supply and then deposited onto a forming
`
`screen, often with the assistance of a vacuum supply. The randomly deposited
`
`30
`
`fibers are then bonded to one another using, for example, hot air or a spray
`
`adhesive.
`
`Mettblown nonwoven webs may be formed by extrusion of thermoplastic
`
`polymers from multiple die orifices, which polymer melt streams are
`
`10
`
`FAST FELT 2024, pg. 14
`Owens Corning v. Fast Felt
`IPR2015-00650
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`immediately attenuated by hot high velocity air or steam along two faces of the
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`die immediately at the location where the pol~aner exits from the die orifices.
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`The resulting fibers are entangled into a coherent web in the resulting turbulent
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`airstream prior to collection on a collecting surface. Generally, to provide
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`5
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`sufficient integrity and strength for the present invention, meltblown webs must
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`be further bonded such as by through air bonding, heat or ultrasonic bonding as
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`described above.
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`A web can be made extensible by skip slitting as is disclosed in, e.g.,
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`International Publication No. WO 96/10481 (Abuto et ai.). If an elastic,
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`t0
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`extensible web is desired, the slits are discontinuous and are generally cut on the
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`web prior to the web being attached to any elastic component. Although more
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`difficult, it is also possible to create slits in the nonelastic web layer after the
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`nonelastic web is laminated to the elastic web. At least a portion of the slits in
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`the nonelastic web should be generally perpendicular (or have a substantial
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`15
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`perpendicuIar vector) to the intended direction of extensibility or elasticity (the
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`at least first direction) of the elastic web layer. By generally perpendicular it is
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`meant that the angle between the longitudinal axis of the chosen slit or slits and
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`the direction of extensibility is between 60 and 120 degrees. A sufficient number
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`of the described slits are generally perpendicular such that the overal! laminate is
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`20
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`elastic. The provision of slits in two directions is advantageous when the elastic
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`laminate is intended to be elastic in at least two different directions.
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`A nonwoven web used in connection with the present invention can also
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`be a necked or reversibly necked nonwoven web as described in U.S. Patent
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`Nos. 4,965,122; 4,981,747; 5,114,781; 5,116,662; and 5,226,992 (all to
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`25 Morman). In these embodiments the nonwoven web is elongated in a direction
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`perpendicular to the desired direction of extensibility. When the nonwoven web
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`is set in this elongated condition, it wilt have stretch and recovery properties in
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`the direction of extensibitity.
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`The substrates used in connection with the present invention may
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`30
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`preferably exhibit some porosity on one or both of the major surfaces of the
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`substrate such that when a molten thermoplastic composition is provided on one
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`of the major surfaces of the substrate, a mechanical bond is formed between the
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`molten thermoplastic composition and the substrate as the molten thermoplastic
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`FAST FELT 2024, pg. 15
`Owens Corning v. Fast Felt
`IPR2015-00650
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`composition infiltrates anddor encapsulates a portion of the porous surface of the
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`substrate. As used in connection with the present invention, the term "porous"
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`includes both structures that include voids formed therein, as well as structures
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`formed of a collection of fibers (e.g., woven, nonwoven, knit, etc.) that allow for
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`5
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`the infiltration of molten thermoplastic composition into the interstices between
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`fibers. If the porous surface includes fibers, the thermoplastic composition may
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`preferably encapsulate fibers or portions of fibers on the surface of the substrate.
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`The type and construction of the material or materials in the substrate
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`should be considered when selecting an appropriate substrate to which a molten
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`10
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`thermoplastic composition is applied. Generally, such materials are of the type
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`and construction that do not melt, soften, or otherwise disintegrate under the
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`temperatures and pressures experienced during the step of transferring the
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`thermoplastic composition to the substrate. For example, the substrate should
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`have sufficient internal strength such that it does not fall apart during the
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`15
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`process. Preferably, the substrate has sufficient strength in the machine direction
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`at the temperature of the transfer roll to remove it intact from the transfer roll.
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`As used herein, the term "fiber" includes fibers of indefinite length (e.g.,
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`filaments) and fibers of discrete length, e.g., staple fibers. The fibers used in
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`connection with the present invention may be multicomponent fibers. The term
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`20
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`"multicomponent fiber" refers to a fiber having at least two distinct
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`longitudinally coextensive structured polymer domains in the fiber cross-section,
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`as opposed to blends where the domains tend to be dispersed, random, or
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`unstructured. The distinct domains may thus be formed of polymers from
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`different polymer classes (e.g., nylon and polypropylene) or be formed of
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`25
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`polymers from the same polymer class (e.g., nylon) but which differ in their
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`properties or characteristics. The term "multicomponent fiber" is thus intended
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`to include, but is not limited to, concentric and eccentric sheath-core fiber
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`structures, symmetric and asymmetric side-by-side fiber structures, island-in-sea
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`fiber structures, pie wedge fiber structures, and hollow" fibers of these
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`30
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`configurations.
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`Although the substrates depicted in the various cross-sectional views of
`
`the articles manufactured according to the methods of the present invention are
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`illustrated as single layer structures, it should be understood that the substrates
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`FAST FELT 2024, pg. 16
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

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`may be of single or multi-layer construction. If a multi-layer construction is
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`used, it will be understood that the various layers may have the same or different
`
`properties, constructions, etc. Some of these variations may be as described in,
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`for example, pending U.S. Patent Application Serial No. 09/257,447, entitled
`
`5 WEB HAVEqG DISCRETE STEM REGIONS, filed on Feb. 25, 1999
`
`(published as International Publication No. WO 00150229).
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`The discrete polymeric regions 14 may be formed of a wide variety of
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`different noneIastomeric thermoplastic pobq-neric materials. As used in
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`connection with the present invention, "thermoplastic" (and variations thereof)
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`t 0 means a polymer or polymeric composition that softens when exposed to heat
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`and returns to its original condition or near its original condition when cooled to
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`room temperature. The thermoplastic compositions used in connection with the
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`methods of the present invention should be capable of flowing or entering into
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`depressions formed in a polymer transfer roll as will be described below.
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`15
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`Suitable thermop