阅读说明：本技术 膜的末端粘结成形层合体 (Film end-bonded laminate ) 是由 丹尼尔·查尔斯·派克 约翰·布莱恩·施特鲁贝 马修·威廉·沃尔德伦 于 2018-06-29 设计创作，主要内容包括：本发明公开了末端粘结的成形层合体和用于制备末端粘结的成形层合体的方法,所述层合体由多层由膜制成的成形基底制成,所述膜在它们形成的突起的末端处粘结在一起。末端粘结的层合体可被设计成具有更大的抗弯强度、改善的抗压缩性,并且可被图案化以用于定向取向的对拉伸载荷的响应。另外,由多层成形基底制成的末端粘结的成形层合体,可使用它们的层状结构来提供更好的美观性以及更好的物理特性诸如改善的耐刺穿性。末端粘结的成形层合体可被构造成具有较厚部分和设计图案,这些对消费者具备吸引力。末端粘结的成形层合体可由两个或更多个成形的基底制成,并且可代替单个厚的未成形基底而使用,因此层合体可使用大约相同量的材料,同时仍提供令人惊讶的功能性有益效果。当与未成形的单层基底比较时,末端粘结的成形层合体可提供这些有益效果而不依赖于更昂贵的聚合物和/或高浓度的添加剂,并且以合理的成本提供显著的改善。(End-bonded, shaped laminates made from multiple layers of shaped substrates made from films bonded together at the ends of protrusions they form, and methods for making end-bonded, shaped laminates. The end bonded laminate can be designed to have greater flexural strength, improved resistance to compression, and can be patterned for directional orientation response to tensile loads. Additionally, end-bonded shaped laminates made from multi-layer shaped substrates may use their layered structure to provide better aesthetics as well as better physical properties such as improved puncture resistance. The end bonded formed laminate can be configured with thicker portions and design patterns that are attractive to consumers. End bonded formed laminates can be made from two or more formed substrates and can be used in place of a single thick unformed substrate, and thus the laminate can use approximately the same amount of material while still providing surprising functional benefits. End-bonded, shaped laminates can provide these benefits without relying on more expensive polymers and/or high concentrations of additives, and at a reasonable cost, provide significant improvements when compared to an unformed, single-layer substrate.)

1. A laminate, comprising:

a first film having a plurality of first elongated pleats disposed side-by-side, integrally connected, incrementally stretched, each pleat having:

a first inward facing valley having a first valley minimum thickness;

a first outwardly facing peak having a first peak minimum thickness; and

a first intermediate portion disposed between the first valley and the first peak, wherein the first intermediate portion has a first intermediate minimum thickness that is less than the first peak minimum thickness;

a second film having a plurality of second elongated rugosities disposed side-by-side, integrally connected, incrementally stretched, each rugositie having:

a second inward facing valley having a second valley minimum thickness;

a second outwardly facing peak having a second peak minimum thickness; and

a second intermediate portion disposed between the second valley and the second peak, wherein the second intermediate portion has a second intermediate thickness that is less than the second peak minimum thickness;

a plurality of attachment areas, wherein each of the attachment areas directly connects a valley from the plurality of first corrugations to a valley from the plurality of second corrugations.

2. The laminate of claim 1, wherein the first intermediate minimum thickness is less than the first valley minimum thickness and the second intermediate minimum thickness is less than the second valley minimum thickness.

3. The laminate of claim 2, wherein each from the first plurality of corrugations is directly connected to only one from the second plurality of corrugations.

4. The laminate of claim 3, wherein each from the plurality of second corrugations is directly connected to only one from the plurality of first corrugations.

5. The laminate according to any one of claims 1 to 4, wherein:

the plurality of first corrugations are discrete corrugations; and is

The plurality of second corrugations are discrete corrugations.

6. The laminate according to any one of claims 1 to 4, wherein:

the plurality of first corrugations are discrete corrugations; and is

The plurality of second corrugations are continuous corrugations.

7. The laminate according to any one of claims 1 to 4, wherein:

the plurality of first corrugations are continuous corrugations; and is

The plurality of second corrugations are continuous corrugations.

8. The laminate of any proceeding claim, wherein the first plurality of corrugations are connected to the second plurality of corrugations only by the plurality of attachment zones.

9. The laminate of any preceding claim, wherein each of the attachment zones is substantially continuous along valleys from the plurality of first corrugations.

10. The laminate of claim 9, wherein each of the attachment zones is substantially continuous along valleys from the plurality of second corrugations.

11. The laminate according to any one of claims 1 to 10, wherein:

the plurality of first pleats are connected to a first non-pleated portion of the first film at a first transition;

the plurality of second corrugations are connected to a second non-corrugated portion of the second film at a second transition offset from the first transition.

12. The laminate according to any one of claims 1 to 10, wherein:

the plurality of first pleats are connected to a first non-pleated portion of the first film at a first transition;

the plurality of second corrugations are connected to a second non-corrugated portion of the second film at a second transition adjacent to the first transition.

13. The laminate according to any one of the preceding claims, wherein for at least some of the first plurality of wrinkles, a ratio of an amplitude of the wrinkles to a wavelength of the wrinkles is from 0.7 to 5.

14. The laminate of claim 13, wherein the ratio of the amplitude to the wavelength is from 1 to 3 for substantially all of the wrinkles in the first plurality of wrinkles.

15. The laminate according to any one of claims 13 or 14, wherein the amplitude is from 1 millimeter to 10 millimeters, preferably from 1 millimeter to 4 millimeters, for at least some of the plurality of first wrinkles, preferably for all wrinkles.

16. The laminate according to any one of claims 13 to 15, wherein the ratio of the wavelength to the overall width of the attachment areas for the corrugations is from 10 to 50, preferably from 25 to 50, for at least some corrugations, preferably for all corrugations, of the plurality of first corrugations.

17. The laminate of claim 18, wherein for at least some corrugations of the first plurality of corrugations, the overall width of the attachment zones is from 0.2 millimeters to 1 millimeter.

18. A disposable wearable absorbent article comprising the laminate of any of the previous claims.

19. A disposable bag comprising the laminate of any one of claims 1 to 17.

20. A method of forming a laminate, the method comprising:

incrementally mechanically stretching a first film by engaging at least a first portion of the first film with at least a first plurality of protrusions to form a juxtaposed, integrally connected plurality of first elongated corrugations within the first portion, each first corrugation having a valley and a peak;

incrementally mechanically stretching a second film by engaging at least a second portion of the second film with at least a second plurality of protrusions to form a juxtaposed, integrally connected plurality of second elongated corrugations within the second portion, each second corrugation having a valley and a peak; and

when the portion of the first film is engaged with the plurality of first protrusions, and when the portion of the second film is engaged with the plurality of second protrusions, directly connecting the plurality of first corrugations to the plurality of second corrugations at a plurality of attachment regions to form the laminate.

21. A machine for forming a laminate, the machine comprising:

longitudinal and transverse;

a first web supply apparatus and a second web supply apparatus, the first and second web supply apparatuses being machine-only web supply apparatuses;

a first rotating patterned roll downstream of the first web supply apparatus and having a plurality of first rigid elongated protrusions, each protrusion having a terminal end; and

a second rotating patterned roller downstream of the first web supply apparatus and having a plurality of second rigid elongated protrusions, each protrusion having a terminal end;

wherein the first roller is positioned relative to the second roller such that when the rollers rotate:

the ends of the first plurality of projections are always unmated from the ends of the second plurality of projections;

the tips of the first plurality of projections come within a vicinity of engagement of the tips of the second plurality of projections, wherein the vicinity of engagement ranges from 0mm to 5 mm.

Technical Field

The present disclosure relates generally to laminates, and in particular to laminates made from multiple layers of a formed substrate made from films bonded together at the ends of the protrusions they form.

Background

Substrates such as films are useful as materials in many different articles, especially disposable consumer products; however, unformed single layer substrates have certain limitations and disadvantages. The unformed single layer substrate has very low resistance to bending, slight compression resilience, and a generally isotropic response to tensile loads. In addition, unformed single ply substrates rely heavily on the chemistry of their polymers and additives to provide aesthetic (e.g., opacity) and structural properties (e.g., puncture resistance). Furthermore, unformed single ply substrates are typically thin and flat, which is not appealing to consumers.

Disclosure of Invention

As described herein, laminates made from multiple layer formed substrates are bonded together at the ends of their formed protrusions, providing a significant improvement over unformed single layer substrates. Such end-bonded laminates can be designed to have greater flexural strength, improved resistance to compression, and can be patterned for directional orientation response to tensile loads. Additionally, end-bonded shaped laminates made from multi-layer shaped substrates can use their layered structure to provide better aesthetics; for example, the multilayer substrate can more completely diffract and diffuse light, resulting in increased opacity. Further, end-bonded shaped laminates made from multi-layer shaped substrates can be shaped using their substrates to provide improved structural properties; for example, substrates having different forms may more effectively distribute and absorb concentrated forces, resulting in improved puncture resistance. Further, such end-bonded formed laminates can be configured with thicker portions and design patterns that are attractive to consumers. End bonded formed laminates may be made from two or more formed substrates and may be used in place of a single thick unformed substrate, and thus the laminate may use approximately the same amount of material while still providing the functional benefits described above. Also, such end-bonded formed laminates can provide these benefits without relying on more expensive polymers and/or high concentrations of additives. Thus, end-bonded formed laminates made from multiple layer formed substrates provide significant improvements at a reasonable cost when compared to unformed single layer substrates.

Accordingly, the present invention relates to a laminate comprising: (a) a first film having a first plurality of elongated pleats disposed side-by-side, integrally connected, incrementally stretched, each pleat having: (i) a first inward-facing valley having a first valley minimum thickness; (ii) a first outward-facing peak having a first peak minimum thickness; and (iii) a first intermediate portion disposed between the first valley and the first peak, wherein the first intermediate portion has a first intermediate minimum thickness that is less than the first peak minimum thickness; (b) a second film having a plurality of second elongated rugosities disposed side-by-side, integrally connected, incrementally stretched, each rugositie having: (i) a second inward-facing valley having a second valley minimum thickness; (ii) a second outwardly facing peak having a second peak minimum thickness; and (iii) a second intermediate portion disposed between the second valley and the second peak, wherein the second intermediate portion has a second intermediate thickness that is less than the second peak minimum thickness. The laminate further comprises a plurality of attachment zones, wherein each of the attachment zones directly connects a valley from the first plurality of corrugations to a valley from the second plurality of corrugations.

The present invention also relates to a method of forming a laminate, the method comprising: incrementally mechanically stretching the first film by engaging at least a first portion of the first film with at least a first plurality of protrusions to form a juxtaposed, integrally connected plurality of first elongated corrugations within the first portion, each first corrugation having a valley and a peak; and (b) incrementally mechanically stretching the second film by engaging at least a second portion of the second film with at least a second plurality of protrusions to form a juxtaposed, integrally connected plurality of second elongated corrugations within the second portion, each second corrugation having a valley and a peak. When the portion of the first film is engaged with the plurality of first protrusions and when the portion of the second film is engaged with the plurality of second protrusions, the plurality of first corrugations are directly connected to a plurality of second corrugations at a plurality of attachment areas to form the laminate.

The invention also relates to a machine for forming a laminate, the machine comprising: longitudinal and transverse; a first web supply device and a second web supply device, which are the only web supply devices of the machine. The machine further includes a first rotary patterning roller located downstream of the first web supply and having a plurality of first rigid elongate protrusions, each protrusion having a terminal end; a second rotating patterned roll downstream of the first web supply apparatus and having a plurality of second rigid elongated protrusions, each protrusion having a terminal end. The first roller is positioned relative to the second roller such that, when the roller is rotated, the tips of the first plurality of projections are always out of engagement with the tips of the second plurality of projections, and the tips of the first plurality of projections come within a 0 to 5 millimeter engagement proximity of the tips of the second plurality of projections.

Drawings

Fig. 1 shows a partially broken top view of a portion of a laminate having a patterned region with corrugations oriented in the machine direction.

Fig. 2 shows a partially broken top view of a portion of a laminate having patterned regions with corrugations oriented in the cross direction.

Fig. 3A shows a top view of a patterned region having longitudinally oriented corrugations with an overall shape resembling a diamond.

Fig. 3B shows a top view of a patterned region having diamond-like shaped rugosities oriented in the lateral direction having an overall shape.

Fig. 3C shows a top view of a patterned region having corrugations with an overall shape resembling a square that are oriented in the machine direction.

Fig. 3D shows a top view of a patterned region having corrugations oriented in the lateral direction having an overall shape resembling a square.

Fig. 3E shows a top view of a patterned region having longitudinally oriented rugosities with an overall shape resembling a circle.

Fig. 3F shows a top view of a patterned region having rugosities oriented in the lateral direction having an overall shape resembling a circle.

Fig. 4A shows an enlarged end view of a laminate having a patterned region formed from a first substrate and a second substrate, the patterned region being a film having a wrinkled portion and an uncreped portion, wherein the film within the wrinkled portion is directly connected at the narrow attachment region and within the uncreped portion the film is offset.

Fig. 4B is a modified version of the laminate of fig. 4A, wherein the film is directly connected at the wide attachment region.

Fig. 5A shows an enlarged end view of a modified version of the laminate of fig. 4A, wherein the outer film is joined to the first and second films.

Fig. 5B shows an enlarged end view of a modified version of the laminate of fig. 4B, wherein the outer film is joined to the first and second films.

Fig. 6A shows an enlarged end view of a laminate having patterned regions formed from a first film and a second film, the films having wrinkled and unwrinkled portions, wherein the films within the wrinkled portions are directly connected at narrow attachment regions and within the unwrinkled portions the films are adjacent to each other.

Fig. 6B is a modified version of the laminate of fig. 6A, wherein the film is directly connected at the wide attachment regions.

Fig. 7A shows an enlarged end view of a modified version of the laminate of fig. 6A, wherein the outer film is joined to the first and second films.

Fig. 7B shows an enlarged end view of a modified version of the laminate of fig. 6B, wherein the outer film is joined to the first and second films.

Fig. 8 shows a flow diagram of a method of making a laminate having a patterned region.

Fig. 9 is an assembly drawing showing a machine with four patterned rolls having protrusions oriented in the machine direction for incrementally stretching the first and second substrates and for joining the substrates together to form an end-bonded shaped laminate having offset uncrimped portions.

Fig. 10A shows an enlarged partial cross-sectional view of two cooperating patterned rollers from the machine of fig. 9, wherein the rollers incrementally stretch the first substrate.

Fig. 10B shows an enlarged partial cross-sectional view of two mating patterned rollers from the machine of fig. 9, wherein the rollers incrementally stretch the second substrate.

FIG. 11A shows an enlarged partial cross-sectional view of a first substrate engaged with a first patterned roll from the machine of FIG. 9, wherein adhesive is applied to the corrugations of the first substrate.

Fig. 11B shows an enlarged partial cross-sectional view of the second substrate engaged with the second patterned roll from the machine of fig. 9.

Fig. 11C illustrates a partial profile view of the first substrate of fig. 11A.

Fig. 12A shows an enlarged partial cross-sectional view in the machine direction of valleys of corrugations from a first substrate attached to valleys of corrugations of a second substrate using an adhesive, while the substrates are engaged with the patterned rolls of the machine of fig. 9 to form the end-bonded shaped laminate of fig. 9.

Fig. 12B shows an enlarged partial cross-sectional view in the cross-direction of valleys of corrugations from a first substrate attached to valleys of corrugations of a second substrate using an adhesive, while the substrates are engaged with the patterned rolls of the machine of fig. 9 to form the end-bonded shaped laminate of fig. 9.

Fig. 12C shows another enlarged portion of the view of fig. 12B.

Fig. 13 is an assembly drawing showing a machine with four patterned rolls with protrusions oriented in the cross direction for incrementally stretching the first and second substrates and for joining the substrates together to form an end-bonded shaped laminate with offset uncrimped portions.

Fig. 14 is an assembly drawing showing a machine with four patterned rolls having protrusions oriented in the machine direction for incrementally stretching a first substrate and a second substrate and for joining the substrates together to form an end-bonded shaped laminate having adjacent uncrimped portions.

Fig. 15A shows an enlarged partial cross-sectional view of two cooperating patterned rollers from the machine of fig. 14, wherein the rollers incrementally stretch the first substrate.

Fig. 15B shows an enlarged partial cross-sectional view of two mating patterned rollers from the machine of fig. 14, wherein the rollers incrementally stretch the second substrate.

FIG. 16A shows an enlarged partial cross-sectional view of a first substrate engaged with a first patterned roll from the machine of FIG. 14, wherein adhesive is applied to the first substrate at the corrugations and adjacent uncrimped portions.

Fig. 16B shows an enlarged partial cross-sectional view of the second substrate engaged with the second patterning roller from the machine of fig. 14.

FIG. 17 shows an enlarged partial cross-sectional view in the machine direction of valleys of corrugations from a first substrate attached to valleys of corrugations of a second substrate using an adhesive, and uncreped portions of the first substrate attached to uncreped portions of the second substrate by the adhesive, while the substrates are engaged with the patterned rolls of the machine of FIG. 14 to form the end-bonded formed laminate of FIG. 14.

Fig. 18 is an assembly drawing showing a machine with four patterned rolls with protrusions oriented in the cross direction for incrementally stretching a first substrate and a second substrate and for joining the substrates together to form an end-bonded shaped laminate having adjacent uncrimped portions.

Fig. 19 is an enlarged cross-sectional view of a portion of a laminate having a patterned region formed from a first film and a second film along with an outer film, wherein the laminate includes a benefit agent disposed at a location within the laminate.

Fig. 20A is an enlarged end view of a portion of an exemplary laminate showing the extent of the peaks.

Fig. 20B is an enlarged end view of a portion of an exemplary laminate showing the extent of the valleys.

Fig. 21 is an enlarged end view of a portion of an exemplary laminate showing multiple measurements.

Fig. 22 is an exemplary drawtape type trash bag that may include the end bonded laminate of the present disclosure.

Fig. 23 is an exemplary tie-up type trash bag that can include the end bonded laminate of the present disclosure.

Detailed Description

The end-bonded formed laminates of the present disclosure may be made from a multi-layer formed substrate, such as a film, and may provide significant improvements over an unformed single layer substrate, including: greater resistance to integrity, improved compression resilience, directional response to tensile loads, more aesthetic appearance, enhanced structural properties, thicker sections, and desirable design patterns without relying on more expensive polymers and/or higher concentrations of additives; thus, such end-bonded formed laminates provide significant improvements at a reasonable cost when compared to an unformed single layer substrate.

Throughout the drawings, the machine direction is shown as MD and the cross direction is shown as CD; the labeled arrow indicates the orientation of the label direction relative to the figure, while the labeled X indicates the label direction is orthogonal to (i.e., into) the page. Also, throughout the figures, a laminate having a patterned region with a particular number of wrinkles is shown, however, for any of the patterned regions disclosed herein, any number of wrinkles may be used; for example, the patterned region may have 2-100 wrinkles, or any number of wrinkles between 2 and 100, or any range formed by any of these values, such as 2-50 wrinkles, 3-40 wrinkles, 4-30 wrinkles, 5-20 wrinkles, and so forth.

Fig. 1 shows a partially broken top view of a portion of a laminate 100 having patterned regions with corrugations oriented in the machine direction. The laminate 100 is made from a first substrate 110 at the top of the laminate 100 and a second substrate 120 at the bottom (shown in broken portions). The first substrate 110 is directly connected to the second substrate 120 at a plurality of attachment regions indicated by straight line segments parallel to the machine direction. The first substrate 110 and the second substrate 120 each include a corrugated portion disposed between adjacent attachment regions and a non-corrugated portion disposed outside of the attachment regions. The plurality of attachment regions form a patterned region 104 having an overall shape 104-os as a diamond; however, in various embodiments, for any laminate disclosed herein, the laminate can include patterned regions having any general shape disclosed herein or known in the art of patterned substrates. The attachment regions forming the patterned region 104 are repeated on the laminate 100 to form a plurality of discrete patterned regions, each having the same configuration, including the same overall shape; however, in various embodiments, for any laminate disclosed herein, the laminate can include two or more different patterned regions, which may or may not be repeated in a pattern on the laminate. The patterned regions are arranged in a repeating linear array that forms a damascene pattern, wherein the patterned regions are separated from each other by linear paths 106 disposed between the patterned regions, and wherein the paths are formed by non-wrinkled portions of the substrate. Each of the paths has a substantially uniform overall width 106-ow. For the laminate 100 and any laminate disclosed herein, any of the paths can have an overall width of 1-100 millimeters, or any integer value between 1 millimeter and 100 millimeters, or any range formed by any of these values, such as 1-50 millimeters, 1-20 millimeters, 1-10 millimeters, or the like; in addition, a portion, portions, or all of any path disposed between patterned regions may have a variable overall width and/or may be curved.

In various embodiments, the laminates disclosed herein can exhibit directionally variable bending stiffness. The attachment zones may act like beams in their orientation direction, providing directional reinforcement of the attached substrates. The paths may or may not function like hinges depending on their configuration in the laminate. For example, the laminate may have a first direction (oriented parallel to the general plane of the laminate) in which the laminate has the lowest bending stiffness; and a second direction (also oriented parallel to the general plane of the laminate) different from the first direction (e.g., perpendicular to the first direction) in which the laminate has a highest bending stiffness, wherein the highest bending stiffness is 50-10,000% greater than the lowest bending stiffness, or any integer value between 50% and 5,000%, or any range formed by any of these values, such as 50-2,000%, 75-1,000%, 100-.

In the embodiment of fig. 1, since all attachment areas of the laminate 100 are oriented in the machine direction, the attachment areas provide the laminate 100 with a relatively high bending stiffness in the machine direction and a relatively low bending stiffness in the cross direction. Also, in the embodiment of fig. 1, since the paths 106 are linear paths arranged in parallel, the paths 106 provide the laminate 100 with a relatively low bending stiffness at angles taken perpendicular to the paths.

The laminate 100 may be constructed according to any of the laminates described herein, such as the laminate 400-a of fig. 4A, the laminate 400-B of fig. 4B, the laminate 600-a of fig. 6A, or the laminate 600-B of fig. 6B, or any alternative laminate embodiment disclosed herein or known in the art. In various embodiments, the laminate 100 may be modified by the addition of a first outer substrate and/or a second outer substrate, such as the laminate 500-a of fig. 5A, the laminate 500-B of fig. 5B, the laminate 700-a of fig. 7A, or the laminate 700-B of fig. 7B. The laminate 100 may be prepared according to the process 800 of fig. 8, or according to any alternative process embodiment disclosed herein. The laminate 100 may be manufactured using the machine 902 of fig. 9, the machine 1402 of fig. 14, or using any of the alternative machine embodiments disclosed herein. In various embodiments, a portion, portions, or all of the laminate 100, or any laminate disclosed herein, may be modified such that some or all of the corrugations are at a positive or negative angle of 1 to 89 degrees, or any integer value between 1 and 89 degrees, or any range formed by any of these values, relative to the machine direction, such as 1 to 60 degrees, 1 to 45 degrees, 1 to 30 degrees, 30 to 89 degrees, 45 to 89 degrees, 60 to 89 degrees, 30 to 60 degrees, 40 to 50 degrees, and the like.

Fig. 2 shows a partially broken top view of a portion of a laminate 200 having patterned regions with corrugations oriented in the cross direction and the machine direction. The laminate 200 is made of a first substrate 210 and a second substrate 220 having discrete patterned regions including patterned regions 204 having an overall shape, such as a diamond, that repeat on the laminate 200, separated from one another by paths 206. The laminate 200 of fig. 2 is constructed in the same manner as the laminate 100 of fig. 1, with like-numbered elements constructed in the same manner, except as described below. The first substrate 210 and the second substrate 220 are directly connected at a plurality of attachment areas, shown as line segments, which are parallel to the cross direction. Because all of the attachment areas of the laminate 200 are oriented in the cross direction, the attachment areas provide the laminate 200 with a relatively high bending stiffness in the cross direction, and because the paths 206 are linear paths arranged in parallel, the paths 206 provide the laminate 200 with a relatively low bending stiffness at angles taken perpendicular to the paths. The laminate 200 may be configured or modified in any manner that the laminate 100 of fig. 1 may be configured or modified. The laminate 200 may be prepared according to the process 800 of fig. 8, or according to any alternative process embodiment disclosed herein. The laminate 200 may be manufactured using the machine 1302 of fig. 13, the machine 1802 of fig. 18, or using any of the alternative machine embodiments disclosed herein.

Fig. 3A-3F illustrate exemplary patterned region top views with attachment regions forming corrugations oriented in various directions and patterned regions having various overall shapes. Fig. 3A shows a patterned region 304-a having longitudinally oriented corrugations and a diamond-like general shape, as shown by patterned region 104 in the laminate 100 of fig. 1. FIG. 3B shows a patterned region 304-B having corrugations and diamond-like general shapes oriented in the cross direction and machine direction, as shown by patterned region 204 in the laminate 200 of FIG. 2. Fig. 3C shows a patterned region 304-C having corrugations oriented in the machine direction, and a square-like overall shape, which may be used for any patterned region of any of the laminates disclosed herein. Fig. 3D shows a patterned region 304-D having corrugations oriented in the cross direction and machine direction, and a square-like general shape, which may be used for any patterned region of any of the laminates disclosed herein. In various embodiments, the laminate can have a patterned region that resembles a rectangle, trapezoid, triangle, pentagon, hexagon, heptagon, octagon, or any other regular or irregular polygon having any number of sides in the overall shape. FIG. 3E shows a patterned region 304-E having corrugations oriented in the machine direction and having an overall shape resembling a circle. FIG. 3F shows a patterned region 304-F having corrugations oriented in the lateral direction and resembling circles in overall shape. In various embodiments, the laminate may have patterned regions with an overall shape resembling an oval, ellipse, or any other circular shape having any configuration. Any of the overall shapes of the exemplary patterned regions of fig. 3A-3F, or any other overall shape disclosed herein or known in the art, may be used in any of the patterned regions in any of the laminates disclosed herein in any operable combination.

4A-7B show enlarged end views of a laminate formed at least in part from a gathered portion of a first substrate directly connected to a gathered portion of a second substrate. These laminates are shown with a patterned region having a particular number of wrinkles, however, any number of wrinkles may be used for any embodiment of the laminates disclosed herein, including any number disclosed herein. For these laminates are shown as having a particular uniform proportion of wrinkles, however, for any embodiment of the laminates disclosed herein, these particular shapes are not necessary, and the uniformity and/or proportion of a portion, portions, or all of any one or more wrinkles can vary between patterned regions in any substrate and/or between any substrates. Any of the embodiments of fig. 4A-7B may be used to form an end-bonded, formed laminate in which some or all of the corrugations are oriented in any direction that is convenient for the laminate, such as the machine direction, cross direction, or any positive or negative angle of 1-89 degrees relative to the machine direction and/or cross direction.

Fig. 4A-4B, 5A-5B, 6A-6B, and 7A-7B illustrate embodiments in which the laminate is at least partially formed from a wrinkled portion of the first film directly connected to a wrinkled portion of the second film. For ease of illustration, each substrate is shown as a smooth continuous film having a particular uniform thickness, however these particular shapes are not required, and for any embodiment of the laminates disclosed herein, the smoothness, continuity, and/or thickness of a portion, portions, or all of one or more of any film substrate may vary within and/or between patterned regions of any substrate and/or between any substrate in any manner disclosed herein and/or known in the art. While each of these embodiments describes and illustrates a first film directly connected to a second film, in various embodiments, some or all of the connections between the films may be indirect connections, including one or more intermediate materials (in addition to any adhesive used to make the connections). Additionally, any of the embodiments disclosed herein can be modified to include one or more intermediate substrates (e.g., film layers) disposed between the first film and the second film.

Fig. 4A shows an enlarged end view of a laminate 400-a formed from a first substrate, which is a first film 410-a and a second substrate, which is a film 420-a. Laminate 400-a has discrete patterned regions 404-a surrounded by paths 406-a. The laminate 400-a also has central gathered portions 401-a and uncrimped portions 408-1a and 408-2a disposed on either side of the gathered portions 401-a. Within the corrugated portion 401-a, the first film 410-a is directly connected to the second film 420-a at a plurality of long (into the page) but relatively narrow (across the page) attachment zones 405-a. The corrugated portion 401-a forms a patterned region 404-a. Within uncrimped portions 408-1a and 408-2a, first film 410-a and second film 420-a are unattached, but offset from each other by offset distances 419-oda. The non-corrugated portions 408-1a and 408-2a of films 410-a and 420-a form a path 406-a between patterned region 404-a and other patterned regions of laminate 400-a.

In the wrinkle part 401-a, the first film 410-a has a plurality of first wrinkles 411-a shaped like a repeating wave having valleys 412-a and peaks 413-a. In the first film 410-a of fig. 4A, the rugosities 411-a have the same wavelength and amplitude, however, in various embodiments, for any of the laminates disclosed herein, the first substrate can have patterned regions comprising rugosities having different wavelengths and/or amplitudes. The pleats 411-a are linear, parallel, side-by-side, and are integrally connected to each other as they are formed of the same material, which is the first film 410-a. However, in various embodiments, for any of the laminates disclosed herein, some or all of the rugosities in the patterned region may not be perfectly parallel to each other, but may have an overall orientation (taken end-to-end) that deviates from being parallel to each other by 1-15, or from being parallel by any integer value between 1 and 15 degrees, or from deviating from any range formed by any of these values, such as 1-10 degrees, 1-5 degrees, 1-2 degrees, and the like. Each of the pleats 411-a is incrementally stretched such that the valleys 412-a and peaks 413-a are permanent features of the first film 410-a, separated by portions of the first film 410-a that are extended and thinned by the solid state forming process. Each of the pleats 411-a is elongated because it has a total length (into the page) that is greater than its overall width. In various embodiments, for any patterned region of any laminate disclosed herein, one, or some, or all of the wrinkles may be continuous, having a total length that continues all the way along the laminate, and/or one, or some, or all of the wrinkles may be discrete, having a total length that does not continue all the way along the laminate. Table 1 below describes nine embodiments of a laminate that represent various combinations of wrinkle lengths and wrinkle orientations of the first and second substrates, which are contemplated as being suitable for any of the laminates described herein. In table 1, "at an angle α" means that the elongated corrugations have an overall orientation that is oriented at any angle α between the machine direction and the cross direction of 1 to 89 degrees.

TABLE 1

In various embodiments, for any patterned region of any laminate disclosed herein, some or all of the wrinkles may have the same overall length and/or some or all of the wrinkles may have different overall lengths; the overall length of the corrugations may be selected such that the patterned region has a particular overall shape (when viewed from a top view), such as any overall shape disclosed herein or known in the art.

The second film 420-a has the same configuration as the first film 410-a, except that the second film 420-a is constructed and oriented in a mirror image version of the first film 410-a, which is a mirror image about an imaginary horizontal line disposed along the bottom of the valley 412-a of the first film 410-a. Thus, in the wrinkle portion 401-a, the second film 420-a has a plurality of second undulated wrinkles 421-a which are also integrally connected, discrete, elongated, incrementally stretched, and are provided with valleys 422-a and peaks 423-a linearly, in parallel, side by side. Because of the mirror image configuration, the corrugation 421-a has the same wavelength and amplitude as corrugation 411-a, and all valleys 412-a and 422-a face inward, while all peaks 413-a and 423-a face outward. The first film 410-a is aligned side-by-side and lengthwise (into the page) with the second film 420-a and is attached to the second film 420-a by a plurality of attachment zones 405-a. Since attachment region 405-a attaches first film 410-a to second film 420-a, pleat 411-a has the same overall length as pleat 421-a.

In various embodiments, for any patterned region of any laminate disclosed herein, the second substrate may not be a mirror image version of the first substrate, but may differ from the first substrate in any manner disclosed herein; in particular, the corrugations of the second substrate may differ in wavelength and/or amplitude from the corrugations of the first substrate. Table 2 below describes nine embodiments of laminates that represent various combinations of wrinkle wavelengths and amplitudes for the first and second substrates, which are contemplated as being suitable for any of the laminates described herein. In table 2, "same", "smaller" and "larger" are used as terms of relative sizes; identical refers to corrugations of equal size; smaller means having wrinkles of relatively small size; larger refers to wrinkles having a relatively large dimension; and the corrugations of either substrate may be of any size disclosed herein or known in the art.

TABLE 2

A plurality of attachment regions 405-a directly connect valley 412-a with valley 422-a such that each of valley 412-a is directly connected to one of valleys 422-a and each of valley 422-a is directly connected to valley 412-a; however, in various embodiments, for any patterned region of any laminate disclosed herein, the plurality of valleys from the rugosities of the first substrate may be directly connected to a single valley from the rugosities of the second substrate. Any attachment zone disclosed herein can be formed by one or more adhesive and/or fused portions that extend continuously or discontinuously along one or more portions of about all, substantially all, nearly all, or all of either or both of the connecting valleys; any suitable adhesive for joining films may be used, such as 5100-N ZP (Full Care), available from h.b. filler of saint Paul, Minnesota, United States of America; the films may be melted together by applying heat and/or pressure to the films while they are held in contact in any manner known in the art. In the embodiment of FIG. 4A, the rugosities 411-a of the first film 410-a are attached to the rugosities 421-a of the second film 420-a only at the plurality of attachment zones 405-a. Also, in the embodiment of FIG. 4A, the first film 410-a is attached to the second film 420-a only at a plurality of attachment regions 405-a; however, in various embodiments, for any of the laminates disclosed herein, the first and second substrates may be engaged together in various ways at one or more other locations on the laminate, such as locations in the uncrimped portions.

The first film 410-a changes from a corrugated shape in the corrugations 411-a of the corrugated portion 401-a to a flat shape in the non-corrugated portions 408-1a and 408-2 a; these shape changes occur at a first transition 417-1a on one side of the corrugated portion 401-a and at a second transition 417-2a on the other side of the corrugated portion 401-a. Similarly, the second film 420-a changes from a wavy shape in the corrugations 421-a of the corrugated portion 401-a to a flat shape in the non-corrugated portions 408-1a and 408-2 a; these shape changes occur at a first transition 427-1a on one side of the corrugated portion 401-a and a second transition 427-2a on the other side of the corrugated portion 401-a. First transitions 417-1a and 427-1a are offset from each other so that in non-corrugated portion 408-1a, first film 410-a and second film 420-a are offset from each other; second transitions 417-2a and 427-2a are also offset from each other, so in non-corrugated portion 408-2a, first film 410-a and second film 420-a are offset from each other; however, in various embodiments, for any of the laminates disclosed herein, the substrates may be adjacent to each other and/or in contact with each other in the non-gathered portions at one or more other locations on the laminate.

FIG. 4B shows an enlarged end view of a laminate 400-B formed from a first substrate (which is the first film 410-B) and a second substrate (which is the film 420-B). The laminate 400-B of fig. 4B is constructed in the same manner as the laminate 400-a of fig. 4A, with similarly numbered elements constructed in the same manner, except that the first film 410-B and the second film 420-B are directly connected at a plurality of attachment zones 405-B that are relatively wider than the attachment zones 405-a of the laminate 400-a. In alternative embodiments, the laminate 400-b may be modified in any manner that the laminate 400-a of figure 4A may be modified.

FIG. 5A shows an enlarged end view of a laminate 500-a formed from a first substrate (which is a first film 510-a), a second substrate (which is a second film 520-a), a third substrate (which is a third film 540-1a), and a fourth substrate (which is a fourth film 540-2 a). The laminate 500-a of fig. 5A is constructed in the same manner as the laminate 400-a of fig. 4A, with like-numbered elements constructed in the same manner, except that the laminate 500-a includes a third film 540-1a, which is an outer film joined to the outward-facing peaks of the corrugations of the first film 510-a; the third film 540-1a may be joined directly or indirectly to the first film 510-a in any manner described herein and/or known in the art. The laminate 500-a comprises a fourth, included film 540-2a, which is an outer film joined to the outwardly facing peaks of the pleats of the second film 520-a; the fourth film 540-2a may be joined directly or indirectly to the second film 520-a in any manner described herein and/or known in the art. In an alternative embodiment, the laminate 500-a may be modified in any manner that the laminate 400-a of fig. 4A may be modified. For any laminate disclosed herein having an outer substrate, a portion, portions, or all of either or both of the outer substrates may be omitted from the laminate and/or may be substituted for a portion, portions, or all of either or both of the outer substrates in any feasible combination. In alternative embodiments, for any laminate disclosed herein, one or more additional substrates (e.g., films or nonwovens) and/or structures in any form disclosed herein or known in the art may be added to the laminate.

FIG. 5B shows an enlarged end view of a laminate 500-B formed from a first substrate (which is the first film 510-B), a second substrate (which is the second film 520-B), a third substrate (which is the third film 540-1B), and a fourth substrate (which is the fourth film 540-2B). The laminate 500-B of fig. 5B is constructed in the same manner as the laminate 400-B of fig. 4B, with like-numbered elements constructed in the same manner, except as described below. The laminate 500-b includes a third film 540-1b, which is an outer film joined to the outwardly facing peaks of the corrugations of the first film 510-b and also joined to the non-corrugated portions 508-1a and 508-2a of the first film 510-a; the third film 540-1b may be joined directly or indirectly to the first film 510-b in any manner described herein and/or known in the art. The laminate 500-b includes a fourth film 540-2b, which is an outer film joined to the outwardly-facing peaks of the corrugations of the second film 520-b and also joined to the non-corrugated portions 508-1a and 508-2a of the second film 520-a; the fourth film 540-2b may be joined directly or indirectly to the second film 520-b in any manner described herein and/or known in the art. In an alternative embodiment, the laminate 500-a may be modified in any manner that the laminate 500-a of fig. 5A may be modified.

FIG. 6A shows an enlarged end view of a laminate 600-a formed from a first substrate (which is a first film 610-a) and a second substrate (which is a second film 620-a). The laminate 600-a of figure 6A is constructed in the same manner as the laminate 400-a of figure 4A, with like-numbered elements constructed in the same manner, except as described below. The first transitions 617-1a and 627-1a are adjacent to each other, such that in the non-corrugated portion 608-1a, the first film 610-a and the second film 620-a are adjacent to each other, in contact with each other, and directly or indirectly joined to each other; the second transitions 617-2a and 627-2a are also adjacent to and in contact with each other, so in the non-corrugated portion 608-2a, the first film 610-a and the second film 620-a are adjacent to each other, in contact with each other, and directly or indirectly joined to each other. In any embodiment of the laminate disclosed herein, in the non-gathered portions, the first and second substrates may be joined together in any convenient manner (e.g., directly connected at one or more locations by an adhesive); however, in various embodiments, the first and second substrates may be proximate to each other and/or not in contact with each other and/or not joined to each other at one or more locations in the uncrimped portion. In an alternative embodiment, the laminate 600-a may be modified in any manner that the laminate 400-a of fig. 4A may be modified.

FIG. 6B shows an enlarged end view of a laminate 600-B formed from a first substrate (which is the first film 610-B) and a second substrate (which is the film 620-B). The laminate 600-B of fig. 6B is constructed in the same manner as the laminate 600-a of fig. 6A, with similarly numbered elements constructed in the same manner, except that the first film 610-B and the second film 620-B are directly connected at a plurality of attachment zones 605-B that are relatively wider than the attachment zones 605-a of the laminate 600-a. In alternative embodiments, the laminate 600-b may be modified in any manner that the laminate 600-a of fig. 6A may be modified.

FIG. 7A shows an enlarged end view of a laminate 700-a formed from a first substrate (which is a first film 710-a), a second substrate (which is a second film 720-a), a third substrate (which is a third film 740-1a), and a fourth substrate (which is a fourth film 740-2 a). The laminate 700-a of fig. 7A is constructed in the same manner and with like-numbered elements in the same manner as the laminate 600-a of fig. 6A, except that the laminate 700-a includes a third film 740-1a, which is an outer film joined to the outward-facing peaks of the corrugations of the first film 710-a; the third film 740-1a may be joined directly or indirectly to the first film 710-a in any manner described herein and/or known in the art. The laminate 700-a comprises a fourth, included film 740-2a, which is an outer film joined to the outwardly facing peaks of the corrugations of the second film 720-a; the fourth film 740-2a may be joined directly or indirectly to the second film 720-a in any manner described herein and/or known in the art. In an alternative embodiment, the laminate 700-a may be modified in any manner that the laminate 600-a of fig. 6A may be modified.

FIG. 7B shows an enlarged end view of a laminate 700-B formed from a first substrate (which is a first film 710-B), a second substrate (which is a second film 720-B), a third substrate (which is a third film 740-1B), and a fourth substrate (which is a fourth film 740-2B). The laminate 700-B of fig. 7B is constructed in the same manner as the laminate 600-B of fig. 6B, with like-numbered elements constructed in the same manner, except as described below. The laminate 700-b includes a third film 740-1b, which is an outer film joined to the outwardly facing peaks of the corrugations of the first film 710-b and also joined to the non-corrugated portions 708-1a and 708-2a of the first film 710-a; the third film 740-1b may be joined directly or indirectly to the first film 710-b in any manner described herein and/or known in the art. The laminate 700-b includes a fourth film 740-2b, which is an outer film joined to the corrugated, outward-facing peaks of the second film 720-b and also joined to the non-corrugated portions 708-1a and 708-2a of the second film 720-a; the fourth film 740-2b may be joined directly or indirectly to the second film 720-b in any manner described herein and/or known in the art. In an alternative embodiment, the laminate 700-a may be modified in any manner that the laminate 700-a of fig. 7A may be modified.

For any of the laminates disclosed herein, the corrugations may be of any convenient size and proportion, including any of the following. The wavelength of any of the corrugations may be 0.5-5 millimeters, or any number of increments of 0.5 millimeters between 0.5 millimeters and 5 millimeters, or any range formed by any of these numbers, such as 1-4 millimeters, 1-3 millimeters, 1-2 millimeters, and so forth. The amplitude of any of the corrugations may be 0.1-10 millimeters, or any number of increments of 0.1 millimeters between 0.1 and 10 millimeters, or any range formed by any of these numbers, such as 0.1-5 millimeters, 1-4 millimeters, 1-2 millimeters, and so forth. The amplitude to wavelength ratio of any of the corrugations may be any value from 0.2 to 10, or increments of 0.1 between 0.2 and 10, or any range formed by any of these values, such as 0.5-7.5, 0.7-5, 1-3, etc. The overall width of any of the attachment zones between the pleats may be 0.1-5 millimeters, or any number of increments of 0.1 millimeters between 0.1 and 5 millimeters, or any range formed by any of these numbers, such as 0.1-3 millimeters, 0.2-1 millimeter, 0.2-0.5 millimeters, and so forth. The ratio of the wavelength of any of the corrugations to the overall width of the attachment zone is 1.1 to 100, or any number of increments of 0.1 between 1 and 100, or any range formed by any of these numbers, such as 1-80, 5-65, 25-50, etc. The overall length of any of the corrugations may be 1-10,000 millimeters, or any integer value between 1 millimeter and 10,000 millimeters, or any range formed by any of these values, such as 1-1,000 millimeters, 1-100 millimeters, 2-60 millimeters, 3-50 millimeters, 4-40 millimeters, 5-30 millimeters, and so forth.

Any of the end-bonded, shaped laminates disclosed herein can be made from any combination (e.g., homopolymers, copolymers, blends, etc.) of various chemicals, including one or more of any variety of polymeric materials, such as polyethylene (e.g., linear low density PE, and high density PE), polypropylene, nylon, ethyl vinyl acetate, and/or any other polymer suitable for making a substrate, together with any additives (e.g., pigments/colorants) and/or modifiers (e.g., titanium dioxide) known in the art of substrate making, and the laminates can be in any form (e.g., monolayer, laminate, layered structure, co-extrusion, etc.) made by any variety of substrate making processes. Any of the end-bonded, shaped laminates disclosed herein can be made from substrates of various thicknesses, such substrates having an overall thickness of 5-250 micrometers (0.2-10 mils), or any integer value between 5 micrometers and 250 micrometers, or any range formed by any of these values, such as 5-100 micrometers (0.2-3.9 mils), 10-50 micrometers (0.39-2 mils), 10-30 micrometers (0.39-1.4 mils), and the like.

For any of the laminates disclosed herein, the first substrate, the second substrate (and either or both outer substrates, if present) may be the same or may differ in any manner known in the art; for example, such differences may include differences in color, opacity, thickness, mechanical properties (e.g., elasticity, inelasticity, extensibility, inextensibility, toughness or brittleness, puncture resistance, etc.), polymer type, presence of additives, use of modifiers, etc., which may be in any operable combination.

Fig. 8 illustrates a flow diagram of a method of making a laminate 800 having a patterned region as described herein. The method 800 includes a first step 801 of using a first patterned surface to incrementally mechanically stretch a first substrate to form a first pleat. The method 800 includes a second step 802 of using the second patterned surface to incrementally mechanically stretch the second substrate to form a second pleat. The method 800 includes a third step 803 performed when the first substrate is engaged with the first patterned surface and the second substrate is engaged with the second patterned surface, where the third step 803 includes directly attaching the corrugations of the first substrate to the corrugations of the second substrate to form an end-bonded shaped laminate.

The incremental stretching and joining of the substrate in the method 800 may be performed using the machine 902 of fig. 9, the machine 1302 of fig. 13, the machine 1402 of fig. 14, the machine 1802 of fig. 18, or any of the alternative machine embodiments disclosed herein. The laminate obtained from process 800 may be configured according to any laminate described herein, such as laminate 400-a of fig. 4A, laminate 400-B of fig. 4B, laminate 400-C of fig. 4C, laminate 400-D of fig. 4D, laminate 600-a of fig. 6A, laminate 600-B of fig. 6B, laminate 600-C of fig. 6C, laminate 600-D of fig. 6D, or any alternative embodiment of any of these disclosed herein. In various alternative embodiments, the method 800 may be modified by the following additional process steps: one or two outer substrates are added to form the laminate 500-a of figure 5A, the laminate 500-B of figure 5B, the laminate 500-C of figure 5C, the laminate 500-D of figure 5D, the laminate 700-a of figure 7A, the laminate 700-B of figure 7B, the laminate 700-C of figure 7C, or the laminate 700-D of figure 7D.

Fig. 9-18 illustrate a machine for incrementally stretching and joining substrates to form end-bonded shaped laminates as described herein. In fig. 9-18, the substrate is a film.

Fig. 9 is an assembly diagram showing a machine 902 having four solid forming rollers, a first patterned roller 960, a second patterned roller 970, a third patterned roller 980, and a fourth patterned roller 990, wherein the machine incrementally stretches and joins the first and second substrates 910, 920 together to form an end-bonded, formed laminate 900. First patterned roll 960 and third patterned roll 980 incrementally stretch first substrate 910; second patterned roll 970 and fourth patterned roll 990 incrementally stretch second substrate 920. First patterned roll 960 and second patterned roll 970 join first substrate 910 and second substrate 920 together to form laminate 900 when first substrate 910 is engaged with first patterned roll 960 and second substrate 920 is engaged with second patterned roll 970. In fig. 9, the overall longitudinal direction of the first substrate 910 is shown on the left as an arrow pointing to the right, and the overall longitudinal direction of the second substrate 920 is shown on the right as an arrow pointing to the left; however, for each of these substrates, the exact machine direction at any particular point is defined by the path of the substrate as it travels through the machine.

The first patterned roll 960 is a solid, raised, solid, forming roll that rotates 960-r clockwise about a transversely oriented axis 965. The first patterned roll 960 has a roll surface that is cylindrical in shape at the base and a plurality of rigid, elongated, discrete protrusions 961 attached to the base as radial protrusions. The projections 961 are in similar rows of teeth and are arranged linearly, parallel, side-by-side on the roller 960 with adjacent teeth separated by a gap. Each of the projections 961 is elongate in that it has an overall length that is greater than its overall width. Also, each of the projections 961 is longitudinally oriented in the longitudinal direction such that its overall length is parallel to the rotation of the roller 960. Each of the projections 961 is discrete and does not continue all the way around the roll surface of the roll 960. Each of the projections 961 has a distal end that forms a tip, which is the portion of the projection furthest from the axis 965. The second patterned roller 970 is also a solid, forming roller having discrete protrusions 971 and is configured in the same manner as the first patterned roller 960, except that the roller 970 is rotated 970-r counterclockwise about a transversely oriented axis 975.

The first patterned roller 960 is positioned relative to the second patterned roller 970 such that the tips of the protrusions 961 always do not mate with the tips of the protrusions 971 when the rollers rotate; that is, when the ends of the projections 961 and 971 pass each other, the end of the projection 961 is never closer to the shaft 975 than the end of the projection 971, and the end of the projection 971 is never closer to the shaft 965 than the end of the projection 961. Thus, as the rollers 960 and 970 rotate, the projections 961 and 971 do not engage each other; thus, the rollers 960 and 970 are uncooperative with respect to each other.

First patterned roll 960 is also positioned relative to second patterned roll 970 such that when the rolls are rotated, the tips of protrusions 961 come within engagement proximity of the tips of protrusions 971 when first substrate 910 is engaged with first patterned roll 960 and when second substrate 920 is engaged with second patterned roll 970; that is, when the end of the protrusion 961 passes the end of the protrusion 971, the substrate engaged with the protrusion 961 may be directly connected to the substrate engaged with the protrusion 971. Thus, the rollers 960 and 970 may engage the substrate as the substrate rotates to form a laminate; thus, rollers 960 and 970 are engaging rollers relative to each other.

First patterned roll 960 is aligned with second patterned roll 970 in both the machine direction and the cross direction to enable joining of substrates 910 and 920. The alignment in the machine direction includes controlling the relative angular positions of the rollers 960 and 970 such that as the rollers 960 and 970 rotate, the tips of the projections 961 and 971 pass within engagement proximity of each other so that the opposing tips of the projections can position the corrugations from the first substrate 910 along their entire length with the corrugations from the second substrate 920 to form a direct connection, as described and illustrated in connection with fig. 12B. The alignment in the cross direction includes positioning the roll faces of the rolls 960 and 970 such that when the rolls 960 and 970 are rotated, the ends are aligned in the cross direction opposite each other when the ends of the projections 961 and the ends of the projections 971 are in engagement proximity, so that the opposite ends can position the corrugations from the first substrate 910 across their width with the corrugations from the second substrate 920 to form a direct connection, as described and illustrated in connection with fig. 12A.

The third patterned roll 980 is a ring roll rotating 980-r counterclockwise about an axis 985 oriented in the cross direction. The third patterned roll 980 has a roll surface that is cylindrical in base and a plurality of rigid, elongated, continuous protrusions 981 attached to the base as radial protrusions. The protrusions 981 are in similar rows of rings and are arranged linearly, parallel, side-by-side with adjacent rings separated by a gap. Each of the loops 981 is elongate in that it has an overall length that is greater than its overall width. Also, each of the protrusions 981 is longitudinally oriented in the longitudinal direction such that its overall length is parallel to the rotation of the roller 980. Each of the protrusions 981 is continuous with an overall length that continues all the way around the roll face of the roll 980. Each of the protrusions 981 has a distal outer surface forming a tip, which is the portion of the protrusion furthest from the axis 995. The fourth patterned roll 990 is also a ring roll with discrete protrusions 991 and is constructed in the same manner as the third patterned roll 980, except that the roll 990 rotates 980-r clockwise about an axis 995 oriented in the cross-machine direction.

The third patterned roll 980 is positioned relative to the first patterned roll 960 such that the ends of the continuous protrusions 981 are always flush with the ends of the discrete protrusions 961 as the roll rotates; that is, the end of protrusion 961 passes within the radius formed by the end of protrusion 981, and the end of protrusion 981 passes within the radius formed by the end of protrusion 961. Thus, as the rollers 960 and 980 rotate, the protrusions 961 and 981 engage each other; thus, the rollers 960 and 980 are cooperative with respect to each other.

Third patterned roll 980 is laterally aligned with first patterned roll 960 to enable incremental stretching of substrate 910. The lateral alignment includes positioning the roll faces of the rolls 960 and 980 such that as the rolls 960 and 980 rotate, the ends of the continuous protrusions 981 are laterally offset from the ends of the discrete protrusions 961 so that the ends can intermesh to form incrementally stretched corrugations in the first substrate 910, as described and illustrated in connection with fig. 10A. Since the protrusions 981 are continuous, there is no need to align the third patterned roll 980 with the first patterned roll 960 in the machine direction.

Fourth patterning roller 990 is positioned and aligned with second patterning roller 970 in the same manner as third patterning roller 980 is positioned and aligned with first patterning roller 960 so that rollers 990 and 970 mate with respect to each other and the tips of continuous protrusions 991 intermesh with the tips of discrete protrusions 971 to form incrementally stretched corrugations in second substrate 920, as described and illustrated in connection with fig. 10B. Since the protrusions 991 are continuous, it is not necessary to align the fourth patterning roller 990 with the second patterning roller 970 in the longitudinal direction.

The machine 902 also includes a number of additional devices. A first web supply apparatus 950-1 is positioned upstream of the third patterned roll 980 and provides the first substrate 910 in the form of a web; the web supply apparatus may take any convenient form, such as an unwind stand. Similarly, a second web supply apparatus 950-2 is positioned upstream of the fourth patterned roll 990 and provides the second substrate 920 in the form of a web. An adhesive application apparatus 952 is positioned adjacent the first patterned roll 960 and applies adhesive to the substrate engaging the protrusions 961 of the roll 960; the adhesive application apparatus may take any convenient form, such as an adhesive head with a comb-shaped shim, a gravure roll, an ink jet printer, and the like. Force application device 954 includes a first component that urges and holds third patterned roll 980 in mating relationship with first patterned roll 960 and a second component that urges and holds fourth patterned roll 990 in mating relationship with second patterned roll 970; the force applying device may take any convenient form, such as a cylinder that moves the axis of rotation of the roller.

The first base 910 generally moves the tibial machine 902 from left to right, as indicated by its general longitudinal direction. First substrate 910 is moved 910-m from first web supply 950-1 onto third patterned roll 980, then between intermeshing protrusions 961 and 981 of mating rolls 960 and 980, then through adhesive application apparatus 952, and then into proximity of the engagement between protrusions 961 and 971 of rolls 960 and 970. When the first substrate 910 is provided by the first web supply apparatus 950-1, the first substrate 910 has the form of a substantially flat, unformed, continuous web. The first substrate 910 moves 910-m from the first web supply 950-1 and along the roll face of the third patterned roll 980. As the third patterning roll 980 rotates, the first substrate 910 moves into and engages the intermeshing protrusions 981 and 961 of the patterning rolls 980 and 960, which incrementally mechanically stretch the first substrate 910 to form a plurality of corrugations having valleys and peaks, as described and illustrated in connection with fig. 10A. As patterning rolls 980 and 960 rotate, first substrate 910 moves out of the intermeshing protrusions 961 and 981 and disengages from protrusions 981 of third patterning roll 980, but remains engaged with protrusions 961 of first patterning roll 960 and follows the roll surface of first patterning roll 960. As the first patterning roll 960 further rotates, the first substrate 910 continues to follow the roll surface of the first patterning roll 960, remains engaged with the protrusions 961, and moves past the adhesive application apparatus 952, which applies adhesive to the valleys of the corrugations of the first substrate 910, as described and illustrated in connection with fig. 11A and 11C. The adhesive application apparatus 952 may be positioned adjacent the first patterned roll 960 at any convenient location that is downstream of the disengagement of the first and third rolls 960, 980 and upstream of the vicinity of the engagement of the first and second rolls 960, 970. In alternative embodiments, another adhesive application apparatus (in addition to or in lieu of adhesive application apparatus 952) may be located at any convenient location adjacent second patterned roller 970, downstream of the disengagement of second roller 970 and fourth roller 990 and upstream of the proximity of the engagement of first roller 960 and second roller 970. As first patterning roll 960 rotates even further, first substrate 910 continues to follow the roll surface of first patterning roll 960, remains engaged with protrusions 961, and moves between patterning rolls 960 and 970.

The second base 920 generally moves the tibial machine 902 from right to left, as indicated by its general longitudinal direction. The second substrate 920 is moved 920-m from the second web supply 950-2 onto a fourth patterned roll 990, then between the intermeshing protrusions 971 and 991 of the mating rolls 970 and 990, and then into proximity of the engagement between the protrusions 971 and 991 of the rolls 970 and 990. When the second substrate 920 is provided by the second web supply 950-2, the second substrate 920 has the form of a substantially flat, unformed continuous web. The second substrate 920 is moved 920-m from the second web supply 950-2 and along the roll surface of the fourth patterned roll 990. As the fourth patterning roller 990 rotates, the second substrate 920 moves into and engages the intermeshing protrusions 991 and 971 of the patterning rollers 990 and 970, which incrementally mechanically stretch the second substrate 920 to form a plurality of corrugations having valleys and peaks, as described and illustrated in connection with fig. 10B. As the patterning rollers 990 and 970 rotate, the second substrate 920 moves out of the intermeshing protrusions 991 and 971 and disengages from the protrusions 991 of the fourth patterning roller 990, but remains engaged with the protrusions 971 of the second patterning roller 970 and follows the roll surface of the second patterning roller 970. As the second patterned roller 970 rotates further, the second substrate 920 continues to follow the roller surface of the second patterned roller 970, remaining engaged with the protrusions 971, as described and illustrated in connection with fig. 11B. As the second patterned roller 970 rotates further, the second substrate 920 continues to follow the roller surface of the second patterned roller 970, remains engaged with the protrusions 971, and moves between the patterned rollers 970 and 960.

As the first and second patterned rolls 960, 970 are further rotated, the first substrate 910 engages the first patterned roll 960, the second substrate 920 engages the second patterned roll 970, and the ends 962 of the protrusions 961 of the first patterned roll 960 enter into proximity of the engagement of the ends 972 of the protrusions 971 of the second patterned roll 970, such that the valleys 912 from the corrugations 911 of the first substrate 910 become adhesively attached to the valleys 922 from the corrugations 921 of the second substrate 920 to form an end-bonded, shaped laminate 900 that is removed in its final form 900-m from the rolls 960 and 970.

In various modified embodiments, one or more additional intermediate substrates (e.g., films) may be fed into proximity to the joint between the first and second substrates, such that the first, intermediate and second substrates may each be joined together by the first and second patterned rolls with the intermediate substrate disposed in the middle, in accordance with embodiments disclosed herein; this method may be used to modify any embodiment, including any alternative embodiment, of the methods and apparatus disclosed in fig. 8-17.

Fig. 10A shows an enlarged partial cross-sectional view of a portion 1003-a of the machine 902 of fig. 9, showing protrusions 981 of a third patterned 980 roller intermeshed with the protrusions 961 of the first patterned roll 960 to incrementally stretch the first substrate 910 and form a plurality of corrugations 911. On the left and right sides of the portion 1003-a, where the first patterned roll 960 has no protrusions that intermesh with the protrusions 981 of the third patterned roll 980, the non-corrugated portion of the first substrate 910 is located on top of the protrusions 981, at about the same height as the peaks of the corrugations 911.

FIG. 10B shows an enlarged partial cross-sectional view of a portion 1003-B of the machine 902 of FIG. 9, showing the protrusions 971 of the second patterned 970 roller intermeshed with the protrusions 991 of the fourth patterned roller 990 to incrementally stretch the second substrate 920 and form a plurality of corrugations 921. On the left and right sides of the portion 1003-b, where the second patterned roll 970 has no protrusions that intermesh with the protrusions 991 of the fourth patterned roll 990, the non-corrugated portion of the second substrate 920 is located on top of the protrusions 991, at about the same height as the peaks of the corrugations 921.

Fig. 11A shows an enlarged partial cross-sectional view of the portion 1103-a of the machine 902 of fig. 9 at a location downstream of the portion 1003-a of fig. 10A, showing the corrugation 911 of the first substrate 910 engaged with the protrusions 961 of the first patterned roll 960, wherein the valleys 912 of the corrugation 911 are disposed on the tips 962 of the protrusions 961 and the adhesive 931 is selectively applied to the valleys 912. In fig. 11A, the non-corrugated portion of the first substrate 910 is in the same position as in fig. 10A.

Fig. 11B shows an enlarged partial cross-sectional view of the portion 1103-B of the machine 902 of fig. 9 at a location downstream of the portion 1003-B of fig. 10B, showing a corrugation 921 of the second substrate 920 engaged with the protrusions 971 of the second patterning roller 970, wherein valleys 922 of the corrugation 921 are disposed on distal ends 972 of the protrusions 971. In fig. 11B, the non-corrugated portion of the second substrate 920 is in the same position as in fig. 10B.

Fig. 11C shows a partial exterior view (not shown) of the first substrate 910 of fig. 11A engaged with a first patterned roll 960 (not shown), showing valleys 912 of corrugations 911 (shown hidden) disposed on ends 962 of protrusions 961 and an adhesive 931 selectively applied to the valleys 912.

Fig. 12A shows an enlarged partial cross-sectional view (in the machine direction) of portion 1203-a of machine 902 of fig. 9 at a location downstream of portion 1103-a of fig. 11A and 1103-B of fig. 11B, where first substrate 910 is engaged with first patterned roll 960, second substrate 920 is engaged with second patterned roll 970, and protrusions 961 of first patterned roll 960 are located in proximity to engagement with protrusions 971 of second patterned roll 970, such that valleys 912 of corrugations 911 from first substrate 910 are attached by adhesive at a plurality of attachment areas 930 to valleys 922 of corrugations 921 from second substrate 920 to form the end-bonded shaped laminate 900 of fig. 9.

Fig. 12B shows an enlarged partial cross-sectional view (in the cross-machine direction) of portion 1203-a of fig. 12A, wherein the first substrate 910 is engaged with the first patterned roll 960, the second substrate 920 is engaged with the second patterned roll 970, and the tip 962 of one protrusion 961 of the first patterned roll 960 is located in close proximity to the junction with the tip 972 of one protrusion 971 of the second patterned roll 970, such that the valley 912 of a corrugation 911 from the first substrate 910 is connected by adhesive 931-1 and 931-2 at the attachment area 930 to one valley 922 of a corrugation 921 from the second substrate 920 to form the end-bonded shaped laminate 900 of fig. 9. The first portion 931-1 of adhesive is an upstream portion of the adhesive and is disposed on the first substrate 910 but not yet in contact with the second substrate 920. The second portion of adhesive 931-2 is a downstream portion of the adhesive and is in contact with both the first substrate 910 and the second substrate 920.

Fig. 12C shows another enlarged portion of the view of fig. 12B, where the first substrate 910 is engaged with the first patterning roller 960, the second substrate 920 is engaged with the second patterning roller 970, and the tip 962 of one protrusion 961 of the first patterning roller 960 is located in the vicinity 900-jp of engagement with the tip 972 of one protrusion 971 of the second patterning roller 970. Upstream of the joint vicinity range 900-jp, the first substrate 910 is separated from the second substrate 920, and the first portion 931-1 of the adhesive is disposed on the outer portion of the valley 912 of the corrugation 911 of the first substrate 910. At the near-engagement range 900-jp, the ends 962 and 972 pass each other and the adhesive contacts the outer portions of the valleys 922 of the corrugations 921 of the second substrate 920. Downstream of the vicinity of the join range 900-jp, a second portion 931-2 of adhesive links the valley 912 of the first substrate 910 to the valley 922 of the second substrate 920 such that the substrates 910 and 920 joined by the adhesive form the end-bonded, shaped laminate 900 of fig. 9.

Fig. 13 is an assembly diagram showing a machine 1302 having four solid forming rollers, a first patterned roller 1360, a second patterned roller 1370, a third patterned roller 1380, and a fourth patterned roller 1390, wherein the machine incrementally stretches the first and second substrates 1310, 1320 and joins the substrates 1310, 1320 together to form an end-bonded formed laminate 1300. First patterned roll 1360 and third patterned roll 1380 incrementally stretch first substrate 1310; second patterning roller 1370 and fourth patterning roller 1390 incrementally stretch second substrate 1320. As the first substrate 1310 is engaged with the first patterning roller 1360 and the second substrate 1320 is engaged with the second patterning roller 1370, the first patterning roller 1360 and the second patterning roller 1370 bond the first substrate 1310 and the second substrate 1320 together to form the laminate 1300. In fig. 13, the overall longitudinal direction of the first substrate 1310 is shown on the left as an arrow pointing to the right, and the overall longitudinal direction of the second substrate 1320 is shown on the right as an arrow pointing to the left; however, for each of these substrates, the exact machine direction at any particular point is defined by the path of the substrate as it travels through the machine.

The machine 1302 of fig. 13 is constructed in the same manner as the machine 902 of fig. 9, with similarly numbered elements constructed in the same manner, except as described below. On the first patterned roll 1360, each of the protrusions 1361 is longitudinally oriented in the cross direction such that its overall length is parallel to the shaft 1365. Each of the protrusions 1361 is discrete and does not extend all the way across the roll surface of the roll 1360. The second patterning roller 1370 includes protrusions 1371 and is configured in the same manner as the first patterning roller 1360, except that the roller 1370 rotates 1370-r counterclockwise about an axis 1375. The rollers 1360 and 1370 are unmated engaging rollers relative to each other and are aligned with each other in both the longitudinal and transverse directions to effect the joining of the substrates 1310 and 1320.

On the third patterning roll 1380, each of the protrusions is oriented longitudinally in the cross direction such that its overall length is parallel to the axis 1385. Each of the projections 1381 is continuous with a total length extending all the way across the roll face of the roll 1380. The third patterned roll 1380 cooperates with the first patterned roll 1360, and the third patterned roll 1380 is registered to the first patterned roll 1360 in both the machine direction and the cross direction to enable incremental stretching of the first substrate 1310.

Fourth patterned roll 1390 includes protuberances 1391 and is constructed in the same manner as third patterned roll 1380, except that roll 1390 rotates clockwise 1380-r about axis 1385. Fourth patterning roller 1390 cooperates with second patterning roller 1370 and fourth patterning roller 1390 is aligned to first patterning roller 1370 in both the machine direction and the cross direction to enable incremental stretching of second substrate 1320.

In various embodiments, the machine 1302 of fig. 13 may be configured in accordance with any of the alternative machine embodiments disclosed herein in any operable combination.

Fig. 14 is an assembly drawing showing a machine 1402 with four solid forming rollers, a first patterned roller 1460, a second patterned roller 1470, a third patterned roller 1480, and a fourth patterned roller 1490, wherein the machine incrementally stretches the first substrate 1410 and the second substrate 1420 and joins the substrates together to form the end bonded shaped laminate 1400. First and third patterning rollers 1460, 1480 incrementally stretch first substrate 1410; the second patterning roller 1470 and the fourth patterning roller 1490 incrementally stretch the second substrate 1420. As the first substrate 1410 is engaged with the first patterning roller 1460 and the second substrate 1420 is engaged with the second patterning roller 1470, the first and second patterning rollers 1460, 1470 bond the first and second substrates 1410, 1420 together to form the laminate 1400. In fig. 14, the overall longitudinal direction of the first substrate 1410 is shown on the left side as an arrow pointing to the right, and the overall longitudinal direction of the second substrate 1420 is shown on the right side as an arrow pointing to the left; however, for each of these substrates, the exact machine direction at any particular point is defined by the path of the substrate as it travels through the machine.

Machine 1420 of fig. 14 is constructed in the same manner as machine 902 of fig. 9, with like-numbered elements constructed in the same manner, except as described below. The first patterning roller 1460 is a ring roller having continuous protrusions 1461. The second patterning roll 1470 is also a ring roll having continuous protrusions 1471. The rollers 1460 and 1470 are unmated engaging rollers relative to each other and are laterally aligned with each other to effect joining of the substrates 1410 and 1420. Since protrusions 1461 and 1471 are continuous, there is no need to align first patterning roller 1460 with second patterning roller 1470 in the machine direction.

The third patterned roll 1480 is a solid, forming roll having discrete protrusions 1481. Third patterning roller 1480 cooperates with first patterning roller 1460 and third patterning roller 1480 is laterally aligned to first patterning roller 1460 to enable incremental stretching of first substrate 1410. Because the protrusions 1461 are continuous, there is no need to align the third patterning roller 1480 with the first patterning roller 1460 in the machine direction.

The fourth patterned roll 1490 is also a solid, forming roll with discrete protrusions 1491. The fourth patterning roller 1490 cooperates with the second patterning roller 1470 and the fourth patterning roller 1490 is aligned in the cross direction to the second patterning roller 1470 to enable incremental stretching of the second substrate 1420. Since the protrusions 1471 are continuous, it is not necessary to align the fourth patterning roller 1490 with the second patterning roller 1470 in the longitudinal direction.

In various embodiments, the machine 1402 of fig. 14 may be configured in accordance with any of the alternative machine embodiments disclosed herein in any operable combination.

Fig. 15A shows an enlarged partial cross-sectional view of a portion 1503-a of the machine 1402 of fig. 14, showing protrusions 1481 of the third patterned 1480 roller that intermesh with protrusions 1461 of the first patterned roller 1460 to incrementally stretch the first substrate 1410 and form a plurality of corrugations 1411. On the left and right sides of the portion 1503-a, where the third patterned roll 1480 has no protrusions that intermesh with the protrusions 1461 of the first patterned roll 1460, the non-corrugated portions of the first substrate 1410 are positioned on top of the protrusions 1461 at about the same elevation as the valleys of the corrugations 1411.

Fig. 15B shows an enlarged partial cross-sectional view of a portion 1503-B of the machine 1402 of fig. 14, showing protrusions 1471 of the second patterning 1470 roll intermeshed with the protrusions 1491 of the fourth patterning roll 1490 to incrementally stretch the second substrate 1420 and form a plurality of corrugations 1421. On the left and right sides of the portion 1503-b, where the fourth patterning roller 1490 has no protrusions that intermesh with the protrusions 1471 of the second patterning roller 1470, the non-corrugated portion of the second substrate 1420 is located on top of the protrusions 1471, at about the same height as the peaks of the corrugations 1421.

Fig. 16A shows an enlarged partial cross-sectional view of the portion 1603-a of the machine 1402 of fig. 14 at a location downstream from the portion 1503-a of fig. 15A, showing a corrugation 1411 of the first substrate 1410 engaged with the protrusions 1461 of the first patterning roller 1460, wherein the valleys 1412 of the corrugation 1411 are disposed on the ends 1462 of the protrusions 1461 and the adhesive 1431 is selectively applied to the valleys 1412. In fig. 16A, the non-corrugated portion of the first substrate 1410 is in the same position as in fig. 15A, and the non-corrugated portion of the first substrate 1410 also receives an adhesive 1431 that is selectively applied across the width of the non-corrugated portion at a position opposite the ends 1462 of the protrusions 1461.

Fig. 16B shows an enlarged partial cross-sectional view of the portion 1603-B of the machine 1402 of fig. 14 at a location downstream of the portion 1503-B of fig. 15B, showing the corrugations 1421 of the second substrate 1420 engaged with the protrusions 1471 of the second patterning roll 1470, wherein the valleys 1422 of the corrugations 1421 are disposed on the ends 1472 of the protrusions 1471. In fig. 16B, the non-corrugated portion of the second substrate 1420 is in the same position as in fig. 16B.

Fig. 17 shows an enlarged partial cross-sectional view (in the machine direction) of the portion 1703-a of the machine 1402 of fig. 14 at a location downstream of the portion 1603-a of fig. 16A and 1603-B of fig. 16B, wherein the first substrate 1410 is engaged with the first patterned roll 1460, the second substrate 1420 is engaged with the second patterned roll 1470, and the projections 1461 of the first patterned roll 1460 are located in proximity to engagement with the projections 1471 of the second patterned roll 1470, such that the valleys 1412 of corrugations 1411 from the first substrate 1410 are connected by adhesive at a plurality of attachment zones 1430 to the valleys 1422 of the corrugations 1421 from the second substrate 1420, and the non-corrugated portions of the first substrate 1410 are connected by adhesive to the non-corrugated portions of the second substrate 1420 to form the end-bonded laminate 1400 of fig. 14.

Fig. 18 is an assembly drawing showing a machine 1802 with four solid forming rollers, first 1860, second 1870, third 1880, and fourth 1890 patterned rollers, incrementally stretching first and second substrates 1810 and 1820 and joining the substrates 1810 and 1820 together to form an end-bonded shaped laminate 1800. The first 1860 and third 1880 patterning rolls incrementally stretch the first substrate 1810; second patterned roll 1870 and fourth patterned roll 1890 incrementally stretch second substrate 1820. When first substrate 1810 engages first patterned roll 1860 and second substrate 1820 engages second patterned roll 1870, first patterned roll 1860 and second patterned roll 1870 join first substrate 1810 and second substrate 1820 together to form laminate 1800. In fig. 18, the overall longitudinal direction of the first substrate 1810 is shown on the left as an arrow pointing to the right, and the overall longitudinal direction of the second substrate 1820 is shown on the right as an arrow pointing to the left; however, for each of these substrates, the exact machine direction at any particular point is defined by the path of the substrate as it travels through the machine.

The machine 1802 of fig. 18 is constructed in the same manner as the machine 1402 of fig. 14, with like-numbered elements constructed in the same manner, except as described below. On the first patterning roller 1860, each of the protrusions 1861 is oriented longitudinally in the cross-direction such that its overall length is parallel to the shaft 1865. Each of the protrusions 1861 is continuous, with a total length extending all the way across the roll face of the roll 1860. Second patterned roll 1870 includes protrusions 1871 and is configured in the same manner as first patterned roll 1860, except that roll 1870 is rotated 1870-r counterclockwise about axis 1875. Rollers 1860 and 1870 are unmated engaging rollers relative to each other and are aligned with each other in both the longitudinal and transverse directions to effect the joining of substrates 1810 and 1820.

On the third patterned roll 1880, each of the protrusions is longitudinally oriented in the transverse direction such that its overall length is parallel to the axis 1885. Each of the projections 1881 is discrete and does not extend all the way across the roll surface of the roll 1880 in total length. The third patterning roller 1880 cooperates with the first patterning roller 1860, and the third patterning roller 1880 is aligned to the first patterning roller 1860 in both the longitudinal and transverse directions to enable incremental stretching of the first substrate 1810.

The fourth patterned roller 1890 includes protrusions 1891 and is configured in the same manner as the third patterned roller 1880, except that roller 1890 is rotated clockwise 1890-r about axis 1895. Fourth patterned roll 1890 cooperates with second patterned roll 1870 and fourth patterned roll 1890 is aligned to first patterned roll 1870 in both the longitudinal and transverse directions to enable incremental stretching of second substrate 1820.

In various embodiments, the machine 1802 of fig. 18 may be configured in accordance with any of the alternative machine embodiments disclosed herein in any operable combination.

While the machine embodiments disclosed herein describe and illustrate solid forming elements as rotating patterned rollers, in various embodiments, any such rollers may be replaced by one or more other types of solid forming elements, such as planar patterned surfaces having similar protrusions, but which are moved into mating relationship and/or within engagement proximity by non-rotational motion (e.g., linear motion), as will be understood by those skilled in the solid forming art.

Fig. 19 is an enlarged cross-sectional view of a portion of a laminate 1900 having patterned regions formed by first and second substrates 1910, 1920 along with first and second outer substrates 1940-1, 1940-2, wherein the laminate 1900 includes a benefit agent disposed at a location within the laminate. A portion of the laminate 1900 is constructed in the same manner as the corresponding portion of the laminate 500-a of figure 5A, and is also constructed in the same manner as the corresponding portion of the laminate 700-a of figure 7A, with similarly numbered elements being constructed in the same manner, except as described below.

The valleys 1912 of the rugosities 1911 from the first substrate 1910 are connected to the valleys 1922 of the rugosities 1921 of the second substrate 1920 at attachment regions 1930 by adhesive 1931, and the adhesive 1931 includes one or more benefit agents, which may be any benefit agent disclosed herein or known in the art; for any of the laminates disclosed herein, any adhesive that connects the gathered valleys of the first and second substrates may include a benefit agent that may be mixed into the adhesive and thus disposed on the laminate as part of the adhesive application process.

The interior portion of the peaks 1913 of the corrugations 1911 from the first substrate 1910 includes benefit agent 1909-1 disposed on its surface and the interior portion of the peaks 1923 of the corrugations 1921 from the second substrate 1920 includes benefit agent 1909-2 disposed on its surface; benefit agents 1909-1 and 1909-2 can be one or more of any benefit agent disclosed herein or known in the art, and can be applied directly or indirectly to a surface in any convenient manner (e.g., by spraying) disclosed herein or known in the art.

The outboard portions of the peaks 1913 of the corrugations 1911 from the first substrate 1910 are connected to the inboard side of the first outer substrate 1940-1 at multiple locations by adhesive 1932-1, and the outboard portions of the peaks 1923 of the corrugations 1921 from the second substrate 1920 are connected to the inboard side of the second outer substrate 1940-2 by adhesive 1932-2, wherein the adhesive 1932-1 and the adhesive 1932-2 each comprise one or more benefit agents, which may be any benefit agent disclosed herein or known in the art; for any of the laminates disclosed herein having an outer substrate, any adhesive that connects the substrate and the peaks of the corrugations of the outer substrate may include a benefit agent that may be mixed into the adhesive and thus disposed on the laminate as part of the adhesive application process.

In various alternative embodiments, the presence of some or all of the benefit agents disposed in a portion of the laminate 1900 may be omitted; the presence or absence of the benefit agent may be repeated on one portion, multiple portions, or all of the laminate.

Fig. 20A is an enlarged end view of a portion of an exemplary laminate 2010-a of the present disclosure showing the extent of peaks 2013 in the corrugations of the substrate of the laminate 2010-a. The peaks 2013 are outward-facing portions of the corrugated corrugations that have convex surfaces that are oriented outward away from the interior of the laminate and its central plane 2007-a. The peaks 2013 refer to a continuation of the outward facing portion where a reference line drawn perpendicular to the base (shown as a dashed line) forms an interior angle of 45-90 degrees with respect to the central plane 2007-a of the laminate 2010-a.

Fig. 20B is an enlarged end view of a portion of an exemplary laminate 2010-B of the present disclosure, illustrating the extent of valleys 2012 in the corrugations of the substrate of the laminate 2010-B. The valleys 2012 are the inward-facing portions of the corrugations, which have convex surfaces that are oriented inward toward the interior of the laminate and its central plane 2007-a. The valleys 2012 refer to the continuous segment of the inward facing portion in which a reference line drawn perpendicular to the base (shown as a dashed line) forms an interior angle of 45-90 degrees with respect to the central plane 2007-b of the laminate 2010-b.

Fig. 21 is an enlarged end view of a portion of an exemplary laminate 2100 of the present disclosure formed from a first substrate 2110 and a second substrate 2120. A portion of the laminate 2100 is constructed in the same manner as the corresponding portion of laminate 400-a of fig. 4A, and is also constructed in the same manner as the corresponding portion of laminate 600-a of fig. 6A, with similarly numbered elements being constructed in the same manner, unless described otherwise below. Fig. 21 is intended to show the wavelength and amplitude measurements for all embodiments of the laminates described herein. The laminate 2100 includes a central plane 2107 disposed in the middle of the entire laminate 2100 for reference; because the first and second substrates 2110, 2120 are symmetrical in the laminate 2100, the central plane 2107 is disposed between the valleys of the substrates.

First substrate 2110 includes inward facing first valleys 2112-a and outward facing first peaks 2113-a that are peaks adjacent to first valleys 2112-a; first valley 2112-a and first peak 2113-a are integrally connected to opposite ends of first intermediate portion 2118-a, which is a substantially straight portion of first base 2110 between first valley 2112-a and first peak 2113-a. First valley 2112-a includes a minimum thickness 2112-a-ot measured linearly perpendicular to first base 2110 at a location on first valley 2112-a where the measurement is minimal; the minimum thickness of the valley may generally be present at or near its furthest extent, near the adjacent intermediate portion, but this is not essential. The first peak 2113-a includes a minimum thickness 2113-a-ot measured linearly perpendicular to the first base 2110 at a location on the peak 2113-a where the measurement is minimal; the minimum thickness of the peak may generally be present at or near its furthest extent, near the adjacent intermediate portion, but this is not required. First intermediate portion 2118-a includes a first minimum thickness 2118-a-ot measured linearly perpendicular to first base 2110 at a location on the first intermediate portion where the measurement is minimal; the minimum thickness of the intermediate portion may generally be at or near the midpoint, but this is not required. The first intermediate minimum thickness 2118-a-ot is less than the first valley minimum thickness 2112-a-ot, and the first intermediate minimum thickness 2118-a-ot is also less than the first peak minimum thickness 2113-a-ot; these differential thickness relationships result from the localized thinning of the first substrate 2110 during incremental stretching thereof, wherein the first substrate 2110 thins at a first intermediate portion which is the least constrained portion of the substrate material as it is stretched. The relationship and thickness of first valleys 2112-a, first intermediate portions 2118-a, and first peaks 2113-a are repeated for the same adjacent elements in first substrate 2110 and are also present for corresponding adjacent elements in second substrate 2120.

The first base 2110 includes a second peak 2113-b, which is a peak adjacent to the first peak 2113-a. The overall distance between the center of the first peak 2113-a and the center of the second peak 2113-b is the wavelength 2114, which is measured linearly parallel to the central plane 2107 of the laminate 2100 and perpendicular to the overall orientation of the peaks for measurement, as described and illustrated in FIG. 21; for any of the laminates disclosed herein, the wavelength between any adjacent peaks can be measured in this manner. The overall height of the second peaks 2113-b is the amplitude 2115, measured perpendicular to the central plane 2107 of the laminate 2100 from the central plane to the outboard portion of the second peaks 2113-b that is farthest from the central plane 2107; for any laminate disclosed herein, the amplitude of any peak can be measured in this manner.

The valleys 2112-a, 2112-b, and 2112-c of the first substrate 2110 are attached to the valleys 2122 of the second substrate 2120 by a plurality of attachment regions 2105, each of which has an overall width 2105-ow measured linearly parallel to the central plane 2107 of the laminate 2100 and perpendicular to the overall orientation of the valleys attached by the attachment regions; for any laminate disclosed herein, the overall width of any attachment zone can be measured in this manner.

FIG. 22 is an exemplary draw tape type trash bag 2200 made of one or more films, the bag 2200 having a top 2200-t, a bottom 2200-b, and sides 2200-s. The bottom portion 2200-b is closed with a fold 2200-f, the sides are sealed with side seals 2200-ss, and the top portion 2200-t includes an opening 2200-o. At the top portion 2200-t, the bag 2200 includes a draw tape 2200-dt disposed within a hem 2200-h of a folded bag material sealed to itself. The fold region 2200-fz in the bottom of the bag 2200 includes the fold 2200-f and a portion of the bag 2200 adjacent to the fold 2200-f. The hem area 2200-hz in the top portion of the bag 2200 includes the hem 2200-h and a portion of the bag 2200 adjacent the hem 2200-h. The body region 2200-bz of the bag 2200 extends entirely across the bag between the top of the fold region 2200-fz and the bottom of the hem region 2200-hz.

The bag 2200 and a portion, portions, or all of its drawtape 2200-dt can be configured to be formed from end-bonded laminates according to any one or more embodiments of the present disclosure, which can also be configured with one or more of any of the patterned regions of the present disclosure, in any feasible combination disclosed herein or known in the art. In particular, a portion, portions or all of the fold region 2200-t, a portion, portions or all of the bottom portion 2200-b, a portion, portions or all of any one or both sides 2200-s, a portion, portions or all of the fold 2200-f, a portion, portions or all of the fold region 2200-fz, a portion, portions or all of the draw tape 2200-dt, a portion, portions or all of the hem 2200-h, a portion, portions or all of the hem region 2200-hz, and/or a portion, portions, or all of the body region 2200-bz, the end-bonded laminates can be configured independently or in combination, which can include one or more patterned regions formed from the end-bonded laminates.

The draw tape garbage bag 2200 may be made from any variety of one or more films, including materials disclosed herein or known in the art; bag 2200 can be made using any method and apparatus for making a drawtape-type trash bag known in the art; the bag 2200 can be further constructed and/or modified according to any embodiment known in the art of disposable bags.

FIG. 23 is an exemplary strapping-type trash bag 2300 made of one or more films, the bag 2300 having a top 2300-t, a bottom 2300-b, and sides 2300-s. The bottom 2300-b is closed with a fold 2300-f, the sides are sealed with side seals 2300-ss, and the top 2300-t includes an opening 2300-o. At the top 2300-t, the bag 2300 includes a tying flap 2300-tf (shown folded down on the front side; shown erected on the back side) provided as a formed integral part of the bag material. The fold region 2300-fz in the bottom portion of the bag 2300 includes the fold 2300-f and a portion of the bag 2300 adjacent to the fold 2300-f. The tab area 2300-fz in the top portion of the bag 2300 includes the tying tab 2300-tf and a portion of the bag 2300 adjacent to the tying tab 2300-tf. The body region 2300-bz of the bag 2300 extends across the entire bag between the top of the fold region 2300-fz and the bottom of the flap region 2300-fz.

One, more, or all of the pouch 2300 may be configured to be formed of end bonded laminates according to any one or more embodiments of the present disclosure, which may also be configured with one or more of any of the patterned regions of the present disclosure, in any feasible combination disclosed herein or known in the art. In particular, a portion, portions, or all of the fold region 2300-t, a portion, portions, or all of the bottom 2300-b, a portion, portions, or all of any one or both sides 2300-s, a portion, portions, or all of the fold 2300-f, a portion, portions, or all of the fold region 2300-fz, one, some, or all of the bundling flaps 2300-tf, a portion, portions, or all of the flap region 2300-fz, and/or a portion, portions, or all of the body region 2300-bz, can be configured, individually or in combination, as an end-bonded laminate, which can include one or more patterned regions formed from end-bonded laminates.

The bundling-type trash bag 2300 may be made of any variety of films, including materials disclosed herein or known in the art; the bag 2300 may be prepared using any method and apparatus for making a strapping-type trash bag known in the art; the bag 2300 may be further constructed and/or modified according to any embodiment known in the art of disposable bags.

In addition to trash bags of the tie and strapping types, the end-bonded laminates of the present disclosure may be similarly applied to a portion, portions, or all of a film-based material, component, and/or article, including: any type of bag (e.g., other types of trash bags, food storage bags, grocery bags, etc.); as packaging and/or component materials for any kind of films used for disposable wearable absorbent articles (e.g., feminine hygiene products, baby diapers, adult incontinence products, sanitary napkins, and the like), bandages, consumer products, other kinds of products, and the like.

The end-bonded formed laminates of the present disclosure may be made from a multi-layer formed substrate and may provide significant improvements over an unformed single layer substrate, including: greater resistance to integrity, improved compression resilience, directional response to tensile loads, more aesthetic appearance, enhanced structural properties, thicker sections, and desirable design patterns without relying on more expensive polymers and/or higher concentrations of substrate additives; thus, such end-bonded formed laminates provide significant improvements at a reasonable cost when compared to an unformed single layer substrate.

Test method for measuring local film thickness

The Hitachi S-3500N scanning electron microscope, tokyo, japan, is an imaging device for quantifying the thickness of a film at a specific location on a 3D substrate.

Sample preparation

Squares of 2cm x 2cm were cut from the article. Square 2cm by 2cm sections were placed in 1 liter of liquid nitrogen for 5 minutes. Immediately after removing the 2cm x 2cm square from the liquid nitrogen, a 5mm x 5mm square was cut from the 2cm x 2cm square with a new razor blade to form the cross-sectional edge. The 5mm by 5mm sample was free of holes, wrinkles or gels. Five separate 5mm by 5mm samples were produced by the same procedure. Prior to imaging, a 5mm by 5mm sample was held at 24 ℃ +/-3 ℃ for 24 hours.

The cross-sectional sample was removed from the liquid nitrogen using tweezers and mounted on an aluminum pin mount (e.g., Ted Pella #16111) using an adhesive tab (e.g., Ted Pella #16084-1) with the cut surface facing upward. The mounted samples were sputter coated with gold to ensure that the surface was not charged in a subsequent scanning electron microscope. Sputter coating at 45mA for three minutes is usually sufficient; however, if charging occurs, the sample should be coated longer.

Imaging

The pin mount containing the coated sample was secured to an adapter (e.g., Ted Pella #15387-2) and inserted into the chamber of a Hitachi S-3500N SEM. The cross section was imaged under high vacuum at a voltage of 5kV, working distance 11mm, magnification 800X, and an image of 2560 pixels × 1920 pixels (160 μm × 120 μm) was obtained with a resolution of 16 pixels/micrometer in both X and Y directions. Images of directly adjacent peaks, spans and intermediate portions were acquired for comparison with the present invention.

Image analysis：

The acquired images were opened in Quartz PCI 7 image software (Quartz imaging Inc. of Vancouver, Canada). Prior to measurement, the software is calibrated by drawing a straight line across the length of a scale stored in the image and inputting at a known length (e.g., 50 μm) of the scale. Then, a vertical line is drawn across the entire cut surface of the imaged sample, and the thickness measurement in the desired portion is calculated using the software. The imaging process was repeated 5 times for each prepared 5mm by 5mm sample. Thickness measurements are reported to the nearest 0.1 micron.

Definition of

As used herein, the term "about," when modifying a particular value, refers to a range equal to the particular value plus or minus twenty percent (+/-20%). For any of the embodiments disclosed herein, any disclosure of a particular value can also be understood to be approximately equal to the disclosed range of that particular value (i.e., +/-20%) in various alternative embodiments.

As used herein, the term "amplitude" refers to the overall height of the peaks in the laminate, wherein the overall height is measured linearly from the central plane of the laminate to the outer portion of the peaks furthest from the central plane, as described and illustrated in connection with fig. 21.

As used herein, the term "about" when modifying a particular value refers to a range equal to the particular value plus or minus fifteen percent (+/-15%). For any of the embodiments disclosed herein, any disclosure of a particular value can also be understood to be approximately equal to the disclosed range for that particular value (i.e., +/-15%) in various alternative embodiments.

As used herein, the term "benefit agent" refers to a chemical (in solid or liquid form) disposed in or on the structure of a material such that the chemical performs one or more different functions, such as an effect that is detectable by a consumer; examples of benefit agents include: abrasives, absorbents, activators, additives, antibacterial agents, antifungal agents, antimicrobial agents, antioxidants, attractants, bleaching agents, brighteners, carriers, catalysts, chelants, detergents, colorants, conditioners, desiccants, detergents, diluents, dispersants, dyes, enzymes, glycolic acids, fertilizers, fragrances or fragrances-like, foaming agents, fragrances, herbicides, humectants, inhibitors, minerals, modifiers, humectants, mold removers, nutrients, odor absorbers, oils, oxidants, fragrances, insecticides, pharmaceuticals, phase change materials, pigments, plasticizers, preservatives, processing aids, purifiers, rinses, scavengers, scourers, sensors, sequestering agents, shampoos, silicones, softeners, solvents, stabilizers, surfactants, thickeners, treating agents, vitamins, waxes, and any other type of benefit agent known in the art, in any feasible manner.

As used herein, the term "peak" refers to a particular outward-facing portion of a wave-like wrinkle in the substrate of an end-bonded, formed laminate of the present disclosure, as described below and as further described and illustrated in connection with fig. 20A. The peaks are outwardly facing in that their convex surfaces are oriented outwardly toward the exterior of the laminate. Peaks refer to a continuous segment of the outward facing portion of the corrugation, where a reference line drawn perpendicular to the base forms an interior angle of 45-90 degrees with respect to the central plane of the laminate (as shown in fig. 20A).

As used herein, the term "similarly numbered" refers to a similar alphanumeric designation for corresponding elements, as described below. The designations of similarly numbered elements have the same last two digits; for example, one element having an identification ending with the numeral 20 and another element having an identification ending with the numeral 20 are numbered similarly. The identification of similarly numbered elements may have one or more different leading digits, where one or more of the leading digits match the numbering in the figures thereof; for example, the elements of FIG. 3 labeled 320 are numbered similarly to the elements of FIG. 4 labeled 420. The designations of like-numbered elements may have the same or possibly different suffixes (i.e., designations after the dashed line symbol), e.g., corresponding to particular embodiments; for example, a first embodiment of the elements in FIG. 3A, identified as 320-a, and a second embodiment of the elements in FIG. 3B, identified as 320-B, are numbered similarly.

As used herein, the term "substantially" when modifying a particular value refers to a range equal to the particular value plus or minus five percent (+/-5%). For any of the embodiments disclosed herein, any disclosure of a particular value can also be understood to be approximately equal to the disclosed range for that particular value (i.e., +/-5%) in various alternative embodiments.

As used herein, the term "overall width of the attachment zones" refers to the total distance between the portions of the attachment zones that are furthest apart, wherein the overall width is measured linearly parallel to the central plane of the laminate and perpendicular to the overall orientation of the valleys attached by the attachment zones, as described and illustrated in connection with fig. 21. For attachment zones formed by adhesion, the overall width is the measured width of the attachment adhesive. For the attachment zones formed by fusion, the overall width is the measured width of the fused portion.

As used herein, the term "solid state forming" refers to a method or apparatus in which a mechanical force is applied to a substrate (e.g., a film) in a solid state, wherein the force is applied by one or more rigid protrusions that contact and permanently deform portions of the substrate by incremental stretching. Examples of solid state forming devices include patterned rolls, patterned plates, and/or patterned belts having discrete and/or continuous rigid protrusions for engaging and deforming one or more material substrates, wherein the protrusions may be of any kind known in the art (e.g., fins, ribs, rings, rods, teeth, etc.), of any convenient size and proportion (e.g., uniform height, variable height, etc.), and of any general shape known in the art (e.g., conical, cubic, cylindrical, prismatic, pyramidal, etc.), and having any particular end shape (e.g., flat, pointed, rounded, pointed, etc.), wherein the protrusions extend from the base over a portion, portions, or all of the patterned roll/plate/belt. In particular, it is contemplated that any of the patterned rolls disclosed herein can be replaced with a patterned roll or a patterned belt, as is known in the solid state forming art. Notably, solid state forming of film-based substrates differs from other substrate forming processes, such as molding (where the substrate is formed while in a semi-molten or molten state), wet-laid processes (where a wet fibrous substrate is formed prior to drying), and embossing (where a low stress deformation pattern is made by pressing the substrate against a flat or deformable roll using a patterned roll).

Any embodiment of a substrate made from a film as described herein can be made using various solid state forming processes known in the art, including any process suitable for use in a film, disclosed in any of the following, each of which is incorporated by reference:

as used herein, the term "substantially" when used in reference to a particular value refers to a range equal to the particular value plus or minus ten percent (+/-10%). For any of the embodiments disclosed herein, any disclosure of a particular value can also be understood to be approximately equal to the disclosed range for that particular value (i.e., +/-10%) in various alternative embodiments.

As used herein, the term "valley" refers to a particular inward-facing portion of a wave-like corrugation in the substrate of an end-bonded formed laminate of the present disclosure, as described below and as further described and illustrated in connection with fig. 20B. The valleys are inward facing because their convex surfaces are oriented inward toward the interior of the laminate. The valleys refer to a continuous segment of the inward-facing portion of the corrugations where a reference line drawn perpendicular to the base forms an interior angle of 45-90 degrees with respect to the central plane of the laminate (as shown in fig. 20B).

As used herein, the term "wavelength" refers to the total distance between the centers of adjacent peaks in a laminate, where the wavelength is measured linearly, parallel to the central plane of the laminate, and perpendicular to the overall orientation of the peaks used for measurement, as described and illustrated in connection with fig. 21.