In the depicted composite depression 34, ceils 34a have the largest
`
`diameter and are formed to the greatest depth into the surface 32. Further, the
`
`cells 34a may be formed first as seen in FIG. 3A. Alternatively, the smaller cells
`
`may be formed first with the larger cells formed later. The cells 34b may be
`
`5
`
`formed next as depicted in FIG. 3B. Cells 34b are, in the depicted embodiment,
`
`formed to a shallower depth in the transfer roll 30 than cell 34a. It can be seen
`
`there that the cells 34b overlap the larger cell 34a, such that not all of the outline
`
`of the smaller cells 34b is actually formed into the transfer roll 30.
`
`The final step depicted in FIG. 3C is the formation of smaller cells 34c
`
`10
`
`farther outward from the central cell 34a than cells 34b. In the depicted
`
`embodiment, these outer cells 34c are formed to a shallower depth than cells
`
`34b, thereby contributing to the general thinning at the edges of a reinforcing
`
`discrete polymeric region as seen in, e.g., FIG. t.
`
`Although not wishing to be bound by any theory, it is hypothesized that
`
`15
`
`the features (e.g., edges, ridges, etc.) formed at the boundaries between the
`
`various cells in the composite structure of depression 34 may enhance its ability
`
`to retain molten thermoplastic composition during the transfer process as
`
`discussed below.
`
`The depressions on transfer rolls used in connection with the present
`
`20
`
`invention may be characterized in terms of the area occupied by their footprint
`
`on the exterior surface of the forming tool, a maximum dimension of the
`
`footprint (in any direction on the surface of the roll), the volume of the
`
`depression, the shape of the footprint, etc.
`
`When characterized in terms of the area occupied by the footprint of the
`
`25
`
`depressions, each of the depressions 34 may have a footprint with an area of
`
`about 4 square millimeters (mm2) or more. In other situations, each of the
`
`depressions 34 may have footprints with an area of about 8 mm2 or more.
`
`Another manner in which the depressions may be characterized is in
`
`terms of the largest footprint dimension as measured on the surface 32 of the
`
`30
`
`transfer roll 30. When characterized in terms of the largest footprint dimension
`
`of the footprint, it may be that the depressions have a largest footprint dimension
`
`of about 2 mm or more, in some instances about 5 mm or more.
`
`15
`
`FAST FELT 2024, pg. 201
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Yet another manner in which the depressions used in connection with the
`
`present invention may be characterized is in ternas of depression volume. For
`
`example, the depressions may have a depression volume of at least about three
`
`(3) cubic millimeters (ram3) or more, or alternatively a depression volume of
`
`5
`
`about five (5) cubic millimeters or more. Volume may be important because at
`
`least some of the molten Iherrnoplastic composition may be retained within the
`
`depression during the transfer process, i.e., the depression volume may
`
`preferably be oversized relative to the preferred volume of the discrete polymeric
`
`regions to be formed by the depressions to compensate for retention of
`
`10
`
`thermoplastic composition within the depressions.
`
`The orientation of the depression 34 on a transfer roll 30 may be selected
`
`based on a variety of factors. The elongated depression 34 may be aligned in the
`
`machine direction (i.e., the direction of travel of a substrate), in the cross-web
`
`direction (i.e., transverse to the direction of travel of the substrate), or any other
`
`15
`
`orientation between machine direction or cross-web direction.
`
`FIGS. 4 and 5 depict yet another variation in the shape of depressions
`
`formed in transfer tools used to provide reinforcing discrete polymeric regions
`
`on substrates in connection wilh the methods of the present invention. The
`
`depression 134 is located in the surface 132 of a transfer tool in the shape of a
`
`20
`
`circular trough with an island 133 located in the center of depression I34 formed
`
`in the exterior surface 132.
`
`Depressions that include islands such as that depicted in FIG. 4 can be
`
`used to provide reinforcing discrete polymeric regions on a substrate in which a
`
`portion of the substrate is exposed within a surrounding ring of polymer. The
`
`25
`
`resulting construction may, for example, be used to reinforce the substrate in the
`
`area of, e.g., a buttonhole, slot, perforation, or other opening formed on in the
`
`substrate. Other uses for similar structures may also be envisioned.
`
`The island 133 formed in the center of depression 134 is preferably the
`
`same height as the exterior surface t32 of the transfer roll that surrounds the ¯
`
`30
`
`depression 134. Although the depression 134 is depicted with only a single
`
`island 133 formed therein, depressions used in connection with the methods of
`
`the present invention may include two or more islands located within each
`
`depression if so desired. Furthermore, the shape of the island and surrounding
`
`16
`
`FAST FELT 2024, pg. 202
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`depression may also vary, e.g., a depression that has a circular outermost
`
`perimeter may be paired with an island having a different shape. In another
`
`variation, the island may not be centered within the depression as depicted in
`
`FIG. 4.
`
`5
`
`Another variation depicted in FIG. 5 is the variation in depth of the
`
`depression t34, with the depression being deepest proximate the island and
`
`rising to a shallower depth at the outermost perimeter of the depression 134.
`
`Such a construction may provide a reinforcing discrete polymeric region with
`
`more flexible edges due to thinning of the polymeric region as discussed above
`
`10
`
`in connection with FIG. 1. Further, although the depression 134 is not depicted
`
`as having a composite construction as does depression 34 in FIG. 2, the
`
`depression I34 including island I33 may advantageously be formed as a
`
`composite depression of multiple cells.
`
`FIG. 6 depicts another depression 234 formed in the surface 232 of a
`
`15
`
`transfer tool, with the depression 234 also including an island 233 in a manner
`
`similar to the depression 134 of FIGS. 4 and 5. Unlike depression 134, the
`
`depression 234 is elongated in a generally oval shape that may be more
`
`conducive to the formation of a buttonhole or sirrtitar structure. Again, although
`
`the depression 234 is not depicted as having a composite construction as does
`
`20
`
`depression 34 in FIG. 2, it may advantageously be formed as a composite
`
`depression of multiple cells.
`
`FIGS. 7 and 8 depict yet another variation in a composite web
`
`manufactured according to the methods of the present invention. The composite
`
`web of FIG. 7 is a laminated structure including a first substrate 310a laminated
`
`25
`
`to a second substrate 310b to form a laminated substrate 3 I0. A number of
`
`discrete polymeric regions 314 are located between the two substrates 310a and
`
`310b. A number of smaller discrete polymeric regions 380 are depicted as being
`
`located between the larger discrete polymeric regions 314. The smaller discrete
`
`polymeric regions 380 are optional, i.e., they may not be required in addition to
`
`30
`
`the larger discrete polymeric regions 314. These smaller features may be helpful
`
`to attach the two substrates 310a and 310b together between the larger discrete
`
`polymeric regions 314.
`
`t7
`
`FAST FELT 2024, pg. 203
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`tn some instances, altachment of the two substrates 3 l Oa and 310b may
`
`be accomplished using the discrete polymeric regions 314 and 380 alone when
`
`the lamination is performed while the polymer regions 314 and 380 are still in a
`
`somewhat molten state such that they can bond with counterpart discrete
`
`5
`
`polymeric regions on the opposing substrate or to the opposing substrate itself.
`
`One advantage of this construction is that the lamination may be accomplished
`
`without the need for additional materials and/or process steps. The lamination
`
`between substrates 310a and 310b may alternatively be assisted by a variety of
`
`materials and!or techniques known to those skilled in the art, e.g., thermal
`
`10
`
`bonding, adhesives, resins, tie films/webs, etc. See, e.g., U.S. Patent Nos.
`
`2,787,244 (Hickin); 3,694,867 (Stumpf); 4,906,492 (Groshens); 5,685,758 (Paul
`
`et al.); and 6,093,665 (Sayovitz et al.).
`
`The laminated construction of FIG. 7 may be useful, for example, to
`
`provide a cloth-like or softer feel or appearance, breathability, porosity, etc. on
`
`! 5
`
`both sides of the composite web. This is in contrast to the composite webs in
`
`which the discrete polymeric regions are located on an exposed surface of the
`
`composite web. A laminated composite web structure such as that seen in FIG.
`
`7 may also be used to provide different properties on opposite sides of the
`
`composite web structure. For example, the porosity or other properties may
`
`20
`
`differ between the different substrates 310a and 310b.
`
`FIG. 8 depicts lamination of the substrates 310a and 310b by forces
`
`operating in the directions of the arrows located at both sides of the figure. One
`
`of the aspects depicted in FIG. 8 is the combination of discrete.polymeric
`
`regions 314a on substrate 3 tOa with discrete polymeric regions 3 t4b located on
`
`25
`
`the opposing surface of substrate 3IOb to form the discrete polymeric regions
`
`314 in the composite web as depicted in FIG. 7.
`
`Another aspect depicted in FIG. 8 is that the smaller polymeric regions
`
`380 seen in FIG. 7 may be constructed from the combination of a polymeric
`
`region 380a on substrate 310a and a polymeric region 380b on substrate 310b.
`
`30
`
`In other instances, the smaller polymeric region is located on only one of the
`
`substrates 3 lOa or 310b and preferably bonds directly to the opposing substrate
`
`during lamination. Similarly, in some instances the larger discrete polymeric
`
`18
`
`FAST FELT 2024, pg. 204
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`regions 314 may be formed by depositing polymer on only one of the substrates
`
`310a or 310b before attaching the opposing substrate.
`
`Another potential advantage of the laminated construction of the
`
`composite web seen in FIGS. 7 and 8 is that the reinforcing discrete polymeric
`
`5
`
`regions 314 formed by laminating two separate polymeric regions 314a and 3!4b
`
`together may provide a combined reinforcing discrete polymeric region 314 that
`
`contains more polymer than could be effectively deposited as a single
`
`reinforcing discrete polymeric region using the methods of the present invention.
`
`That additional polymer may provide reinforcing discrete polymeric regions that
`
`t0
`
`are stiffer, thicker, or have other advantageous features.
`
`FIG, 9 is a plan view of a composite web that may be used to form the
`
`composite web depicted in FIG. 7 in which two porlions 310a and 310b of a
`
`single, unitary substrate 310 can be folded along a fold line 302 to provide the
`
`laminated structure of FIGS. 7 and 8. Alternatively, the substrates 310a and
`
`15
`
`3 lOb as seen in, e.g., FIG. 8, may be separate from each other before lamination.
`
`The substrate 310 includes opposing reinforcing discrete polymeric regions 314a
`
`and 314b on portions 310a and 310b that are combined when the substrate 310 is
`
`folded along fold line 302.
`
`The substrate 3 I0 also includes a number of opposing smaller discrete
`
`20
`
`polymeric regions 380a and 380b on portions 3 I0a and 310b that are combined
`
`when the substrate 310 is folded along fold line 302. Further, the substrate 3 I0
`
`includes some smaller discrete polymeric regions 380a and 380b that do not
`
`oppose any similar deposits on the opposite side of the fold line 302.
`
`Although the discrete polymeric regions 314a and 314b are shown as
`
`25
`
`being uniformly spaced over the surface of the substrate 310 in a regular,
`
`repeating pattern (in both the x and y directions), it should be understood that
`
`spacing between the reinforcing discrete polymeric regions 314a and 314b may
`
`be non-uniform if so desired. Furthermore, the pattern in which the reinforcing
`
`discrete polymeric regions are arranged, may be irregular and/or non-repeating.
`
`30
`
`In other variations, portions of the composite webs manufactured in
`
`accordance with the present invention may include uniformly-spaced discrete
`
`polymeric regions as depicted in FIG. 9 while other portions of the same
`
`composite web may be free of any discrete polymeric regions. In yet another
`
`19
`
`FAST FELT 2024, pg. 205
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`alternative, portions of the composite web manufactured in accordance with the
`
`present invenlion may include uniformly spaced discrete polymeric regions as
`
`seen in FIG. 9, while other portions of the same composite web may include
`
`discrete polymeric regions that are arranged in a non-uniform and/or non-
`
`5
`
`repeating patterns. Further, different portions of a composite web manufactured
`
`according to the present invention may include different sets of discrete
`
`polymeric regions that are both uniformly spaced in repeating patterns that are
`
`different from each other.
`
`The discrete polymeric regions could be provided in any desired shape,
`
`10
`
`e.g., squares, rectangles, hexagons, etc. The shapes may or may not be in the
`
`form of recognized geometric shapes, but may be randomly formed with
`
`irregular perimeters. In addition, the shapes may not necessarily be solid figures,
`
`but may include islands formed within the shape in which none of the
`
`thermoplastic composition is transferred. In yet another alternative, some or all
`
`15
`
`of the discrete polymeric regions may be in the form of indicia, i.e., letters,
`
`numbers, or other graphic symbols.
`
`FIG. ! 0 illustrates yet another embodiment of a composite web
`
`manufactured in accordance with the present invention. The composite web
`
`includes a substrate 410 with opposing major surfaces 418 and 419. One feature
`
`20
`
`illustrated in FIG. 10 is the two-sided nature of the reinforcing discrete
`
`polymeric regions located on the opposing major surfaces 418 and 419,
`
`respectively. Reinforcing discrete polymeric region 414 is provided on major
`
`surface 418 and reinforcing discrete polymeric region 424 is provided on
`
`opposing major surface 419. Both discrete polymeric region 414 and discrete
`
`25 polymeric region 424 are exposed on opposite sides of the composite web.
`
`The discrete polymeric regions on opposing major surfaces are depicted
`
`as being in registration through the substrate 410. In other words, the discrete
`
`polymeric region 414 is aligned with the discrete polymeric region 424 on the
`
`opposite side of the substrate 410. Further, the discrete polymeric region 414 is
`
`30
`
`depicted as being substantially the same size as the discrete polymeric region
`
`424 located on the opposite side of the substrate 4 !0. It should, however, be
`
`understood that when a composite web having discrete polymeric regions on
`
`bolh major surfaces is desired, the discrete polymeric regions on the opposing
`
`20
`
`FAST FELT 2024, pg. 206
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`surfaces may or may not be the same size as seen in FIG. 10. Also, it should be
`
`understood that the discrete polymeric regions may or may not be in registration
`
`with each other through the substrate 410 as seen in FIG. t0.
`
`The reinforcing discrete polymeric regions 414 and 424 may be
`
`5
`
`envisioned as forming a grommet structure on the substrate 410. As a result, it
`
`may be desired to provide an optional opening 404 through the substrate 410 as
`
`seen in FIG. 10. The opening may be formed by any suitable technique, e.g.,
`
`mechanical perforation wi~h a tool, laser ablation, water or gas-jet cutting, etc. It
`
`will be understood that similar openings could be provided in, e.g., the laminated
`
`10
`
`composite web seen in FIG. 7 as well.
`
`FIG. t 1 is a perspective view of one system and method of providing
`
`discrete polymeric regions on one surface of a substrate i0 in accordance with
`
`the principles of the present invention. The system depicted in FIG. t I includes
`
`a substrate I0 that defines a web path through lhe system. The substrate 10
`
`15 moves through the system in a downstream direction indicated by the rotation
`
`arrows on the various rolls. After being unwound or otherwise provided from a
`
`supply (e.g., the substrate i0 may be manufactured in-line with the system
`
`depicted in FIG. 11), the subst~ate 10 is directed into a transfer nip formed
`
`between a backup roll 20 and a transfer rol! 30.
`
`20
`
`The process of providing discrete polymeric regions on the substrate 10
`
`includes delivering a supply of a molten thermoplastic composition to the
`
`exterior surface 32 of transfer roll 30 that includes a one or more depressions 34
`
`formed in its exterior surface 32. The molten thermoplastic composition 41 is
`
`supplied to the exterior surface 32 of the transfer r011 30 by a delivery apparatus
`
`25
`
`in the form of a trough 40 (or other supply apparatus, e.g., extruder, gear pump,
`
`etc.).
`
`The excess molten thermoplastic composition is wiped or removed from
`
`the exterior surface 32 by a doctor blade 42 acting against lhe exterior surface 32
`
`of the transfer roll 30. Although it may be ideal to remove all of the
`
`30
`
`thermoplastic composition from the exterior surface 32 of the transfer roll 30,
`
`some of the thermoplastic composition may remain on the exterior surface 32
`
`after wiping by the doctor blade 42.
`
`21
`
`FAST FELT 2024, pg. 207
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`The depressions 34 formed in the exterior surface 32 of the transfer roll
`
`30 preferably receive a portion of the molten thermoplastic composition when
`
`the molten thermoplastic composition is deposited on the exterior surface 32 of
`
`the transfer roll 30. If the depressions 34 are not completely filled during or by
`
`5
`
`the deposition of molten thermoplastic composition, the wiping action of the
`
`doctor blade 42 on the exterior surface 32 of the transfer roll 30 may assist in
`
`substantially filling the depressions with molten thermoplastic composition.
`
`Control over the temperatures of the various rolls in the system depicted
`
`in FIG. 11 may be useful in obtaining the desired products. It may be preferred,
`
`I0
`
`e.g., that the exterior surface 32 of the transfer roll 30 be heated to a selected
`
`temperature that is at or above the melt temperature of the thermoplastic
`
`composition to be transferred to the substrate 10. Heating the transfer roll 30
`
`may also enhance filling of the depressions 34 by the molten thermoplastic
`
`composition.
`
`15
`
`Because the molten thermoplastic composition 4t is itself heated within
`
`the trough 40, the doctor blade 42 wilt typically be heated by the molten
`
`thermoplastic composilioJa. It may alternatively be desirable to control the
`
`temperature of the doctor blade 42 separately from the trough 40 containing the
`
`molten thermoplastic composition 4 t. For example, it may be desirable to heat
`
`20
`
`the doctor blade 42 to a temperature above the melt temperature of the molten
`
`thermoplastic composition.
`
`FIG. 11A is an enlarged partial cross-sectional view depicting one
`
`relationship between a doctor blade 42 and depression 34 in a transfer roll 30.
`
`Another characteristic of the doctor blade 42 that may be controlled is its
`
`25
`
`thickness or length 43 along the exterior surface of the transfer roll 30 (as
`
`measured in the machine direction or the direction of rotation of the transfer
`
`roll). For example, a thicker or longer doctor blade 42 may help by allowing the
`
`molten thermoplastic composition more time to relax within the depressions 34,
`
`thereby improving filling of the depressions. In addition to varying the lenglh of
`
`30
`
`the doctor blade 42, the pressure or force exerted on the transfer roll 30 by the
`
`doctor blade 42 may also be adjusted based on a variety of factors including,
`
`e.g., the characteristics of the molten lhemaoplastic composition, the transfer roll
`
`characteristics, etc.
`
`22
`
`FAST FELT 2024, pg. 208
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`With the depressions 34 at least paniatly filled with the desired molten
`
`~hennoplastic composition, the transfer roll 30 continues to rotate until the
`
`depressions 34 and the molten thermoplastic composition they contain are forced
`
`into contact with the substrate 10 against backup roll 20 at the transfer nip (i.e.,
`
`5
`
`the nip formed by the transfer roll 30 and the backup roll 20. tt is at this point
`
`that transfer of the molten thermoplastic composition in the depressions 34 to the
`
`substrate 10 begins. It should be understood that under certain conditions, only a
`
`portion of the thermoplastic composition in the depressions 34 may transfer to
`
`the substrate 10.
`
`I0
`
`When a subslrate I0 that includes one or more porous major surfaces on
`
`which the molten thermoplastic composition is deposite~l is used in connection
`
`with the methods of the present invention, a mechanical bond is preferably
`
`formed by infiltration of the molten thermoplastic composition into the porous
`
`surface of the substrate 10. As used in connection with the present invention, the
`
`15
`
`term "porous" includes both structures that include voids formed therein, as well
`
`as structures formed of a collection of fibers (e.g., woven, nonwoven or knit) that
`
`allow for the penetration of molten thermoplastic compositions.
`
`The nip pressure between the transfer roll 30 and the backup roll 20 is
`
`preferably sufficient such that a portion of the thermoplastic composition in the
`
`20
`
`discrete polymeric regions infiltrates and/or encapsulates a portion of the porous
`
`substrate t0 to improve attachment of the discrete polymeric regions to the
`
`substrate 10. Where the surface of the substrate 10 includes fibers (e.g., where
`
`the substrate 10 includes woven, nonwoven, or knit materials on its major
`
`surfaces), it may be preferred that the thermoplastic composition encapsulate all
`
`25
`
`or a portion of at least some of the fibers on the surface of the substrate 10 to
`
`improve attachment of the discrete polymeric regions to the subslrate t0.
`
`Under some conditions the molten thermoplastic composition in the
`
`depressions 34 may completely permeate the substrate I0 if, e.g., the substrate
`
`I0 is porous throughout its thickness. In other instances, penetration of the
`
`30 molten thermoplastic composition may be limited to the outer layer or layers of
`
`the substrate 10.
`
`It should, however, be understood that although the outer surfaces of the
`
`substrate 10 may exhibit some porosity, that porosity may not necessarily exfend
`
`23
`
`FAST FELT 2024, pg. 209
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`through the entire thickness of the substrate 10. For example, the substrate 10
`
`may have a variety of different layers, with one of the layers being substantially
`
`non-porous. In another alternative, the overall thickness of the substrate 10 may
`
`render it non-porous as a whole, even though the outer surfaces of the substrate
`
`5
`
`10 exhibit some porosity as discussed above.
`
`The backup roll 20 may possess a variety of different characteristics
`
`depending on the types of substrate materials and/or molten thermoplastic
`
`compositions being processed. In some instances, the exterior of the backup roll
`
`20 may be a rubber or other conformable material that conforms to the shape of
`
`10
`
`the transfer roll 30. If a conformable material such as rubber is used, it may,
`
`e.g., have a durometer of, e.g., about 10-90 Shore A.
`
`One such variation at the transfer nip is depicted in FIG. 11B, in which a
`
`conformable backup roll 130 is depicted as forcing a portion of the substrate 1 I0
`
`into the depression 134 (and the thermoplastic composition 141 contained
`
`15
`
`therein)+ If the surface of the substrate 110 facing the depression 134 is porous,
`
`a portion of the molten thermoplastic composition 141 may be forced in the
`
`porous surface of the substrate 110+ Forcing the substrate 110 into the
`
`depression may be particularly beneficial if the depression 134 is not completely
`
`filled with the molten thermoplastic composition 141 to improve the likelihood
`
`20
`
`of contact between the substrate 10 and the molten thermoplastic composition
`
`141.
`
`Alternatively, the surface of the substrate may be forced into the
`
`depressions on the transfer roll using a mating backup roll. This variation at the
`
`transfer nip is depicted in FIG. 11C in which the backup roll 220 includes
`
`25
`
`protrusions 222 that are complementary to or mate with the depressions 234 on
`
`the transfer roll 230. The protrusions 222 would preferably force a substrate into
`
`the depressions with the same results and benefits described above with respect
`
`to FIG. 1 lB. A mating backup roll 220 could be formed of any conformable
`
`rnaterial, nonconformable material, or combination of conformable or
`
`30
`
`nonconformable materials.
`
`Heating or otherwise controlling the temperature of the transfer roll is
`
`discussed above+ It should also be appreciated that the lemperature of the
`
`exterior surface of the backup roll may be controlled. For example, it may be
`
`24
`
`FAST FELT 2024, pg. 210
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`desirable to cool the surface of the backup roll to a selected temperature below
`
`the temperature of the transfer roll. Cooling of the backup roll may be beneficial
`
`in maintnining the integrity of the substrate, particularly if the substrate integrity
`
`can be degraded from the heat of the transfer roll (if the transfer roll is heated)
`
`5
`
`and/or the molten thermoplastic composition in lhe depressions of the transfer
`
`roll.
`
`The substrate 10 continues around the 15ackup roll 20 as seen in FIG. 1 I.
`
`In some instances, a portion of the molten thermoplastic composition in the
`
`depressions may remain in the depressions 34 while the substrate 10 is pulled
`
`10
`
`away from the transfer roll 30. As a result, the molten thermoplastic
`
`composition in the depressions 34 may tend to elongate or string between the
`
`depressions in transfer roll 30 and the substrate 10.
`
`A device, such as a hot wire 44 seen in FIG. 11, may be used to sever any
`
`strands of thermoplastic composition that may be formed as the substrate 10
`
`15
`
`separates from the transfer roll 30. Other devices and/or techniques may be used,
`
`to accomplish the desired severing of any molten thermoplastic composition
`
`strands. Examples may include, but are not limited to hot air knives, lasers, etc.
`
`Furthermore, under certain conditions, stringing of the thermoplastic
`
`composition may not be encountered during manufacturing.
`
`20
`
`The lendency of the molten thermoplastic composition in the depressions
`
`34 to string as the substrate exits the transfer nip also raises another issue that
`
`should be considered when developing processes according to the present
`
`invention. That issue is the internal cohesive strength of the ~;ubstrate 10 and/or
`
`the tensile strength of the substrate 10. This issue may be of more concern if the
`
`25
`
`substrate 10 includes a fibrous construction (e.g., woven, nonwoven, or knit
`
`fibers) that could be separated from the remainder of the substrate by the forces
`
`exerted when the substrate 10 is pulled away from the transfer roll 30. These
`
`considerations may be more important if the molten thermoplastic composition
`
`has properties (e.g., tackiness, tensile strength, elc.) such that strands of the
`
`30 molten thermoplastic composition can exert forces on the substrate 10 that
`
`exceed the internal cohesive strength and/or tensile strenglh of the substrate 10.
`
`For example, if the substrate 10 includes a resin-bonded nonwoven
`
`portion, the temperature of the lransfer roll 30 and/or molten thermoplastic
`
`25
`
`FAST FELT 2024, pg. 211
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`composition may vise above the melting temperature of the resin, thereby
`
`potentially degrading the internal cohesive strength and!or tensile slrength of the
`
`substrate 10. Alternatively, a nonwoven substrate may include fibers that have a
`
`melting temperature similar to the temperature of the transfer roll 30 and/or
`
`5 molten thermoplastic composition, thereby potentially degrading the internal
`
`cohesive strength and/or tensile strength of the substrate 10.
`
`In either instance, the roll temperatures and/or molten thermoplastic
`
`composition temperature may need to be controlled to maintain the integrity of
`
`lhe substrate while transferring the molten thermoplastic composition. For
`
`10
`
`example, the backup roll 20 may be cooled to, in turn, cool the substrate 10 to
`
`maintain its internal cohesive strength.
`
`In another alternative, heating of the transfer roll 30 and!or backup roll
`
`20 may be used to enhance the internal cohesive strength and/or tensile strength
`
`of the substrate 10. For example, if the substrate 10 includes multi-component
`
`15
`
`fibers or fibers having different compositions, some consolidation of the fibers
`
`or other components in the substrate lO may be caused by heating the substrate
`
`10 while transferring the nlolten thermoplastic composition from the lransfer roll
`
`30 to the substrate 10. That consolidation may improve the integrity of the
`
`substrate by forming a skin layer or other strength-enhancing structure on or
`
`20 within the substrate 10. Some exemplary processes may be described in, e.g.,
`
`U.S. Patent No. 5,470,424 (Isaac et al.).
`
`Although the system and method depicted in FIG. 11 produces composite
`
`webs ~vith reinforcing discrete polymeric regions on only one major side thereof,
`
`those of skill in the art will recognize the modifications required to provide
`
`25
`
`discrete polymeric regions on both major surfaces of the substrate in accordance
`
`with the principles of the present invention. One example may include, e.g.,
`
`forming discrete polymeric regions on one surface of each of two separate
`
`substrates, with the two substrates then being laminated together to form a single
`
`substrate with discrete polymeric regions on both major surfaces (see, e.g., FIG.
`
`30
`
`t0). Alternatively, a single substrate may be directed into a nip formed by two
`
`transfer rolls, with each of the transfer rolls depositing discrete polymeric
`
`regions on both sides of the web essentially simultaneously.
`
`26
`
`FAST FELT 2024, pg. 212
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Although FIG. 11 depicts the application of only one thermoplastic
`
`composition using the transfer roll 30, it will be understood that two or more
`
`different thermoplastic compositions may be applied to the exterior surface of
`
`the transfer roll 30. FIG. 12 depicts a portion of one system in which a trough
`
`5
`
`340 is used to deliver three molten thermoplastic compositions (in zones A, B, &
`
`C) to the surface of a transfer roll 330 that rotates about an axis 331. The trough
`
`340 may, for example, include barriers 342 such that molten thermoplastic
`
`compositions in the different zones of the trough 340 do not mix during
`
`processing. In another alternative, separate and distinct troughs could be used
`
`10
`
`for each different thermoplastic composition to be applied to the transfer roll
`
`330.
`
`The transfer roll 3313 also includes different sets of depressions 334a,
`
`334b, and 334c over which the different molten thermoplastic compositions may
`
`be applied. The depressions in the different zones on transfer roll 330 are
`
`I5
`
`differently shaped, have different sizes, and have different spacings. For
`
`example, the triangular depressions in zone C are arranged in an irregular, non-
`
`repeating pattern while the depressions in zones A & B are arranged in regular,
`
`repeating patterns.
`
`With the system of FIG. 12, different sets of discrete polymeric regions
`
`20 may be formed on a single substrate usi~g different thermoplastic compositions.
`
`As a result, the thermoplastic compositions may be selected for any of a number
`
`of different properties related to manufacturing or end-use performance of the
`
`finished articles made using the composite webs.
`
`FIGS. 13 and 14 depict an article that may be manufactured from a
`
`25
`
`composite web according to the methods of the present invention, with FIG. 13
`
`being a plan view of the article and FIG. 14 being a cross-sectional view of the
`
`article taken along line 14-14 in FIG. 13. The article includes a frame 560
`
`formed by a reinforcing discrete polymeric region on a substrate 510. The
`
`article may be, e.